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Xerox DocuTech 128 HighLight Color Operating Guide

1. PA ig ag LJ 1 OOOI T Za X i X RSI Ph fae Figure 4 9 Area 10 eo N oO Figure 4 10 Area 11 all feeder stackers 4 NOTE High volume printer configuration only Ki 4 12 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Figure 4 11 Area 12 all feeder stackers 4 NOTE High volume printer configuration only E DocuTech 128 155 180 HighLight Color Operator Guide 4 13 Problem Solving Clearing paper jams in the Feeder Stackers Figure 4 12 Area 13 i 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 Es we Figure 4 14 Area 15 4 NOTE High volume printer configuration only DocuTech 128 155 180 HighLight Color Operator Guide 4 15 Problem Solving
2. Figure 4 4 Area 5 4 8 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving sss Figure 4 5 Area 6 Sn 00 Figure 4 6 Area 7 DocuTech 128 155 180 HighLight Color Operator Guide 4 9 Problem Solving Figure 4 7 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 NOTE fa jammed sheet rips as you are removing it from area 8 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving CUO DETE ZZ HA i OOOI T E
3. ARL 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 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 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 4 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
4. XEROX Figure 4 29 Location of printing system serial number e Your name e Your company name e The system condition or status 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 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 This section contains information on expected print rates for the DocuTech printers as well as information on the weight sizes and capacities for their paper trays Printer rates Print rate DT HLC 180 180 prints per minute 8 5 x 11 inch 216 x 279 per minute 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 12
5. 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 or 3 Tray Interposer stitcher binder Convenience tray Interposer 2 Tray shown Finisher oe IN 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 Systemcomponents 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 Sheet
6. ATRAANNA TAD Figure 2 9 2 Tray Interposer production publisher only DocuTech 128 155 180 HighLight Color Operator Guide 2 15 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 Paper transport lower Paper transport upper Inserter tray Feeder inserter tray Tray 5 Feeder inserter tray Tray 6 OP ONS QTC0100B TOR Figure 2 10 3 Tray Interposer production publisher only DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents Finisher NOTE Production publisher configuration only ad lt 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 Bindexer Stitcher Stacker Binder Binder tape reel Stitcher wire spools Top tray DOD
7. 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 e 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 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 Sample tr
8. 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 lt DocuTech 128 155 180 HighLight Color Operator Guide 4 17 Problem Solving Figure 4 17 Area 18 Points to note for clearing jams in area 18 e 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 e 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 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 Figure 4 18 Area 19 3 Remove any paper from the exposed area 4 Press th
9. Table 5 14 Top tray satisfaction guide Drilled paper Slightly curled paper Precut tabs cannot be sent to the top tray 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 Stock not defined here is included in the Using various stocks section in this guide DocuTech 128 155 180 HighLight Color Operator 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 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 inf
10. The 7 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 2 19 System components High volume printer paper path The following figure shows the path the paper takes through the high volume printer O 9b 9a 10b PA 9c 10c R P gt z 9 10 Be 6 gt m 126 12b 3 4 2 w 3c 4c Figure 2 12 Route of paper through the high volume printer Processor feeder tray 1 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 Origin 0 0 portrait orientation 2 20 DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents 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 te 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
11. Load the stock with the white stripe to the right into trays 1 and 2 Load 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 5 and 6 Do not select 2 sided prints Letterhead preprinted Load the paper into trays 3 4 5 and 6 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 Technical information Stock Type Instructions for use Textured paper Heavily textured pap
12. 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 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 3 42 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XEA098A 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 XE039B Figure 3 40 Clearing the Q1202 and Q1203 sensors 4 Close the finisher top cover DocuTech 128 155 180 HighLight Color Operator Guide 3 43 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 A RI E ss XEA099A Figure 3 41 Locating the Q1222 and Q1210 sensors 3 Locate the Q1222 and Q1210 sensors as shown in figure 3 41 3 44 DocuTech 128 155
13. 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 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 Perchlorate Law Compliance Announcement This announcement is required for all Xerox products which contain perchlorate materials and are destined fo
14. Printer rateS ocat aua ae a a teen ee 5 1 Paper tray capacities nnan 00 00 cee 5 2 Additional paper capacities 0 0 0 0 5 4 Printer satisfaction guides 00 cette eens 5 5 Stock satisfaction guides 1 6 eee ee 5 6 Using non standard stock 0 0 uaaa aeaaee 5 11 Paper stock rotation 0 000 tee 5 12 Finisher satisfaction guides 1 0 00 ce nee 5 16 6 Service and supplies Xerox support serviceS 0000 eee eee 6 1 Customer SUPPO ao naaa vos nee ee oe ee ee Sa We ew ee ees 6 1 Operator training eaae a edger a ace Pea eR aed badd awale peed Ra ee ed RES 6 2 Supplies SEFVICE oces pddide did 2 ee Sees eh pede Rod de phd ae Eh oy ead ore 6 2 Routine maintenance 020 cee 6 4 Meter reading and reporting 0 000 c eee eee 6 4 Consumable supplies table DocuTech 128 155 180 HighLight Color Operator Guide vi DocuTech 128 155 180 HighLight Color Operator Guide About this guide Contents Introduction 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
15. e 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 DocuTech 128 155 180 HighLight Color Operator Guide 2 27 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 e 7 by 10 inch B5 A4 e US letter e B4 e US legal The following papers which have long edges greater than 14 33 inches 364 mm must feed short edge first e A3 e US ledger or US tabloid 4 NOTE JIS B4 can be fed either long edge or short edge first 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 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 You should respond to the fault or message as soon as possible to
16. 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 DocuTech 128 155 180 HighLight Color Operator Guide 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 3 3R2193 hole 8 5 x 11 inch 4024 Dual Purpose Paper 4 hole 3R1983 8 5 x 11 inch 4024 Dual Purpose Paper 4 3R3008 hole 8 5 x 11 inch 4024 Dual Purpose Paper 7 hole 3R1984 8 5 x 11 inch 4024 Dual Purpose Paper 7 3R3010 hole 8 5 x 11 inch 4024 Smooth 3R2675 8 5 x 14 inch 4024 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 Co
17. measurement chart on the line that best represents the curve of the sheets e 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 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 print server e Indicator lights that may or may not be lit e Status codes that appear in the message display of the tape DocuTech 128 155 180 HighLight Color Operator Guide 4 31 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 e Your printing system serial number which is located on a panel inside the printer behind the small door on the left Le F
18. to less than 13 7 inches 348 mm Unresolved stock size mismatch 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 DocuTech 128 155 180 HighLight Color Operator Guide 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 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 Bef
19. 128 155 180 HLC system use the on line help system and the other documents for the FreeFlow Print Server 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 e Routine maintenance describes the routine activities you perform to maintain the reliability and productivity of your printer e 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 gt e s viii All caps and angle brackets Within procedures the names of keys are shown in all caps within angle brackets for example press lt RETURN gt
20. 128 155 180 HighLight Color Operator Guide 2 23 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 The system also communicates messages and instructions to you on the Print Server interface screen The print server 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 FreeFlow Print Server user interface NOTE Print server hardware configurations are subject to 4 change to keep up with advances in technology lt Print Server overview The print server 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 print server also provides the printer with print data and commands and receives status information from the printer The print server consists of a workstation which is run by the Sun Solaris Operating environment Also resident on the print server is softw
21. 180 HighLight Color Operator Guide Routine maintenance XE041C 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 4 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 Locate the Q1205 Q1206 and Q1207 sensors as shown in figure 3 42 DocuTech 128 155 180 HighLight Color Operator Guide 3 45 Routine maintenance XE040B 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 4 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 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 4
22. 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 3 24 When directed by a message add fuser lubricant as soon as possible If it is not 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 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 approximately 425 F 218 C Exercise care to prevent burns when working in this area DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance CAUTION Fuser lubricant for other
23. Angle brackets Variable information or the position of a specified argument in the command syntax 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 Italics 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 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 Mi WARNING Use of co
24. 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 20 DocuTech 128 155 180 HighLight Color Operator Guide 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 f 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
25. DocuTech 128 155 180 HLC can print the following data formats e ASCII e LCDS e IPDS e PCL e PDF e PostScript e TIFF e PPML 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 prints IPDS data from a host computer emulating an IBM 3812 3825 3827 or 3935 printer The printing system can receive data through a channel card with bus and tag connectivity and through a TCP IP interface using Ethernet The system also prints PostScript and PCL data submitted over a network Ethernet or AppleTalk from a variety of clients PCs Windows and Windows XP e Sun workstations UNIX UNIX command line clients lpr including Ip and Xerox Command Line Client CLC e NetWare Q Server through a Novell print server bindery mode only e Apple Macintosh workstations DocuTech 128 155 180 HighLight Color Operator Guide 2 3 System components Paper weights 2 4 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 printer running at optimum efficiency The printer functions best and produces the best pr
26. 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 Refer to the System Guide If the paper tray lights are out the power to the processor is off Proceed with step 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 If the processor has a ground fault protector determine whether the protector has shut off the power e Ifthe red light is visible on the protector proceed with step 4 e 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 Press the reset button on the processor ground fault protector Ifthe red light switches off proceed with step 5 e Ifthe red light does not switch off or immediately switches on again refer to the procedure Calling for assistance in this guide Switch the white handled circuit breakers near the protector to the on up position e If the power comes on proceed with step 6 e Ifthe circuit breakers i
27. 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 6 2 To avoid downtime always have an adequate amount 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 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
28. 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 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 15 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 2 26 DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents I 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 e If an exact match is found the print job continues
29. Whenever you use or remove a part from the system handle the part carefully Note any informative labels on the system e Keep atomized and aerosol sprays away from the system e 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 e 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 425 F 218 C Exercise care to prevent burns when working near this area Finisher precaution 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 stitcher spool A in this guide The system applies binder tape from a reel mounted in the bind
30. business application 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 DocuTech 128 155 180 HighLight Color Operator Guide DocuTech 128 155 180 HighLight Color Operator Guide Table of Contents 1 Safety notices DY SUCM e sg cece c g Mean caste EEE teat ae cer enay E Se aes ee cent EE 1 1 Laser Salely o rera wade 6 vt Bath
31. cart top cover 11 Close the printer doors 12 Store the cart DocuTech 128 155 180 HighLight Color Operator Guide 3 21 Routine maintenance 3 22 Storing the cart and CCU NOTE f 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 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 Ifthe 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 Place the service stand next to the developer housing By turning the jack screws adjust the height of the front feet so that the alignmen
32. e Remove the copy paper carefully being sure not to drop any wire fragments into the system DocuTech 128 155 180 HighLight Color Operator Guide 4 29 Problem Solving 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 Checking paper curl 4 30 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 DocuTech 128 155 180 HighLight Color Operator Guide 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
33. feature 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 no dark areas on the lead edge This is the system default setting and is the recommended setting 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 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 Fault Code P09 447 Fault Code P10 216 When this fault is appears call for service or replace the waste dry ink filter Refer to the customer replaceable waste filter procedure in this guide 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 4 4 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving Problem Suggested Solution Processor power is off unexpectedly The processor or the
34. guide Refer to the binder tape reel storage information in this guide 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 4 24 DocuTech 128 155 180 HighLight Color Operator Guide 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 gu
35. heavier than substance 20 75 g m2 for main body or inserts Stacker Delivers 12 sets inboard To allow continuous run capacity and 12 sets outboard unload outer stack before inner stack reaches capacity Type 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 14 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 75 g m2 or less substance 20 75 g m2 415 sheets substance 24 unload the tray before the 90 g m2 count in the tray reaches 500 310 sheets substance 32 Check the stitch quality 120 g m2 225 sheets substance 110 200 g m2 5 18 DocuTech 128 155 180 HighLight Color Operator Guide Technical information
36. occur following a printer malfunction for example fuser jams Running stock 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 DocuTech 128 155 180 HighLight Color Operator Guide 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 14 33 inches B4 JIS 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 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
37. reel drive a Move the reel retainer in the center of the reel to the horizontal unlocked position TA810A Figure 3 65 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 If necessary rotate the tape reel slightly until it clicks into position DocuTech 128 155 180 HighLight Color Operator Guide 3 63 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 66 Locking the reel 4 NOTE Ensure that the tape passes through the binder tape 4 sensor 6 Follow the instructions on the binder tape loading label and thread the tape through the tape feeder TA615C 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 3 64 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XEAO76A 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 65 Routine mainten
38. shown in figure 3 57 DocuTech 128 155 180 HighLight Color Operator Guide 3 57 Routine maintenance Sey a W ate ZB qa LN Lf S S D LE oy JH XEAO65A Figure 3 58 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 3 58 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XEAO66A Figure 3 59 Removing 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 60 Feeding the wire 11 Remove the stitcher plug from the measuring bracket DocuTech 128 155 180 HighLight Color Operator Guide 3 59 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 t
39. stacked in bin 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 DocuTech 128 155 180 HighLight Color Operator Guide 2 21 System components Production publisher paper path The following figure shows the path the paper takes through the production publisher Y DPC0202A TOR Figure 2 13 Route of paper through the production publisher 9 CO E OVP GN Processor feeder tray 1 Processor feeder tray 2 High capacity paper tray Paper inserter tray High capacity paper tray Two tray Interposer shown 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 2 22 DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents High volume printer bypass transport paper path Sheet path 0 0 10 6mm 0 4 J O g a _ Sheet path O A 1418 4mm 56in 87 5mm 3 4in 860mm 34in Exit rolls Floor Figure 2 14 Bypass transport paper path high volume printer configuration shown 1 Sheet path 2 Exit rollers 3 Floor DocuTech
40. the binder platen 0 00 ee nee 3 50 Cleaning the flappers 20200 c eee eee 3 51 Cleaning the calipers 0 2 2 0 0 00 eee 3 52 Closing the binder 0 0 06 EEE E a E eee 3 53 Replacing the stitcher spoolA 0 002 3 53 Storing the binder tape reels 0 0 ee 3 60 Replacing the binder tape reel 2 000 c cee ee eee 3 62 Adjusting the binder tape registration 0 0 cee eee 3 66 Replacing the Customer Replaceable Filter 220000 00 eee eeee 3 69 4 Problem Solving How problems are displayed 0 000 teeta 4 1 Printer faults and fault windows 00 000 c eee 4 1 When a fault occurs 2 0c teeta 4 2 Resolving a processor problem 0 0c eect ete 4 2 Solving print quality problems 000 eee tee 4 6 Clearing paper jams 6 0200 eee eee 4 6 Incorrect paper size message 00 eee 4 22 Interposer problems 20 0c cece eet 4 23 Finisher problems 22 00 cece eee teen eee 4 23 Binder tape fault t c2444 d0 0a Pdodanet dd dhad de enan delhi phada deemed dare 4 4 25 Stitcher spool A fault 2 2 0 0 22 eee 4 26 Checking paper curl 0 00000 cee eee 4 30 Customer Support Center 0 000 c cee 4 31 iv DocuTech 128 155 180 HighLight Color Operator Guide 5 Technical information DocuTech printer specifications 0 0000 cee 5 1
41. 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 Systemcomponents 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 use In each tray a control panel consisting of a button indicators and paper level displays controls the elevator tray and indicates its status UUWew Ss Boe B B
42. 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 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 Table 5 9 Common sizes used in Europe Japan Canada etc T Comment Common Inches x Millimeter roar Can be tat f 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 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 x 432 20 25 NO 2 up of US 8 5 x US B Size 11 0 in Letter 5 14 DocuTech 128 155 180 HighLight Color Operator Guide Technical information Table 5 10 Other paper sizes that can be rotated aii Comment Common Inches x Millimeter oe Can be Pas size name inches equivalent Diagonal in inches rotated ee Largest 12 73 x 12 73 323 x 323 18 00 YES square Largest 10 89 x 14 33 2
43. 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 4024 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 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 DocuTech 128 155 180 HighLight Color Operator Guide 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 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 6R1193 US CA coverage as highlight color 6R90345 EU Dry Ink Royal 300K Carton with 1 5 area 6R1255 US CA Blue coverage as highlight color 6R90356 EU D
44. 155 180 HighLight Color Operator Guide Technical information Reliable feeds may Less 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 4 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 Capacit
45. 3 3 46 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XEA101A 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 4 NOTE Production publisher configuration only j 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 47 Routine maintenance XE042C Figure 3 45 Locating the Q1221 Q1218 and Q1227 sensors Cleaning the binder 2 gt 3 48 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 WARNING All areas of the binder drawer including 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 1 Open the finisher doo
46. 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 Adjusting for paper curl Each sheet of paper has a 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 9 Routine maintenance rte 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 th
47. 5 g m2 shown are not recommended Set or stack size Substance 16 to 20 60 to 75 g m2 Over substance 20 75 g m2 stock as sets or stacks increases the likelihood of bindexer jams When using copy paper heavier than substance 20 75 g m2 limit the stack or set 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 Unfinished 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 paperin 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 5 16 DocuTech 128 155 180 HighLight Color Operator Guide Technical information Table 5 12 Stitcher satisfaction guide 200 g m2 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 m
48. 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 Royal Blue Packaged 2 bottles per carton 5R715 Developer Effective life is approximately 5R716 FX one carton per 500 000 pages Cyan Developer Packaged 2 bottles per carton 5R719 Effective life is approximately one carton per 500 000 pages Violet Packaged 2 bottles per carton 5R725 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 4 mm blank cartridge 8 GB 109R00314 Diskettes 3 5 inch double sided dual 8R3704 density 1 44 MB unformatted 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 DocuTech 128 155 180 HighLight Color Operator Guide Service and supplies Item Description U S part number Binder Tape Black 8R7186 W
49. 77 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 w 2 5 ISO A4 LEF ISO A3 SEF A e 3 8 5x11 LEF 11x17 SEF 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 inches 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 DocuTech 128 155 180 HighLight Color Operator Guide 5 15 Technical information Finisher satisfaction guides lt 4 NOTE Production publisher configuration only The following guides summarize the stacker stitcher binder and top tray capabilities Table 5 11 Stacker capacity Reliable stacking may be Less reliable stacking may be Stock expected 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 7
50. 8 128 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 DocuTech 128 155 180 HighLight Color Operator Guide 5 1 Technical information 5 2 Paper tray capacities Stock weight all trays Tray 1 Stock sizes Capacity Tray 2 Stock sizes Capacity Tray 3 Stock Sizes Capacity 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 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 J
51. Council Directive 1995 5 EC on radio equipment and telecommunications terminal equipment 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 S3G 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 4 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
52. FA 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 2 18 DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents 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 4 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 AN can have a maximum of two 2 feeder stacker modules See figure 2 13 lt 7 by 10 inch enablement kit
53. IS 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 DocuTech 128 155 180 HighLight Color Operator Guide Technical information Tray 4 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 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 4 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 203 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 Tray 5 and 6 US Letter 8 1 2 x 11 inches Stock Sizes 3 Tray US Legal 8 1 2 x 14 inches miernpaseni siegger 17 x41 inches 9 x 11 inches A3 A4 8 1 2 x 13 inches DocuTech 128 155 180 HighLight Color Operator Guide 5 3
54. LCDS or non IPDS jobs and for LCDS or IPDS jobs PostScript PCL When the job is sent from the application for printing a print data TIFF ASCII LCDS file is created This file becomes the job that is submitted to the IPDS 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 Printer overview The printer receives data from the print server 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 either a 2 Tray or 3 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 Sample tray Attention light Purge tray Feeder stacker modules Inverter feeder stacker OaRwns Feeder paper tray High volume printer Multiple feeder paper trays can be configured
55. Mie eee ee eel we etek yeaa Ea Gk 2 7 High volume printer erres risia erara ee ee ed ee ee ee 2 8 Production publisher 0 0000 cee eee eee 2 14 TAG SYStOM esrar annA a Pale dr ane hued eee anaes eee a vad deeds 2 24 System Hardware e remua ae a a a a T a a a a A E 2 24 Paper sizing and print speed naana anaana 2 27 3 Routine maintenance Cleaning and maintenance overview 00 eee eee 3 1 Necessary Precautions 00 000 ete eens 3 1 Finisher precaution 000 0 tees 3 2 Papel tk ih earen epee baw ea 4 ON ERE Age Pn ea a a De 3 3 Storing PAPCM eas ccm he ea aeie SS Sea ca A ene Oe ae ee aaa ea 3 3 Conditioning paper 34 icavedeais fan vevaw e eae tae GG bd wie dee ee dane 3 4 PAP el CUM sorida Arges hod geek earn a a A yee Le he eee A epee a 3 5 Adding paper to tray 1 or 2 2 0 tees 3 6 Adding paper to trays 3 4 5 0r6 0 eee 3 8 Using the custom transfer assist blade 1 2 0 0 0 0 ee eee 3 8 Adjusting for paper curl 0 00 eee eee 3 9 Adjusting the decurler lever 0 0 cent eee 3 12 Maintaining the printer 2 0 eee ae 3 13 DocuTech 128 155 180 HighLight Color Operator Guide Replacing the black dry ink bottle nuanua eee 3 13 Replacing the highlight color container 0 0 0 cee 3 15 Changing the highlight color Customer Changeable Units 3 17 Adding fuser shield 0 0 00 ccc teens 3 24 Waste containers 0 00 ccc e
56. O NS The bindexer 4 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 configuration 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 FreeFlow Print Server software NOTE For more information about setting stitch placement refer to the on line help system DocuTech 128 155 180 HighLight Color Operator Guide 2 17 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 NOTE For more information refer to the on
57. Operator Guide 3 13 Routine maintenance NN 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 anew 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 3 14 DocuTech 128 155 180 HighLight Color Operator Guide 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 u p o S L gt if HG i 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 4 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 t
58. Production publisher configuration finisher sensors e Q1201 sensor e Q1202 and Q1203 sensors Q1205 Q1206 and Q1207 sensors e Q1213 sensor 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 35 Routine maintenance A AN P ag a gt S Ss Uy I a Figure 3 31 Area 4 and green handle 3 Locate the Q850 and Q861 sensor Figure 3 32 Q850 and Q861 sensor 3 36 DocuTech 128 155 180 HighLight Color Operator Guide 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 AN X S s ARRON 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 Cleaning the Q1106 and Q1166 sensors 4 NOTE High volume printer configuration only lt 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 windo
59. Suggested alternatives Size 8 x 10 inches to 9 x 14 Stock smaller than 8 x 10 inches inches 203 x 254 mm cannot 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 4 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 5 6 11 inches 203 x 254 mm to 432 x 279 mm used DocuTech 128
60. Technical information Capacity lt 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 500 sheets in each tray substance 20 75 g m2 pre or post process This tray information applies to the Production publisher configuration Additional paper capacities Inverter Stock sizes Top tray Stock sizes Capacity Stacker Stock sizes Capacity Stitcher Stock sizes Capacity Stitches per spool Binder Stock sizes Capacity Binds per spool 5 4 or duplex tray 8 x 10 inches to 17 x 11 inches 203 x 254 mm to 432 x 279 mm 8x10 inches to 17 x 11 inches 203 x 254 mm to 432 x 279 mm 500 sheets substance 20 75 g m2 8 x 10 inches to 9 x 14 inches 203 x 254 mm to 229 x 356 mm 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 DocuTech 128 155 180 HighLight Color Operator Guide 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 facto
61. XEROX 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 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 typographic errors will be corrected in subsequent editions Document Version 1 0 July 2007 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
62. ace as shown in figure 4 23 XE059D Figure 4 23 Stitcher head release handle TA828A Figure 4 24 Removing the stitcher wire plug 5 Remove the stitcher wire plug DocuTech 128 155 180 HighLight Color Operator Guide 4 27 Problem Solving 4 28 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 e 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 Cut the wire carefully leaving approximately 2 inches 50 mm of wire extending from the stitcher plug as shown in figure 4 25 XEA084A Figure 4 25 Cutting the wire 7 Insert the plug into the measuring bracket as shown in figure 4 26 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving 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 e 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
63. acker 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 mj Dm 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 e A selection 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 fo
64. an substance 32 4 120 g m2 can be achieved between 1 and 1 curl 3 10 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance curl shown in this chart Move green Move green decurler lev curler lever Figure 3 6 Measuring the paper curl DocuTech 128 155 180 HighLight Color Operator Guide 3 11 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 pa 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 Ifthe 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 3 12 DocuTech 128 155 180 HighLight Color Operator Guide 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 poss
65. ance XEAO078A Figure 3 70 Cutting the tape 10 Close the binder drawer 11 Close the finisher doors Adjusting the binder tape registration 4 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 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 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 3 66 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XE159A 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 Adjust the tape position by performing one of the following steps e P
66. aper 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 paper 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 th
67. are which manages all printing diagnostic and administrative functions on the printing system The FreeFlow Print Server 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 2 24 DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents 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 Server 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 FreeFlow Remote Print Server 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 FreeFlow Print Server GUI on the print server Moving the print server To ensure consistent performance and avoid any damage to equipment follow these rules for placing the components of the print server Do Use the print ser
68. 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 approved or recommended by Xerox If you use other DocuTech 128 155 180 HighLight Color Operator Guide 3 1 Routine maintenance 3 2 A supplies you may damage the system e Keep supplies in stock as listed in the Service and supplies chapter e
69. ay 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 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 print server 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 paper The system does not notify you when the tray is full DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents Inverter feeder stacker NOTE High volume printer configuration only Each output feeder st
70. butors supply to customers conforms with all the relevant safety legislation and standards 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 DocuTech 128 155 180 HighLight Color Operator Guide Safetynotices Question Answer Question Answer Additional queries
71. der 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 Systemcomponents 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 feeder stacker modules _ CaF Te ele Ce 2 ES i DPC0208A SOR Figure 2 6 Printer with inverter feeder stacker feeder stacker feeder stacker e a fe Care
72. e 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 48 Cleaning the tape guides Cleaning the binder platen NOTE Production publisher configuration only The following steps must be performed to clean the binder platen 3 50 DocuTech 128 155 180 HighLight Color Operator Guide 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 XEA028A 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 51 Routine maintenance Figure 3 50 Cleaning the flappers Cleaning the calipers 4 NOTE Production publisher configuration only Using the binder platen cleaner clean the binder caliper surfaces until all the glue is removed 3 52 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Figure 3 51 Cleaning the calipers Closing the binder 4 NOTE Production publisher co
73. e 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 Figure 4 19 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 Ho 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 e The paper supply is neatly stacked e 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 e For the high capacity feeder trays also ensure the side guide is firmly touchi
74. e 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 1 Position the wire module on the HLC developer module DocuTech 128 155 180 HighLight Color Operator Guide 3 31 Routine maintenance 3 32 2 en 2S SS Ensure that the brush on the wire module is at the toner bottle end as shown in the figure below Wire module assembly Brush location y OC y Gin foe 8 ie Qy SS oR CS OAR Ny wy 0CD00017A SOR Figure 3 30 Wire module assembly brush location 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 Close the doors DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Cleaning the system and its components NOTE Follow the procedures in this section only when directed 4 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 diske
75. e stock is within the limits described in the Technical information chapter DocuTech 128 155 180 HighLight Color Operator Guide 4 3 Problem Solving 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 If the 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
76. e tenes 3 28 Wire Module Removal and Replacement 2 200 0c eee ee eeeaee 3 31 Cleaning the system and its components 0 00 3 33 Cleaning the 18 36 track cartridge tape drive 0 0 cee ee 3 33 Cleaning the 26 track cartridge tape drive 0 ee 3 34 Cleaning the DVD drive 2 2 tees 3 34 Cleaning the diskette drive 0 eee 3 34 Cleaning the sensors and the reflecting surfaces 0 00 eee eee eee 3 35 Cleaning the Q850 and Q861 sensor saaana eee 3 35 Cleaning the Q1011 1009 sensor and mirror 0200200 eee eee 3 37 Cleaning the Q1106 and Q1166 sensors 0 00 cece 3 37 Cleaning the Q1107 Sensor 0 2 eae 3 38 Cleaning the Q1164 sensor 2c eae 3 39 Cleaning the display 0 ccc eee 3 40 Cleaning the exterior surfaces of the system 0 0 00 eee eee 3 40 Clearing or cleaning the finisher Sensors 0 0000 eee cece eee eee 3 41 Clearing the Q1201 sensor 1 6c ee eee eens 3 41 Clearing the Q1202 and Q1203 sensors 0 0 cee 3 42 Cleaning the Q1222 and Q1210 sensors 0 c ce 3 44 Clearing the Q1205 Q1206 and Q1207 sensors 220000 ee eee 3 45 Clearing the Q1213 sensor 1 0 eee teenies 3 46 Clearing the Q1221 Q1218 and Q1227 sensors 200000 cee eee 3 47 Cleaning the binder 0 00 0062 cc eee 3 48 Cleaning the binder tape guides 0 0 eee 3 50 Cleaning
77. ect 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 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Table 3 1 Paper conditioning Temperature difference between storage and operating areas Centigrade 10 15 20 25 30 40 50 Fahrenheit 55 8 5 11 13 179 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 paper Paper curl Before the manufacturer cuts paper into sheets it is stored on large rolls Aft
78. eder Stackers 2 Tray or 3 Tray Interposer and Finisher 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 Duplex printing Media handling of multiple weights sizes and types Optional modules for enhanced finishing and output to third party finishing devices Optional enabling of a third party roll feeder Depending on your configuration optional high capacity feeder stacker modules which provide additional feeder trays and output bins Depending on your configuration 2 Tray or 3 Tray Interposer with a stape binder and stitcher High resolution of IPDS LCDS PostScript and PCL data streams shown in the following table DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents Table 1 Data stream resolution Data stream Input resolution Print resolution DP128 155 180 HLC IPDS 240 by 240 dpi or 300 600 x 2400 dpi High volume printer only by 300 dpi or 600 by 600 dpi LCDS 300 by 300 dpi 600 x 2400 dpi High volume printer only PostScript and PCL 300 by 300 dpi or 600 by 600 dpi 600 x 2400 dpi High volume printer 600 x 600 dpi Production publisher Data formats supported The Xerox
79. edure Cleaning the binder in this guide 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 7 If 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 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 e Stitcher wire not feeding properly A kink in the stitcher wire Open the finisher doors 2 Lift the stitcher panel which is located directly above the stitcher spools 4 26 DocuTech 128 155 180 HighLight Color Operator Guide Problem Solving NOTE fthe 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 pl
80. emcomponents e 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 e 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 e Precut or full tabs e 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 e Low moisture content a paper to moisture ratio below 5 7 percent Paper with higher moisture content may curl and jam e Smooth surface e Moisture resistant wrapping e No defects such as bent edges or uneven surfaces e Grain runs parallel with the long side of paper Graphical user interface overview The graphical user interface GUI on the print server enables you to interact with the printing system It contains windows icons and menus through which you can issue commands and perform operator and system administration tasks When the print server is powered on and booted the FreeFlow Print Server home screen displays DocuTech 128 155 180 HighLight Color Operator Guide 2 5 S
81. equipment the external radiation from the ISM equipment may have to be limited or special mitigation measures taken Certification to 1999 5 EC Radio Equipment and Telecommunications Terminal Equipment Directive 1 4 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 e Belgium Denmark e France Finland e Germany e Greece e Iceland e Ireland e Italy e Luxembourg e Netherlands e Norway e Portugal e Spain e Sweden e Switzerland e United Kingdom DocuTech 128 155 180 HighLight Color Operator Guide Safetynotices 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
82. er 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 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 FreeFlow Print Server 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 FreeFlow Print Server for complete information on how to view and print the billing meter readings Consumable supplies table 6 4 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
83. er drawer in the finisher You will need to replace the binder tape periodically WARNING All areas of the binder drawer including the binder tape are approximately 425 F 218 C 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 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 temperature and humidity for paper storage Conditioning paper 3 4 Because temperature and humidity aff
84. er 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 3 6 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 7o 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 CN 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 with the package wrapper seam side facing up NOTE When loading drilled paper be sure to fan the ed
85. er 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 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 5 and 6 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 5 and 6 Image offset may
86. erator Guide 3 29 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 and 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 3 30 DocuTech 128 155 180 HighLight Color Operator Guide 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 A AAN N NA Ay WY V D lt lt D A Muy Y 0CD00013A SO Figure 3 29 Wir
87. erox Europe Technical Centre for advice prior to any test implementation 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 1 6 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 distri
88. ersonal 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 FreeFlow Print Server and a DocuTech printer FreeFlow Print Server The FreeFlow Print Server 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 Print Server software performs the necessary data conversion creating an electronic file which is stored temporarily in a print queue on the Print Server 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 4 highlight color NOTE Prints per minute vary depending on paper size for all 4 printers lt DocuTech 128 155 180 HighLight Color Operator Guide 2 1 System components Optional Components Functional overview 2 2 Inverter Feeder Stacker and up to 3 Fe
89. ge 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 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 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 7 Routine maintenance 3 8 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 Follow the described steps in the previous section to add paper to Trays 3 4 5or6 Using the custom transfer assist blade lt Installing the custom transfer assist blade Setting tray size with the custom transfer assist blade The custom transfer assist blade in the printer assures good print quality for your jobs A kit is available allowi
90. he 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 conditions that affect paper especially moisture Figure 3 60 shows good storage conditions for the binder tape 3 60 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XE157B 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 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 tig
91. he 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 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 3 15 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 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 3 16 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Changing the highlight color Customer Changeable Units The highlight color Customer Changeable Unit CCU consists of the c
92. he order should be placed and the actual date of the order Table 6 3 Custom Color Supplies checklist DocuTech 128 155 180 HighLight Color Operator Guide a Date of Date Item Description Quantity order ordered Dry ink Developer 6 11 Service and supplies 6 12 DocuTech 128 155 180 HighLight Color Operator Guide
93. hite 8R7187 Gray 8R7188 Blue 8R7189 Packaged 1 reel per carton Consumption rate is approximately 425 binds per carton 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 NOTE Color developer the Dry ink waste bottle and the waste filter are ordered and stocked by the Xerox Service Representative for your site The part numbers are provided here for informational purposes only 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 Item Description Quantity ae Pinel d Paper Dry ink Developer DocuTech 128 155 180 HighLight Color Operator Guide 6 9 Service and supplies Date of Date Item Description Quantity order 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 t
94. htly XE158A Figure 3 62 Storing the binder tape 5 Store the partially used rolls of binder tape in a dry place cooler than 90 F 32 C DocuTech 128 155 180 HighLight Color Operator Guide 3 61 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 approximately 425 F 218 C 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 XEAO70A Figure 3 63 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 3 62 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance XEAO71A Figure 3 64 Removing the tape b Rewind the tape onto the tape reel 4 Slide the tape reel off the tape
95. hts 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 65 176 g m2 Minimum substance 20 75 g m2 Heavier than substance 65 176 g m2 Lighter than substance 20 75 g m2 Limit the inserts outside of substance 16 to 24 60 to 90 g m2 to 10 of the sheet count 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 5 17 Technical information Table 5 13 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
96. ible 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 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 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 t CAUTION Do not use warm or hot water or general cleaning 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
97. ide 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 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 stoc
98. ied setting Clearing paper jams 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 e If enabled the Attention light flashes e Messages appear on the print server informing you of the paper jam and its location in the printer 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 print server 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 print server screen telling you that there is a suspected page delivery error and advising you to check the output DocuTech 128 155 180 HighLight Color Operator Guide Problem So
99. ing bat ee deena ae Saeed 1 1 OZONE SAIC reese cds RE ete 1 2 Operation Safety cerei iae sser a ta eae ERa E a ee daa 1 2 European Union declaration of conformity 0 00 eae 1 3 Certification to 1999 5 EC Radio Equipment and Telecommunications Terminal Equipment Directive 1 4 Electricity at Work Regulation UK 00 eae 1 5 Check your understanding 0 0 e eee eee 1 6 Additional querieS oses co 4s 2 04 tachi pia veebad bebe E aa na bia ddeoeaewe aad te dwe an 1 7 Perchlorate Law Compliance Announcement 0020 20 c eect eee ees 1 8 Product Recycling and Equipment End of Life Disposal Language Requirements for Xerox Customer Documentation 1 8 2 System components Electronic reprographics process 0 000 e eee eee ete 2 1 FreeFlow Print Server 2 000 tee e eee 2 1 DocuTech Printer sicveias cee saga waa bed Meena ce Wed ba tke Ae gees eh 2 1 Optional Components 20 cece ete eee 2 2 Functional OVerview apesse siida giaa ehh oe eine d i a eed eae Mae EAS AD ad 2 2 Paper WelQIts s csccink pga t s ced oa Sle a gaa Ae Deeg aes haga pee ahaa ales 2 4 Special Stoks agin ranna hie bee hee SP Le aa i ee Boe oh Bae ely 2 4 General paper characteristics 0 0 0 0 0 ccc eee eee eens 2 5 Graphical user interface overview 0 0 ee eee nes 2 5 System software and job flOW 0 2 0 cee eens 2 6 Printer OVervieW wuss aiecta raga diiine We aee
100. int 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 e 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 formulated for use in laser printers DocuTech 128 155 180 HighLight Color Operator Guide Syst
101. is level a Ifthe 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 3 17 Routine maintenance c When the HLC unit is level tighten the lock nut OCD00002A SOR 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 3 18 DocuTech 128 155 180 HighLight Color Operator Guide 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 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 19 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
102. is simple and requires little time 1 2 3 If there is a cartridge in the tape remove it Insert the cleaning cartridge in the tape drive and close the door Cleaning begins automatically once the tape is inserted Allow the tape to run for approximately 30 seconds then remove it NOTE Replace the foam pad on the cleaning cartridge after it 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 2 If there is a DVD disk in the drive remove it Follow the directions to clean the DVD drive Cleaning the diskette drive The floppy disk drive must be cleaned 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 Remove the cleaning diskette DocuTech 128 155 180 HighLight Color Operator Guide 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 Q1011 1009 sensor and mirror High Capacity Feeder Stacker configuration e Q1106 sensor e Q1166 sensor e Q1107 sensor Q1164 sensor
103. 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 with excessive force There is an anti splash seal in the reservoir that could be damaged DocuTech 128 155 180 HighLight Color Operator Guide 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 27 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 co
104. itcher 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 XEA084A Figure 3 54 Removing the wire from the tubing DocuTech 128 155 180 HighLight Color Operator Guide 3 55 Routine maintenance e 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 itm N ne WE XEA061A Figure 3 55 Rewinding the remaining wire 6 Insert the plug into the measuring bracket as shown in figure 3 55 OA196A Figure 3 56 The measuring bracket 7 Release and remove stitcher spool A 3 56 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance a Locate the green pin release handle under spool B as shown in figure 3 56 yay l A Wy TEN a Neti Ez NA S CS kan IT TE XEA062A 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 Replace the stitcher spool pin Push it down until it locks into place as
105. k 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 To clear a binder tape fault 1 Open the finisher doors DocuTech 128 155 180 HighLight Color Operator Guide 4 25 Problem Solving 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 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 proc
106. 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 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 4 NOTE Production publisher configuration only lt Prints are delivered to the top tray because the prints are oversized or because the top tray was selected at the print server Bypass transport Function of the The bypass transport moves paper from the printer to a third party bypass transport 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 DFA support The bypass transport meets the Xerox Document Feeding and Finishing Architecture DFA specifications The system software supports D
107. ling Printer faults and fault windows When the printer needs attention it is called a fault There are three types of faults those that require 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 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 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 cleari
108. lors 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 DocuTech 128 155 180 HighLight Color Operator Guide 6 5 Service and supplies 6 6 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 3 3R3080 hole 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
109. lving 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 1 f J 1 olaa a A T E Figure 4 1 Area 2 a LHN He i al _ i ion NS Si Figure 4 2 Area 3 DocuTech 128 155 180 HighLight Color Operator Guide 4 7 Problem Solving em Figure 4 3 Area 4 L al Hiha D T i i Sassy
110. m Suggested solutions Repeated jams in Follow the jam clearance diagram in the Printer Fault Clearance interposer 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 Refer to the Satisfaction guides in chapter 4 Technical Information for information on loading stock in trays 4 and 5 2 Tray or 4 5 and 6 3 Tray Make sure the stock loaded meets the specifications for these trays as indicated in the Satisfaction guides in chapter 4 Technical Information Tray 6 error Messages are displayed in the status area of the FreeFlow Print messages Server Click on any Tray 6 messages to display more information about the message and the actions to perform This information is displayed in a separate Printer Fault Clearance window 3 Tray Interposer To determine if the 3 Tray Interposer is licensed and enabled select licensed and Setup gt Feature Licenses on the FreeFlow Print Server to open the enabled error if not License Manager window installed Look for and double click the 3 Tray Interposer line If the 3 Tray Interposer is installed but not licensed an error message appears Follow the steps for installing a license as documented in the Getting Ready for the FreeFlow Print Server Installation guide Select Yes if the new license information should be used the printer Select No if the printer should use the curren
111. m to sizes 229 x 356 mm Weight Substance 16 to 110 60 to Weights outside the limits shown are not recommended Set size limit due to copy paper weight Stacker capacity Type or condition Collated Up to 65 sheets of substance 20 75 g m2 or 0 28 inch 7 mm thick sets Uncollated 50 copies maximum per stitch 0 28 inch 7 mm thick sets Stacker capacity adjusts automatically to suit various set sizes Xerographic bond paper in good condition Drilled paper Collated Up to 70 sheets of substance 20 75 g m2 Slightly curled paper Reduce the paper weight to enable stitching more sheets per collated set Check the stitch quality To allow a continuous run unload outer stack before inner stack reaches capacity Do not use excessively curled 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 13 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 weig
112. mmediately 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 If the power repeatedly switches 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 _ 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 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 4 6 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 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 Selecting Reset sets the image quality parameters to the most recently appl
113. nation and approval and compliance to established environmental standards Attention to the 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 e Do not place the system near a heat source To move the system call a Service Representative e 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 e 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
114. nfiguration 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 E 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 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 53 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 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 3 54 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance TA828A Figure 3 53 Removing the st
115. ng all jams Table 4 1 Resolving a processor problem Problem Suggested Solution Paper tray elevator Ensure that the stock is loaded properly in the paper trays with the rear fails to rise or lower and side guides against the stock stack e If the 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 p
116. ng 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 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 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 printer purges any dog eared or skewed sheets In addition the printer may stop and issue an incorrect paper size message 4 NOTE n order to assure good print quality for your jobs the 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 Proble
117. ng 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 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 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 DocuTech 128 155 180 HighLight Color Operator Guide 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
118. ntains 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 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 3 28 DocuTech 128 155 180 HighLight Color Operator Guide 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 DocuTech 128 155 180 HighLight Color Op
119. ntrols 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 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 1 2 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 exami
120. ocks 5 8 The following table lists stock that have 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 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 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 5 and 6 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
121. olor 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 to remove the CCU for service CAUTION CCU carts should be used exclusively for changing and storing CCUs 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 Ifthe 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 4 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
122. ore creating a document to be rotated by the Bypass Transport 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 FreeFlow Print Server 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 siz Comment Common Inches x Millimeter E Can be at f 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 DocuTech 128 155 180 HighLight Color Operator Guide 5 13 Technical information za Comment Common Inches x Millimeter z Ss Can be niir A A Diagonal in inches similar to or the size name inches equivalent rotated same as
123. ormation 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 development 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 e 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
124. power cables and call a service representative when any of the following conditions occur DocuTech 128 155 180 HighLight Color Operator Guide Safetynotices 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 e Never attempt any maintenance function that is not specifically described in this Operator Guide e 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
125. priately It is not recyclable 3 70 DocuTech 128 155 180 HighLight Color Operator Guide 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 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 cyc
126. 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 Grasp the green handle on the fuser drawer and pull it out until it stops 7 JS amp Na 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 a b 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 25 Routine maintenance 3 26 Figure 3 22 Preparing to add fuser blend WARNING Fuser lubricant spills cause the floor to be slippery If any fuser lubricant
127. r 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 1 800 ASK XEROX to determine whether this Xerox product is part of the program For more information about Xerox environmental programs visit www xerox com environment If you are managing the disposal of your Xerox product please note that the product contains lamp s with mercury and may contain lead Perchlorate and other materials whose disposal may be regulated due to environmental considerations The presence of these materials is fully consistent with global regulations applicable at the time that the product was placed on the market For disposal information contact your local authorities In the United States you may also refer to the Electronic Industries Alliance web site http www eiae org Perchlorate Material This product may contain one or more perchlorate containing devices such as batteries Special handling may apply please see http www dtsc ca gov HazardousWaste Perchlorate index cfm 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 These versatile high performance printing systems enable p
128. r 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 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 fee
129. rayed 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 Routine maintenance Clearing or cleaning the finisher sensors 4 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 4 cover under the finisher top 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 SS XEA037A Figure 3 37 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 41
130. rs WARNING A sharp edge on the plastic binder platen cleaner or on the tape spool sometimes occurs as a result of removing the 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 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance 2 Grasp the green handle on the binder drawer Pull the drawer out until it stops M lt M y XEA070A 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 XEA092 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 Lift up on the cleaner and push down against the single DocuTech 128 155 180 HighLight Color Operator Guide 3 49 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 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 th
131. rs 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 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 e Store the reams of paper in their carton e 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 e 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 e To make adjustments to the DocuTech 128 155 180 HLC for the curl in the paper refer to the Routine maintenance and Problem solving sections of this guide DocuTech 128 155 180 HighLight Color Operator Guide 5 5 Technical information 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
132. ry 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 Magenta 300K Carton with 1 5 area coverage as highlight color 6R1296 US CA 6R90360 EU Dry Ink Yellow 300K Carton with 1 5 area 6R1299 US CA coverage as highlight color 6R90361 EU Dry Ink Violet 300K Carton with 1 5 area 6R1325 US CA coverage as highlight color Dry Ink Waste 500K bottle 93K1393 Bottle HLC Customer 1 Filter Cartridge 53K02390 Replaceable Waste Filter 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 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 DocuTech 128 155 180 HighLight Color Operator Guide 6 7 Service and supplies 6 8 Item 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
133. s fed from Tray 4 are not imaged and feed directly into the finisher Sheets from Tray 5 or Tray 6 Three tray Interposer can be set either to feed through the Interposer via the print engine passing through the Fuser or to deliver pre printed stocks into the Finisher post Fuser Both models of Interposer have the ability to process ordered sets fed from Tray 4 This makes it unnecessary to have additional trays for each page type in a set However for jobs that include pre printed sheets that are not pre collated or several jobs that use ordered sets Tray 5 and Tray 6 3 Tray Interposer can also be set to feed directly into the Finisher post Fuser NOTE Ordered sets can also be fed for imagining from Trays 1 2 and 3 Two tray Interposer The 2 Tray Interposer allows applications to utilize up to five trays production to feed different paper stocks Both trays may be used to feed pre publisher only printed stocks bypassing the Fuser If just Tray 4 is used for post Fuser feeding four pick points are available for imaging passing through the fuser The following lists the 2 Tray interposer components Paper transport lower Paper transport upper Inserter tray Feeder inserter tray Pees
134. set to use DTMF signalling DTMF signalling provides reliable and faster call 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 X
135. t license information DocuTech 128 155 180 HighLight Color Operator Guide 4 23 Problem Solving Finisher problems NOTE Production publisher configuration only lt Table 4 3 Resolving a finisher problem Problem Repeated jams in area 14 bindexer Jammed binder tape such as binder tape sticking together or cosmetic defects in the bound book Binder tape not positioned correctly on the top edge of the output prints Suggested solutions 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 Replace the tape reel with a new reel using the procedure Replacing the binder tape reel in this
136. t 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 ma Figure 3 18 Service stand DocuTech 128 155 180 HighLight Color Operator Guide 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 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 8 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 9 Tighten the lock nuts on the jack screws to lock the jack screws in position 10 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 23 Routine maintenance OCDO0005A SOF Figure
137. to the right load the paper into trays 3 4 5 and 6 with holes to the left 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 5 and 6 with holes to the left Do not bind or run 2 sided prints Never tear Do not bind or run 2 sided prints DocuTech 128 155 180 HighLight Color Operator Guide 5 9 Technical information 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
138. tte 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 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 4 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 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 33 Routine maintenance 3 34 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
139. ull the knob and rotate it clockwise to move the tape toward the top edge of the book as shown in figure 3 71 DocuTech 128 155 180 HighLight Color Operator Guide 3 67 Routine maintenance XE160A Figure 3 72 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 73 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 3 68 DocuTech 128 155 180 HighLight Color Operator Guide 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 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 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 CAUTION Do not use warm or hot water or general cleaning Replace the waste dr
140. ver stand that comes with your printing system equipment 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 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 print server 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 DocuTech 128 155 180 HighLight Color Operator Guide 2 25 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
141. ws lightly 2 Remove any dust present in the area DocuTech 128 155 180 HighLight Color Operator Guide 3 37 Routine maintenance Figure 3 34 Q1106 and Q1166 sensors Cleaning the Q1107 sensor 4 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 3 38 DocuTech 128 155 180 HighLight Color Operator Guide Routine maintenance Figure 3 35 Q1107 sensor Cleaning the Q1164 sensor 4 NOTE High volume printer configuration only lt 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 DocuTech 128 155 180 HighLight Color Operator Guide 3 39 Routine maintenance 3 40 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 Clean the exterior surfaces with a mild household detergent that has been poured or sp
142. y 2600 sheets substance 20 75 g m2 DocuTech 128 155 180 HighLight Color Operator Guide 5 7 Technical information Stock po palate id Less eee may be 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 i ie raed Less e 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 st
143. y ink filter The following steps must be performed to replace the waste dry ink filter 1 Ensure that the printer has stopped printing 2 Obtain a new filter Open the box and remove filter from the bag and set aside 3 Seta piece of paper larger than the filter on the top cover to the right of the Highlight Color module 4 Open the top cover of the Highlight Color module LA 87 eS XE162A Figure 3 74 Opening the cover and removing the filter 5 Unsnap the 4 clips on top of the waste dry ink filter housing DocuTech 128 155 180 HighLight Color Operator Guide 3 69 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 Insert the new filter into the filter housing Firmly press straight down The filter clicks into place Lf ay q XE163A Figure 3 75 Inserting the new filter and closing the cover 10 Replace the filter housing cover Ensure that the yellow arrows align with each other 11 Snap the 4 clips back into the latched position 12 Close the top cover 13 Discard the old filter appro
144. 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 diskettes 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 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 ord
145. ystem components System software and job flow 2 6 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 OU IN 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 DocuTech 128 155 180 HighLight Color Operator Guide Systemcomponents 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

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