October 2007 701P47034 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 ©2007 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.
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.
ii DocuTech 128/155/180 HighLight Color Operator Guide
Table of Contents 1 Safety notices System safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Laser safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Ozone safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Operation safety . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the black dry ink bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the highlight color container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the highlight color Customer Changeable Units . . . . . . . . . . . . . . . . . . . . . Adding fuser shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Waste containers . . . . . . . . . . . . . . . . . . . . . . . . .
5 Technical information DocuTech printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Printer rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Paper tray capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Additional paper capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi DocuTech 128/155/180 HighLight Color Operator Guide
Introduction About this guide 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.
Introduction • “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. Conventions This guide uses the following conventions: • All caps and angle brackets–Within procedures, the names of keys are shown in all caps within angle brackets (for example, press ).
1 Safety notices System safety 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. Laser safety WARNING: Use of controls or adjustments, or performances other than specified herein, may result in hazardous radiation exposure. The Xerox DocuTech 128/155/180 HLC models are certified to comply with laser performance standards set by the U.S.
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.
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. • 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.
Safety notices 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).
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.
Safety notices Check your understanding Please review the questions and answers that follow to ensure that you understand the Electricity at Work Regulation in England and Wales. Question Answer Question Answer What is the Electricity at Work Regulation? The Electricity at Work Regulation 1989 came into force in England and Wales on 1 April 1990.
Safety notices MUST BE CARRIED OUT ONLY BY PERSONS WHO POSSESS THE RELEVANT SKILL, KNOWLEDGE 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. Question Answer Question Answer I would like to carry out my own safety tests on the Xerox equipment in my premises.
Safety notices Perchlorate Law Compliance Announcement This announcement is required for all Xerox products which contain perchlorate materials and are destined for the State of California. Product Recycling and Equipment End-of-Life Disposal Language Requirements for Xerox Customer Documentation Xerox operates a worldwide equipment take back and reuse/ recycle program. Contact your Xerox sales representative (1-800ASK-XEROX) to determine whether this Xerox product is part of the program.
2 System components The Xerox DocuTech HLC printers are electronic reprographics systems. They are high volume printers available in multiple configurations. 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.
System components Optional Components • Inverter Feeder/Stacker and up to 3 Feeder/Stackers • 2-Tray or 3-Tray Interposer and Finisher Functional overview 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.
System components Table 1.
System components 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 printer running at optimum efficiency.
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: Has 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).
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. Figure 2-1. Job flow 1. Job 2. Input Queue 3. Decomposer 4. Output queue 5. Printer Job The job and the job ticket (if applicable) are received from the network by one of the protocol gateways.
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 from the Input Queue. The printing process and job flow is different for PostScript, PCL, TIFF, ASCII, PDF jobs (that is, non-LCDS or non-IPDS jobs) and for LCDS or IPDS jobs.
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. Figure 2-2. Printer with inverter feeder/stacker + feeder/ stacker (standard base configuration) 1. 2. 3. 4. 5. 6.
System components Processor feeder/ paper trays Two processor feeder/paper trays (trays 1 and 2) are located in 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.
System components Paper Level indicators Display the approximate 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.
System components Inverter feeder/stacker 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. Figure 2-4.
System components Figure 2-5. High capacity stacker bin control panel 1. 2. 3. 4. Ready to Unload indicator on stacker bins Please Wait indicator on stacker bins Bin Unload button on stacker In Use indicator on stacker bin Ready to Unload indicator on stacker bins When this indicator glows, you can remove printed sheets from the stacker bin. Please Wait indicator on stacker bins When this indicator glows, the elevator is in motion. This indicator turns off when the platform reaches its destination.
System components High-capacity stackers The high-capacity stacker (HCS) bins are located in the top half of 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 feeder/stacker modules. Figure 2-6.
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. Figure 2-8. Production publisher: Printer + 2-Tray or 3-Tray Interposer + stitcher/binder 1. Convenience tray 2. Interposer (2-Tray shown) 3. Finisher 4. Top tray Convenience tray The convenience tray provides an area to place documents or other items while you are at the printer.
System components Interposer NOTE: Production publisher configuration only. The 2-Tray or 3-Tray Interposer module is located between the print engine and the Finisher. The Interposer inserts blank or preprinted sheets as required. Sheets fed from Tray 4 are not imaged and feed directly into the finisher.
System components 3-Tray Interposer (production publisher only) The 3-Tray Interposer allows applications to utilize up to six trays to feed different paper stocks. All three trays may be used to feed pre-printed stocks (bypassing the Fuser). If just Tray 4 is used for post-Fuser feeding, five pick points are available for imaging (passing through the fuser). The following lists the 3-Tray interposer components 1. Paper transport (lower) 2. Paper transport (upper) 3. Inserter tray 4.
System components Finisher NOTE: Production publisher configuration only Figure 2-11. Finisher In the finisher, prints can be collated, and stitched or bound, as required for a job. The following lists the finisher components: 1. Bindexer 2. Stitcher 3. Stacker 4. Binder 5. Binder tape reel 6. Stitcher wire spools 7. Top tray The bindexer NOTE: Production publisher configuration only The bindexer is a three-bin sorter that collates the pages of each print set.
System components The stacker 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.
System components 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.
System components High volume printer paper path The following figure shows the path the paper takes through the high volume printer. Figure 2-12. Route of paper through the high volume printer 1. Processor feeder tray 1 2. Processor feeder tray 2 3. High-capacity feeder tray 3 a. Side 1 of sheet leaving feeder tray b. Drilled holes (on right edge) c.
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 5. Paper inverter 6. Duplex inverter 7. Sample tray 8. 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 bin b. Drilled holes (on left edge) c. Origin 0,0: portrait orientation 10. Purge tray 11.
System components Production publisher paper path The following figure shows the path the paper takes through the production publisher. Figure 2-13. Route of paper through the production publisher 1. Processor feeder tray 1 2. Processor feeder tray 2 3. High capacity paper tray 4. Paper inserter tray 5. High capacity paper tray (Two-tray Interposer shown) 6. Duplex inverter 7. Purge tray 8. Bypass transport 9. Bindexer area 10. Bind area 11. Stitch area 12.
System components High volume printer bypass transport paper path Figure 2-14. Bypass transport paper path (high volume printer configuration shown) 1. Sheet path 2. Exit rollers 3.
System components The System System Hardware The basic hardware components of the DocuTech 128/155/180 HLC systems are the FreeFlow Print Server and the printer. The FreeFlow Print Server The FreeFlow Print Server is the connection between you and the system. You communicate through the FreeFlow Print Server software by selecting and managing the jobs displayed on the screen and sending them to the printer for production.
System components Accessing FreeFlow Remote Print Server remotely FreeFlow Remote Print Server, a remote graphical user interface (GUI), is available for installation from a CD. FreeFlow Remote Print Server allows you to manage your FreeFlow Print Serverbased 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.
System components The FreeFlow Print Server Tape Client software enables transmission of data from a cartridge or open reel tape to the FreeFlow Print Server via the Socket gateway. The 4 GB external SCSI quarter inch cartridge (QIC) tape drive is an external device. The cartridge tape drive connects to the print server 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.
System components Figure 2-16. 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: • If an exact match is found, the print job continues.
System components Long and short edge feeding To feed through the printer, the leading edge of the paper must be 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 NOTE: JIS B4 can be fed either long edge or short edge first.
3 Routine maintenance This section describes the routine activities you perform to maintain the reliability and productivity of your printer. Cleaning and maintenance overview 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 FreeFlow Print Server window on the print server.
Routine maintenance supplies, you may damage the system. • 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.
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.
Routine maintenance Figure 3-2 Recommended temperature 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.
Routine maintenance Table 3-1. Paper conditioning Temperature difference between storage and operating areas Centigrade 10o 15o 20o 25o 30o 40o 50o Fahrenheit 5.5o 8.5o 11o 13o 17o 22o 26o 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 90o F.
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. 2. 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. 3. Press the green release tab. 4. Lift the metal handle on the feed belt and remove any paper under the belt. 5.
Routine maintenance For stock outside the recommended limits, refer to the "Technical information" chapter in this guide. 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.
Routine maintenance Adding paper to trays 3, 4, 5, or 6 Paper Tray 3 is used to supply the largest volume of paper required for your jobs. Trays 3, 5 and 6 (3-tray Interposer only) can also be used to supply oversized paper for special jobs. Paper in Tray 4 is only used for post-process insertion. These trays lower one ream at a time as paper is added. More than one ream can be loaded by pressing the Tray unlock button again after the tray is fully opened.
Routine maintenance 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.
Routine maintenance Figure 3-5 Measuring the paper curl 3. Place the bottom edge of the prints over the paper curl measurement chart in this guide. • If the print curl on the printed paper measures between +1 and - 2, do not change the decurler setting. • If the 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 (120 g/m2) can be achieved between +1 and -1 curl.
Routine maintenance Note: Corners of the sheets of paper should not exceed curl shown in this chart.
Routine maintenance Adjusting the decurler lever Perform the following 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 Locating the decurler lever 3. If the print curl is +2 or more, move the green decurler lever to the right. 4. If the print curl is -3 or more, move the green decurler lever to the left. 5.
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.
Routine maintenance 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 thoroughly 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.
Routine maintenance d. Hold the bottle in place with one hand and remove the paper seal by pulling it toward you with the other hand. Discard the seal along with the drop cloth. Figure 3-10 Removing the paper seal 5. Close the processor access door. NOTE: If 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.
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 4. 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.
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.
Routine maintenance c. When the HLC unit is level, tighten the lock nut. Figure 3-12 Leveling the cart 7. Push down firmly on the 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.
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. Figure 3-14 Removing the CCU from the printer 10. Push down firmly on the cart pedal until you hear or feel a click.
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.
Routine maintenance 3. Push the cart firmly against the printer until you can feel the two latch together. 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.
Routine maintenance Storing the cart and CCU NOTE: If any dry ink gets on your hands, wash them with soap and cold water. Heat sets the ink permanently. If any dry ink gets on your clothes, brush them with a dry paper towel or a stiff bristled brush. If this does not remove the ink 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.
Routine maintenance 5. Slide the stand toward the machine to engage the pins with the holes and the slot. The end of the service stand may need to be lifted slightly to ensure pin engagement. 6. 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. 7.
Routine maintenance 6. Then, turn the yellow CCU handle a quarter turn clockwise. 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.
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. 1. Open the processor doors. 2. Place a drop cloth on the floor under the fuser area. 3. Open the fuser drawer. a. Locate the fuser drawer. b.
Routine maintenance Figure 3-22 Preparing to add fuser blend WARNING: Fuser lubricant spills cause the floor to be slippery. If 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.
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.
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.
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. 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.
Routine maintenance 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 and snapping it down. 7. Insert the new bottle into the waste module. Figure 3-28 Inserting a new waste bottle 8. Close the HLC module door.
Routine maintenance Wire Module Removal and Replacement Replace the wire module only when directed to by the Customer Support Center. CAUTION: In 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.
Routine maintenance 2. Ensure that the brush on the wire module is at the toner bottle end as shown in the figure below. Figure 3-30 Wire module assembly brush location. 3. Snap the wire module retainer springs behind the tabs. 4. Slide the HLC developer module into the machine. 5. Latch the CCU into place. 6. Remove the cart or service stand. 7. Close the doors.
Routine maintenance Cleaning the system and its components NOTE: Follow the procedures in this section only when directed by Xerox Customer Support center personnel.
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.
Routine maintenance Cleaning the sensors and the reflecting surfaces CAUTION: Never use abrasive materials or strong solvents when cleaning sensors.
Routine maintenance Figure 3-31 Area 4 and green handle 3. Locate the Q850 and Q861 sensor.
Routine maintenance 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. Figure 3-33 Q1011/1009 sensor and mirror 2. Apply a small amount of lens and mirror cleaner to a cleaning pad. 3. Wipe the sensor gently with the cleaning pad.
Routine maintenance Figure 3-34 Q1106 and Q1166 sensors Cleaning the Q1107 sensor NOTE: High volume printer configuration only 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.
Routine maintenance Figure 3-35 Q1107 sensor Cleaning the Q1164 sensor NOTE: High volume printer configuration only To access sensor Q1164, open 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.
Routine maintenance Figure 3-36 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.
Routine maintenance Clearing or cleaning the finisher sensors NOTE: Production publisher configuration only 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 cover, under the finisher top cover, and behind the finisher and bindexer doors. Use the following procedure to clear any obstructions from the finisher sensors. 1. Fold a sheet of 8.
Routine maintenance Figure 3-38 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 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 338.
Routine maintenance Figure 3-39 Locating the Q1202 and Q1203 sensors 3. Brush a folded sheet of paper under each sensor to clear any obstructions, as shown in figure 3-39. Figure 3-40 Clearing the Q1202 and Q1203 sensors 4. Close the finisher top cover.
Routine maintenance Cleaning the Q1222 and Q1210 sensors 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. Figure 3-41 Locating the Q1222 and Q1210 sensors 3.
Routine maintenance Figure 3-42 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 NOTE: Production publisher configuration only 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.
Routine maintenance Figure 3-43 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 NOTE: Production publisher configuration only 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°C).
Routine maintenance Figure 3-44 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.
Routine maintenance Figure 3-45 Locating the Q1221, Q1218, and Q1227 sensors Cleaning the binder 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.
Routine maintenance 2. Grasp the green handle on the binder drawer. Pull the drawer out until it stops. Figure 3-46 Opening the binder drawer 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. Figure 3-47 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. c.
Routine maintenance end tab. Move the cleaner back and forth until the end tab breaks. d. Continue to move the cleaner in the same manner until the 2-sided tabs break. NOTE: NOTE: Ensure that the following cleaning procedures are 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.
Routine maintenance 1. Use the binder platen cleaner to clean the top and side surfaces of the binder platen until all the glue is removed. 2. Ensure that the glue is removed from the grooves on the binder platen surface, which align with the top and bottom edges of the book. Figure 3-49 Cleaning the binder platen Cleaning the flappers 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.
Routine maintenance Figure 3-50 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.
Routine maintenance Figure 3-51 Cleaning the calipers Closing the binder 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 NOTE: Production publisher configuration only Use this procedure to replace stitcher spool A in the system. Check stitcher spools A and B visually during the warm-up cycle.
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. Figure 3-52 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. c. Pull the plug out of the stitcher head.
Routine maintenance Figure 3-53 Removing the stitcher wire plug 5. Perform one of the following steps: • 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 is located next to stitcher spool B.
Routine maintenance • 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. Figure 3-55 Rewinding the remaining wire 6. Insert the plug into the measuring bracket, as shown in figure 3-55. Figure 3-56 The measuring bracket 7. Release and remove stitcher spool A.
Routine maintenance a. Locate the green pin release handle under spool B, as shown in figure 3-56. Figure 3-57 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. 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.
Routine maintenance Figure 3-58 Replacing the pin 9. Remove any damaged wire. WARNING: Hold the wire on the spool to prevent eye injury and 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.
Routine maintenance Figure 3-59 Removing the paper wrapper NOTE: Hold the wire between the thumb and forefinger of both hands. 10. Feed the wire slowly into the tubing until the wire extends from the stitcher plug, as shown in figure 3-59. Figure 3-60 Feeding the wire 11. Remove the stitcher plug from the measuring bracket.
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.
Routine maintenance Figure 3-61 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). 2. Keep stored rolls in their original unopened containers. 3. 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.
Routine maintenance Replacing the binder tape reel NOTE: Production publisher configuration only 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.
Routine maintenance Figure 3-64 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. Figure 3-65 Unlocking the reel b. Remove the tape reel. 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. If necessary, rotate the tape reel slightly until it clicks into position.
Routine maintenance NOTE: NOTE: The tape will not feed properly if the retainer is not locked. b. Move the reel retainer to the locked position. Figure 3-66 Locking the reel NOTE: NOTE: Ensure that the tape passes through the binder tape sensor. 6. Follow the instructions on the binder tape loading label and thread the tape through the tape feeder. Tape Sensor Figure 3-67 Threading the tape through the tape feeder 7. Thread the tape around the drive roll to the edge of the pressure roll.
Routine maintenance Figure 3-68 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 3-69 Feeding the tape manually 9. Cut the tape. a. Lift up on the green tape cutter handle, as shown in figure 3-69. b. Remove the cut piece of tape.
Routine maintenance Figure 3-70 Cutting the tape 10. Close the binder drawer. 11. Close the finisher doors. Adjusting the binder tape registration NOTE: Production publisher configuration only 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.
Routine maintenance Figure 3-71 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.
Routine maintenance Figure 3-72 Adjusting the tape position up • Pull the knob and rotate it counterclockwise to move the tape toward the bottom edge of the book. Figure 3-73 Adjusting the tape position down 8. Close the finisher doors. 9. Run a test binder job to check your adjustment. 10. Perform the procedure again as needed.
Routine maintenance Replacing the Customer Replaceable Filter When directed by the screen message P09-447, HLC Waste Dry Ink Filter full, call for service or replace the waste dry ink filter. CAUTION: To prevent dry ink spills, remove the waste dry ink filter only when directed to do so by a message on the screen. 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.
Routine maintenance 6. Remove the filter housing cover and set it on the piece of paper from step 3. 7. Remove the filter by pulling straight up with the handle. Immediately place the filter in the empty bag that contained the new filter. 8. Place the used filter into the box that contained the new filter. 9. Insert the new filter into the filter housing. Firmly press straight down. The filter clicks into place. Figure 3-75 Inserting the new filter and closing the cover 10.
4 Problem Solving The system is designed to help you 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.
Problem Solving When a fault occurs When a fault occurs in the printer an indicator appears on the FreeFlow Print Server 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.
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.
Problem Solving Problem Suggested Solution Missing sheets in a After recovering from a jam, an incomplete set may be purged and the set set immediately after reprinted. Check the prints to ensure that you are not confusing the purged a jam. 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.
Problem Solving Problem Suggested Solution Processor power is off unexpectedly The processor or the FreeFlow Print Server may have an electrical problem. If the FreeFlow Print Server has an electrical problem, it may shut off the power to the processor. 1. Determine if the FreeFlow Print Server power and the processor power are off. • If the print server's screen is blank and the power-indicator light is not blinking, the print server power is off.
Problem Solving Solving print quality problems A print quality problem means that the job was submitted successfully, but does not print correctly. NOTE: If the Image Quality parameters are changed, you must restart or reboot the FreeFlow Print Server 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].
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.
Problem Solving 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 Figure 4-6 Area 7 DocuTech 128/155/180 HighLight Color Operator Guide 4- 9
Problem Solving Figure 4-7 Area 8 NOTE: If a jammed sheet rips as you are removing it from area 8, 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.
Problem Solving 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. Pull the 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.
Problem Solving Figure 4-9 Area 10 Figure 4-10 Area 11 (all feeder/stackers) NOTE: High volume printer configuration only 4-12 DocuTech 128/155/180 HighLight Color Operator Guide
Problem Solving Figure 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 printer configuration only.
Problem Solving NOTE: You may sometimes find paper lying on top of area 14, even though there is no message indicating a jam in this area. Discard the paper.
Problem Solving Figure 4-15 Area 16 NOTE: High volume printer configuration only 4-16 DocuTech 128/155/180 HighLight Color Operator Guide
Problem Solving Figure 4-16 Area 17 NOTE: If your printer has frequent jams in this area, you may need to clean the Q1106 sensor.
Problem Solving Figure 4-17 Area 18 Points to note for clearing jams in area 18: • Sometimes the print server 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.
Problem Solving Figure 4-18 Area 19 3. Remove any paper from the exposed area. 4. 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.
Problem Solving Figure 4-19 Area 20 6. Remove any paper from the exposed area. 7. 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 1. If the Ready to Open indicator is not lit, press the Tray Unlock button located on the feeder tray control panel. Figure 4-20 2. When the Ready to Open indicator lights, open the feeder tray.
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. • 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.
Problem Solving Figure 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 print server. 1. Check the paper in the indicated tray.
Problem Solving Interposer problems 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 (2-Tray) or 4, 5, and 6 (3-Tray) have been loaded correctly.
Problem Solving Finisher problems NOTE: Production publisher configuration only 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.
Problem Solving Table 4-3. Resolving a finisher problem 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 maintenance" chapter. Refer to the binder tape storage information in this guide. Refer to the binder cleaning information in this guide.
Problem Solving 2. Open the top cover. WARNING: The binder tape adhesive is hot, approximately 425°F (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. If 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.
Problem Solving NOTE: If the spool is empty, replace the stitcher spool A. Refer to online 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. Figure 4-23 Stitcher head release handle Figure 4-24 Removing the stitcher wire plug 5. Remove the stitcher wire plug.
Problem Solving • The stitcher wire plug is located above the binder area, as shown in figure 4-24. • Press and hold down the release clip. • Pull the plug out of the stitcher head. 6. Remove any damaged wire. • Using the wire cutters, slowly and carefully pull approximately 3 feet (1 meter) of wire out of the stitcher plug. • 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.
Problem Solving 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. • 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. • 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.
Problem Solving 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.
Problem Solving 2. Hold the printed sheets by the top center 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. • If the curl on the printed paper stock measures between +2 and -2, do not change the decurler setting. • If the curl is between +2 and +3, or -3 and -4, adjust the decurler lever.
Problem Solving 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: • Your printing system serial number, which is located on a panel inside the printer, behind the small door on the left.
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.
Technical information Paper tray capacities Stock weight (all trays) Tray 1 Stock sizes Substance 16 to 110 (60 to 200 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)) Capacity Tray 2 Stock sizes 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 =
Technical information Tray 4 Stock Sizes 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)) Capacity 550 sheets, substance 20 (75 g/m2), post-process only NOTE: This tray information applies to the Production publisher configuration.
Technical information 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 500 sheets in each tray, substance 20 (75 g/m2), pre or postprocess This tray information applies to the Production publisher configuration.
Technical information 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. Humidity and moisture cause the natural paper curl to increase. Too much curl causes jams in the system.
Technical information Stock satisfaction guides Table 5-1. Satisfaction guide for paper trays 1 and 2 Stock Reliable feeds may be expected Size 8 x 10 inches to 9 x 14 inches (203 x 254 mm to 229 x 356 mm) Weight Substance 20 to 110 (75 to 200 g/m2) Capacity Tray 1 - 1100 sheets, substance 20 (75 g/ m2) Tray 2 - 600 sheets.
Technical information Stock Reliable feeds may be expected Weight Substance 16 to 110 (60 to 200 g/m2) Capacity 550 sheets, substance 20 (75 g/m2) Type or condition Xerographic bond paper in good condition Drilled stock, fanned thoroughly Less reliable feeds may be expected Suggested alternatives Weights outside the limits shown 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.
Technical information Stock Type or condition Reliable feeds may be expected Xerographic bond paper in good condition Drilled stock, fanned thoroughly Less reliable feeds may be expected Slightly curled paper Intermixed weights Xerox vellum Full cut tabs Label stock Adhesive drafting film Paper with reinforced edges Suggested alternatives Do not use excessively curled paper Substance 110 (200 g/m2) must be long grain. Do not use short grain. Precut tabs - use tray 1 or 2.
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, 5, or 6. 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, 5, or 6. Optimum satisfaction can be expected from tray 3, 4, 5, or 6.
Technical information Stock Type 5-10 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 on the Trays pulldown menu.
Technical information Stock Type Instructions for use Textured paper Heavily textured paper may produce prints with a ragged character appearance or deletions. To 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.
Technical information 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).
Technical information device that is not a Signature Booklet Maker, there is no message displayed on the FreeFlow Print Server to warn the 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.
Technical information Common size name US Ledger/ US B-Size Inches x inches Millimeter equivalent Diagonal in inches Can be rotated Comment (similar to or the same as) 10.5 x 14.5 267 x 368 17.90 NO* 2-up of US 7.25 X 10.5 in. (Executive) 11.0 x 17.0 279 x 432 20.25 NO 2-up of US 8.5 x 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.
Technical information Table 5-10. Other paper sizes that can be rotated Common size name Inches x inches Millimeter equivalent Diagonal in inches Can be rotated Largest square 12.73 x 12.73 323 x 323 18.00 YES Largest rectangle 10.89 x 14.33 277 x 364 18.00 YES Comment (similar to or the same as) Length is constrained by paper path width. For media sizes that are not listed in the above tables, view the graph shown in figure 5-1.
Technical information Finisher satisfaction guides NOTE: Production publisher configuration only The following guides summarize the stacker, stitcher, binder, and top tray capabilities. Table 5-11.
Technical information Table 5-12. Stitcher satisfaction guide Stock Reliable stacking may be expected Less reliable stacking may be expected Size 8 x 10 inches to 9 x 14 inches (203 x 254 mm to 229 x 356 mm) Use the top tray for larger sizes Weight Substance 16 to 110 (60 to 200 g/m2) Weights outside the limits shown are not recommended. Set size limit due to copy paper weight Collated: Up to 65 sheets of substance 20 (75 g/m2) or 0.
Technical information Table 5-13.
Technical information Table 5-14. Top tray satisfaction guide Stock Reliable stacking may be expected Less reliable stacking may be expected Suggested alternatives Type or condition Xerographic bond paper in good condition Drilled paper These may yield stacking registration problems: Slightly curled paper Precut tabs cannot be sent to the top tray. Do not use excessively curled paper. Stock not defined here is included in the “Using various stocks” section in this guide.
Technical information 5-20 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.
Service and supplies The key to effective use of the support center is correct identification of the problem.
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 States only.
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: • Adding dry ink • 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 Guide. You need to decide how many operators will be responsible for performing these maintenance tasks.
Service and supplies Table 6-1. Consumable supplies 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 4024 Dual Purpose Paper 3R721 A4 4024 Dual Purpose Paper 3R2594 8.5 x 14 inch 4024 Dual Purpose Paper 3R727 8.5 x 11 inch 4024 Dual Purpose Paper, 3-hole 3R723 8.5 x 11 inch 4024 Dual Purpose Paper, 3hole* 8.5 x 11 inch 4024 Dual Purpose Paper, 4-hole 3R1983 8.
Service and supplies Item Description U.S. part number 8.5 x 14 inch Dual Purpose Colors, Goldenrod 3R3094 8.5 x 11 inch Dual Purpose Colors, Ivory 3R3064 8.5 x 11 inch Dual Purpose Colors, Ivory, 3hole 3R3080 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, 3hole 3R3802 8.5 x 14 inch Dual Purpose Colors, Gray 3R3098 8.
Service and supplies Item Description U.S. part number 8.5 x 11 inch Custom form (uncut) Contact Xerox Supplies Order Service Dry Ink Black Packaged 3 cartridges per carton. 220K/carton with 6% black only area coverage 6R206 (US/CA) Dry Ink Blue 300K/Carton with 1.5% area coverage as highlight color 6R1191 (US/CA) 6R90343 (EU) Dry Ink Red 300K/Carton with 1.5% area coverage as highlight color 6R1192 (US/CA) 6R90344 (EU) Dry Ink Green 300K/Carton with 1.
Service and supplies Item 6-8 Description U.S. part number Blue Developer Packaged 2 bottles per carton. Effective life is approximately one carton per 500,000 pages. 5R688 Red Developer Packaged 2 bottles per carton. Effective life is approximately one carton per 500,000 pages. 5R689 Green Developer Packaged 2 bottles per carton. Effective life is approximately one carton per 500,000 pages. 5R690 Cardinal Red Developer Packaged 2 bottles per carton.
Service and supplies Item Description Binder Tape Black White Gray Blue Packaged 1 reel per carton. Consumption rate is approximately 425 binds per carton. U.S. part number 8R7186 8R7187 8R7188 8R7189 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. CAUTION: *Fuser blend and Fuser shield are NOT interchangeable. Contact your Xerox representative before switching from one to the other.
Service and supplies Item Description Quantity Date of order Date ordered Fuser shield Labels Transparencies Cleaning supplies Other 6-10 DocuTech 128/155/180 HighLight Color Operator Guide
Service and supplies If you use custom colors, 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 6-3.
Service and supplies 6-12 DocuTech 128/155/180 HighLight Color Operator Guide
