Xerox 128 User Manual

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DocuTech 128/155/180 HighLight Color

Operator

Guide

Version 51.xx, October 2006

701P25101

Prepared by: Xerox Corporation Global Knowledge and Language Services 800 Phillips Road Bldg. 845-17S Webster, New York 14580 USA ©2006 by Xerox Corporation. All rights reserved. Copyright protection claimed includes all forms and matters of copyrightable material and information now allowed by statutory judicial law or hereinafter granted, including without limitation, material generated from the software programs displayed on the screen such as icons, screen displays, or looks. Printed in the United States of America. XEROX® and all Xerox product names mentioned in this publication are trademarks of XEROX CORPORATION. Other company trademarks are also acknowledged. Changes are periodically made to this document. Changes, technical inaccuracies, and typographic errors will be corrected in subsequent editions.

Product Recycling and Disposal

If you are managing the disposal of your Xerox product, please note that the product contains lead, mercury and other materials whose disposal may be regulated due to environmental considerations in cert ain countries or states. The presen ce of lead and mercury is fully consistent with global regulations applicable at the time that the product was placed on the market.

European Union

Some equipment may be used in both a domestic/household and a professional/business application.

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 equi pment 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 di sposal must be managed within agreed procedures.

Prior to disposal please conta ct your local dealer or Xerox representative for end of life take back information.T

DocuTech 128/155/180 HighLight Color Operator Guide i

ii DocuTech 128/155/180 HighLight Color Operator Guide

1 Safety notices

System safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Laser safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Ozone safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operation safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

European Union declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Certification to 1999/5/EC Radio Equipment and Telecommunications Terminal Equipment Directive 1-4

Electricity at Work Regulation - UK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Check your understanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Additional queries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

2 System components

Electronic reprographics process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

DocuSP controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

DocuTech Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Optional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Functional overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Paper weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Special stocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

General paper characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Graphical user interface overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

System software and job flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Printer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

High volume printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Production publisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

System Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Paper sizing and print speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Table of Contents

3 Routine maintenance

Cleaning and maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Necessary Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Finisher precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Storing paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Conditioning paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Paper curl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Adding paper to tray 1 or 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Using the custom transfer assist blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Adjusting for paper curl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Adjusting the decurler lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Maintaining the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Replacing the black dry ink bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Replacing the highlight color container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Changing the highlight color Customer Changeable Units . . . . . . . . . . . . . . . . . . . . . 3-16

Adding fuser shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

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iii

Waste containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Wire Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Cleaning the system and its components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Cleaning the 18/36-track cartridge tape drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Cleaning the 26-track cartridge tape drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Cleaning the DVD drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Cleaning the diskette drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Cleaning the sensors and the reflecting surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Cleaning the Q850 and Q861 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Cleaning the Q1011/1009 sensor and mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Cleaning the Q1106 and Q1166 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Cleaning the Q1107 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Cleaning the Q1164 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Cleaning the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Cleaning the exterior surfaces of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Clearing or cleaning the finisher sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Clearing the Q1201 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Clearing the Q1202 and Q1203 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Cleaning the Q1222 and Q1210 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Clearing the Q1205, Q1206, and Q1207 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Clearing the Q1213 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Clearing the Q1221, Q1218, and Q1227 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Cleaning the binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Cleaning the binder tape guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Cleaning the binder platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Cleaning the flappers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Cleaning the calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Closing the binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Replacing the stitcher spool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Storing the binder tape reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Replacing the binder tape reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Adjusting the binder tape registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

4 Problem Solving

How problems are displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Printer faults and fault windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

When a fault occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Resolving a processor problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Solving print quality problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Clearing paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Incorrect paper size message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Interposer problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Finisher problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Binder tape fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Stitcher spool A fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Checking paper curl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Customer Support Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

5 Technical information

DocuTech printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Printer rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Paper tray capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Additional paper capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Printer satisfaction guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

iv DocuTech 128/155/180 HighLight Color Operator Guide

Stock satisfaction guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Using non-standard stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Paper stock rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Finisher satisfaction guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

6 Service and supplies

Xerox support services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Customer support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Operator training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Supplies service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Routine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Meter reading and reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Consumable supplies table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

DocuTech 128/155/180 HighLight Color Operator Guide v

vi DocuTech 128/155/180 HighLight Color Operator Guide

About this guide

Introduction

The DocuTech 128/155/180 HLC Operator Guide is one of a number of publications that make up the Xerox Document Services Platform Series.

The guide is intended for Xerox DocuTech 128/155/180 HLC operators whose job consists of the routine operation of this printing system: operating each of the system components, running print jobs, solving simple system probl ems, and performing basic maintenance tasks, such as replenishing printer supplies .

If you are a lead operato r, or your job i nvolves some progr amming or systems administration tasks, as well as operating the DocuTech 128/155/180 HLC system, use the on-line help system and the other documents in the Xerox Document Services Platform Series to supplement the i nformation in this guide.

Contents

Before using this guide, become familiar with its contents and conventions.

WARNING: Both power cords wi th the printer must be disconnected from the printer in order to completely power down the machine.

This section lists the contents of this guide.

• “System components” contains an explanation of each of the system components.

• “Routine maintenance” describes the routine activities you perform to maintain the reliability and productivity of your printer.

• “Problem solving” describes how the system informs you of problems. When you know there is a system problem, you can take measures suggested by the system to correct the problem. You can also use the problem and solution tables in this section to resolve recurri ng 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 :

• All caps and angle brackets–Within procedures, the names of keys are shown in all caps within angle bra cket s (f or example, press <RETURN>).

• Angle brackets–Variable information, or the position of a specified argument in the command syntax, appears in angle brackets (for example, List Fonts <Pattern>).

• 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 <RETURN> (for example, enter y).

• Italics–Document and library names are shown in italics (for example, the Xerox Document Services Platf orm Series System Guide).

• Square brackets–Names of options you select are shown in square brackets (for exampl e, Select [Exit]).

• Quotes–Keywords you can enter as arguments appear in quotes (for example, “US Letter”).

• Vertical bars–Alternatives to spec ified arguments are separated by vertic al bar s (for example , -pdl < p s | hpp cl | asci i | tiff>).

NOTE: Notes contain important supplemental information pertaining to the task that you should read.

CAUTION: Cautions alert you to an action that could damage hardware, software, or your data.

WARNING: Warnings alert you to conditions that may affect the safety of people.

viii DocuTech 128/155/180 HighLight Color Operator Guide

System safety

Laser safety

1 Safety notices

It is your responsibility to ensure your Xerox equipment is safe at all times. This section includes equi pment safety notices rel ated to laser safety, ozone safety, and operation safety.

WARNING: Use of controls or adjustments, or performances other than specified herein, may result in hazardous r adiation 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 i s possible onl y because the l aser beam is totally enclosed duri ng all modes of customer operation.

When performing operator functions, laser warning l abels may be visible. These labels are to alert and remind the se rvice representative and are placed on or near p anels 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.

Figure 1-1. Laser warning label

DocuTech 128/155/180 HighLight Color Operator Guide 1-1

Safety notices

Ozone safety

Operation safety

This product produces ozone during normal oper ation. The ozone produced is dependent on copy volume and is heavier than air. Providing the proper e nvironment al p arameters as specif ied in t he Xerox installation instructions ensures that concentration levels meet safe limits.

Your Xerox equipment and supplies have been designed and tested to meet strict safety requirements. These include safety agency examination and approval, and compliance to est ablished environmental standards.

Attention to the following notes ensures the cont inued safe operation of your equipment.

• The system is heavy. Ensure that the floor is level and strong enough to support the weight of the system.

• Do not place the system near a heat source.

• To move the system, call a Service Representative.

• Do not use an extension cord. Always connect the system power cable to a properly grounded power source recept acle. 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: Improper connection of the equipment grounding conductor can result in risk of electrical shock.

• Do not locate the system where people may walk on the system power cable. Do not place objects on the system power cable.

• Never override or disable electrical or mec hanical interlocks.

WARNING: Do not push objects into slots and openings on the system. Making contact with a volt age p oint or shorting out a part could result in fire or electrical shock.

• If you 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.

• Switch off the sy stem power , disco nnect the power cables, a nd call a service representative when any of the following conditions occur:

1-2 DocuTech 128/1 55/180 High Light Col or Operat or Guide

Safety notices

– The power cable is damaged or frayed. – Liquid is spilled into the system. – The system is exposed to water. – Any part of the system is damaged.

• Always use materials and supplies specifically designed for your Xerox equipment. Use of unsuit able materials may result in poor performance and can possibly create a hazardous situation.

• Never attempt any maintenance functi on that is not specifica lly described in this Operator Guide.

• Never remove any covers or guards that are fastened with screws. There are no operator-serviceable areas within these covers.

• 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

certification

The CE marking applied to this product symbolizes Xerox Europe Declaration of Conformity with the following applicable Directives of the European Union as of the dates indicated below.

• 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.

• January 1, 1996: Council Directive 89/336/ EC, a pprox imation of the laws of the member Stated related to electromagnetic compatibility.

• March 9, 1999: Council Directive 1995/5/EC on radio equipment and telecommunications terminal equi pmen t 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 modif ication to this equipment not specifically approved by Xerox Europe may void user’s authority to operate the equipment. Shielded cables mus t be used wit h this equipment to maintain compliance with the EMC Directi ve (89/ 336/EEC).

WARNING: Thi s is a Clas s A produ ct. In a do mesti c envir onment this product may cause radio interference in which case the user may be required to take adequate measures.

DocuTech 128/155/180 HighLight Color Operator Guide 1- 3

Safety notices

WARNING: This sys tem is cer ti fied manufactured and tested in compliance with strict safety and radio fr equency 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: In order to allow this equipment to operate in proximity to industrial , scientific, and medical (ISM) equipment, the external radiation from the ISM equipment may have to be limited or special mitigation measures taken.

Certification to 1999/5/EC Radio Equipment and Telecommunications Terminal Equipment Directive

This Xerox product has been self-certified by Xerox for panEuropean 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:

•Austria

• Belgium

• Denmark

• France

• Finland

• Germany

•Greece

• Iceland

• Ireland

•Italy

• Luxembourg

• Netherlands

•Norway

• Portugal

•Spain

• Sweden

• Switzerland

• United Kingdom

1-4 DocuTech 128/1 55/180 High Light Col or Operat or Guide

Safety notices

In the event of problems, you should contact your local Xerox representative in the first instance.

The product has been tested to and is complaint with TBR21, a specification for termi nal equi pment fo r use on analogue swit ched 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 (pulse) or DTMF (tone) signalling, it is recommended that it is set to use DTMF signalling. DTMF signalling provides reliable and faster call set-up.

Modification, connection to ext ernal control soft ware or to ext ernal control apparatus not authorized by Xerox, will invalidate it s certification.

Electricity at Work Regulation - UK

The Electricity at Work Regula ti on applies only to England and Wales.

The Regulation

The Electricity at Work Regula tion 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, insul a tion resistance and electrical strength tests. Xero x Europe ma nufacturing plants have been awarded ISO 9000 quality certification and are subj ect to regular audits by the British Standards I nstitution or equivalent national standards body.

Xerox equipment which has been properly and regularly serviced and maintained should not have to undergo additional specific safety tests pursuant to the 1989 Regulation. Customers wishing to complete safety testing should contact Xerox Europe Technical Centre for advice prior to any test implementation.

Xerox equipment should, however, be properly and regularly serviced and maintained at all ti mes.

DocuTech 128/155/180 HighLight Color Operator Guide 1- 5

Safety notices

Check your understanding

Please review the questions and answers that follow to ensure that you understand the Electricity at Work Regulation in England and Wales.

Question What is the Electricity at Work Regulation?

Answer 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 pr event, so far as reasonably practicable, danger. This includes ensuring all electrical products conn ected to such ele ctrical syst ems are safely constructed, maintained and oper ated.

Question Does Xerox Europe comply with the Electricity at Work

Regulation?

Answer The regulation places a duty on all employers and self

employed persons to ensure the electri cal systems in their

premises are, effectively safe. This regulation does not impose on, amongst others,

manufacturers or suppliers of such electrical systems. However , rest assured that all Xerox equipment which Xerox

Europe and its authorized distributors supply to customers conforms with all the relevant safety legislation and standards.

Question Is Xerox equipment safe?

Answer All Xerox equipment supplied by Xerox Europe and their

authorized distributors conforms to all relevant safety legislation and standards.

Question Is the Xerox equipment in my premises safe?

Answer 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 maintai ned 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.

Question Does the Xerox equipment in my premises comply with the

Electricity at Work Regulations?

Answer 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 test s wh ich may be completed by your Xerox Europe Customer Service Organization. THESE TESTS

1-6 DocuTech 128/1 55/180 High Light Col or Operat or Guide

Safety notices

MUST BE CARRIED OUT ONL Y BY PERSONS WHO POSSESS THE RELEVANT SKILL, KNOWLEDGE AND EXPERIENCE TO CARRY OUT SUCH TESTS.

Please contact the Xerox Europe Customer Service Organizat ion for further information.

THE USE OF INAPPROPRIATE TEST PROCEDURES AND TEST EQUIPMENT MAY PROVIDE MISLEADING RESULTS AND MAY CAUSE DEATH, PERSONAL INJURY AND/OR DAMAGE TO PROPERTY.

Question I would like to carry out my own safety tests on the Xerox

equipment in my premises.

Answer You may, of course, re quest such te st s as you deem neces sary to

satisfy yourself that your Xerox equipment is safe. Your Xerox Europe Customer Support will be pleased to advise you on such testing.

Question I require records of all tests.

Answer After safety testing, your Xerox Europe Customer Service

Engineer will provide you with a certificate whic h details the r esults of all tests completed.

Additional queries

In the event of any defect being noted, the Xerox equipment will be switched off and disconnected fr om the suppl y unti l 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 represent ative if you hav e any queries regardi ng the information provided in this document.

DocuTech 128/155/180 HighLight Color Operator Guide 1- 7

Safety notices

1-8 DocuTech 128/1 55/180 High Light Col or Operat or Guide

2 System component s

The Xerox DocuTech HLC printers are electronic reprographics systems. They are high volume printers available in multiple configurations. These versatile, high performance printing systems enable personal computers and o ther network-connected devices (such as workstations and graphic scanners) to produce documents incorporating graphi cs, forms, logos, signatures, and fonts.

Electronic reprographics process

The Xerox DocuTech HLC system consists of a DocuSP control ler and a DocuTech printer.

DocuSP controller

DocuTech Printer

The DocuSP controller accepts electronic print input created by client software in ASCII, TIFF, HP PCL, PostScript, PPML, LCDS, IPDS, VIPP or PDF format. This print input is passed on to the system through a network connection. The DocuSP software performs the necessary data conve rsi on, creating an electronic file which is stored temporarily in a print queue on the DocuSP controller. This electronic image is then passed directly on to the printer for production.

The DocuTech 180 prints up to 180 prints per minute using 8.5 x 11 inch/A4 (216 x 279 mm) stock.

The DocuTech 155 prints up to 155 prints per minute using 8.5 x 11 inch/A4 (216 x 279 mm) stock.

The DocuTech 128 prints up to 128 prints per minute using 8.5 x 11 inch/A4 (216 x 279 mm) stock.

NOTE: The DocuTech HLC prints in black and white plus one highlight color.

NOTE: Prints per minute vary, depending on paper size, for all printers.

DocuTech 128/155/180 HighLight Color Operator Guide 2-1

System components

Optional Components

Functional overview

• Inverter Feeder/Stacker and up to 3 Feeder/Stackers

• 2-Tray Inte rposer and Finisher (Production publisher configuration)

NOTE: The initial release of the Production publisher (Interposer and Finisher) configuration is 180 PPM only and does not suppor t LCDS & IPDS.

The Xerox DocuTech HLC prints high quality, high resolution documents in simplex or duplex mode at high product ion speeds, from LCDS, PostScript, PCL, and other data strea ms. 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 thirdparty finishing devices

• Optional enabling of a third-party roll feeder

• Depending on your configuration: optional hi gh-capacity feeder/stacker modules, whi ch provide additional feeder trays and output bins

• Depending on your configuration: Interposer/Finisher/Binder

• High resolution of LCDS*, PostScript, and PCL data streams (shown in the following table)

NOTE: *The initial release of the Pr oduction publ isher (Interposer and Finisher) configuration is 180 PPM only and does not suppor t LCDS & IPDS.

2-2 DocuTech 128/1 55/180 High Light Col or Operat or Guide

System components

Table 1. Data stream resolution

Data stream Input resolution

Print resolution: DP128/155/180 HLC

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

Data formats supported

The Xerox DocuTech 128/155/180 HLC can print the following data formats:

• ASCII

• LCDS*

• IPDS*

• PCL

• PDF

•PostScript

•TIFF

• PPML

NOTE: * Not supported on the Production pub li sher conf igurat i on at this time.

The system prints LCDS data from a mainframe host compu ter, 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.

600 x 2400 dpi (High volume printer) 600 x 600 dpi (Production publisher)

The system also prints PostScript and PCL data submitted over a network (Ethernet or AppleTalk) from a variety of clients:

• PCs (Windows and Windows NT)

• Sun workstations (UNIX)

• UNIX command line clients: lpr (incl uding lp) and Xerox Command Line Client (CLC)

• NetWare Q-Server through a Novell print server (bindery mode only)

• Apple Macintosh workstations

DocuTech 128/155/180 HighLight Color Operator Guide 2- 3

System components

Paper weights

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, sto re, condit ion, and l oad print medi a properly in order to keep your printer running at optimum efficiency.

The printer functions best and produces the best prin t quality when using stocks that have the correct:

•Size

• Weight

•Type

• Color

For more comprehensive information on paper stocks for Xerox printers, refer to Helpful facts about paper, 721P82493.

Special stocks

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 s tandard 75 gsm paper. The available stock that is closest in weight to 20 pound paper is 80 gsm.

The following special stocks can be used with the DocuTech 128/ 155/180 HLC:

• Labels: Must be the type designed fo r high-speed pr inter s and must meet the specifications described in the secti on above. Loading instructions are print ed o n all paper trays.

• Transparencies: Must be the type designed for high-speed printers and must meet the specifications described in the section above. Loading instructions are pr inted on all paper trays.

• Colored paper: Available in a variety of colors, colored paper has many uses, including calling attentio n to certain printed material, separating special sections, or dividing chapters of a report.

• Preprinted paper: May be letter head, forms, or logos. ( Refer to the “Helpful Facts about Paper” guide to verify that the preprinting inks used on your stock are t he ki nd formula ted f or use in laser prin te r s .)

2-4 DocuTech 128/1 55/180 High Light Col or Operat or Guide

• Predrilled paper: Has holes for use in binders or binder rings. Before loading predrilled paper, fan it to remove any loose plugs that could cause paper jams.

• Perforated paper: Have been pi erced with one or more rows of holes to permit easy tearing or separating into sections. Read and follow the instructions on the ream packaging.

• Precut or full tabs

• Carbonless paper: Is paper that is treated or coated to produce an image under pressure (without the use of carbon paper). After opening, close and seal the original ream wrapper to store. Do not leave in paper trays overnight. Read and follow the instructions on the ream packaging.

General paper characteristics

When selecting paper, look for the following :

• Low moisture content (a paper to moisture ratio below 5.7 percent). Paper with higher moisture content may curl and jam.

System components

• Smooth surface

• Moisture resistant wrapping

• No defects such as bent edges or uneven surfaces

• Grain runs parallel with the long side of paper

Graphical user interface overview

The graphical user i nterface (GUI) on the control ler enables yo u to interact with the printing sys tem. It contains windows, icons, and menus through which you can issue commands and perform operation and system administration tasks.

When the workstation controller is powered on and booted, the DocuSP Print Services main menu displays on the controller screen.

DocuTech 128/155/180 HighLight Color Operator Guide 2- 5

System components

System software and job flow

This section describes how the system softwar e processes are used as a typical job flows through the system.

NOTE: There are no job flow differences between the High volume printer and the Production publisher configurations.

Figure 2-1. Job flow

1. Job

2. Input Queue

3. Decomposer

4. Output queue

5. Printer

Job

The job and the job ticket (if applicable) are recei ved 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 attr ibutes are attached to the job. The job remains i n the Input Queue until i t can be printed; for example, “held” and “fau lted” jobs reside in the input queue.

Decomposer

The Job Chooser reconciles the job attributes with the virtual printer attributes. Once the job is ready for print, the Job Chooser gives the job to the appropriate decomposer, PostScript or PCL.

2-6 DocuTech 128/1 55/180 High Light Col or Operat or Guide

System components

Output queue

After decomposition, the job is stored in the output queue.

Printer

The marker transfers the job from the Output Queue to the pr inter. After the job has successfully printed, it is removed from the Output Queue and also from the Input Queue.

The printing process and job flow is different for PostScript, PCL, TIFF, ASCII, PDF jobs (that is, non-LCDS jobs) and for LCDS jobs.

PostScript, PCL,

TIFF, ASCII, IPDS,

and PDF jobs

Printer overview

When the job is sent from the application for printing, a print data file is created. This file becomes the job that is submitted to the printer for printing. The prin t 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 t he queue from a given application.

NOTE: IPDS and LCDS are not supported on the Production publisher configuration at this time.

The printer receives data from the controller and prints the document according to the print options s pecified by the us er. The printer also stacks and collates the printed output.

The printer system is available in two configurations:

1. High volume printer with invert er feeder/stacker and up to three feeder/stackers

2. Production publisher with a 2-tray interposer and finisher

DocuTech 128/155/180 HighLight Color Operator Guide 2- 7

System components

High volume printer

The components, special features, and configurations of the Xerox DocuTech 128/155/180 HLC printer are shown in the following figures.

Figure 2-2. Printer with inverter feeder/stacker + feeder/ stacker (standard base configuration)

1. Feeder tray

2. Sample tray

3. Attention light

4. Purge tray

5. Feeder/stacker modules

6. Inverter feeder/stacker

Feeder/paper tray (High volume printer)

Multiple feeder/paper trays can be configured to feed paper for jobs in the most effective manner. For example, the trays can provide nonstop printing of a complex job that requires many paper stocks, or only a few stocks, by using the trays continuous loading capability. A different input tray can also be selected for each copy of a specific page in a print job, for exa mple, to prov ide 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 128/1 55/180 High Light Col or Operat or Guide

System components

Processor feeder/

paper trays

Feeder/paper tray

capacity

Two processor feeder/paper trays (trays 1 and 2) are located in the main part of the printer.

Trays 1 and 2 can handle paper sized from 8 by 1 0 inches / 203 by 254 mm to 9.02 by 14.02 inches / 230 by 356 mm.

Depending on your configuration, the feeder/paper trays have the 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 i n use. In each tray, a control panel consisting of a button, indicators, and paper level displays controls the elevator tray and indicates its status.

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

indicator

Please Wait

indicator

Tray Unlock button Enables the tray to be opened.

Glows green when the tray can be pulled out and paper can be added to it.

Shows that the tray is in motion. This indicator is lit red when the Tray Unlock button i s pressed, while the tray is lowering, and while the tray is rising. The indicator goes off when the tray elevator reaches its destination.

• If the tray is in use when this button is pressed, the feed selection switches to the backup tray if one has been identified. Otherwise, pri n ting stops.

• If the tray is in use and selected as a bac kup tray, pressing the Tray Unlock button causes the tray elevator to lower and the tray to be unavailable for auto switching.

• If the tray elevator is in the raised posit ion 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 p aper in the tray. Each display shows paper by quarter reams up to one ream, and then by full reams. The green indicator appears above it s Paper Level indicator.

Sample tray

NOTE: High volume printer configuration only

The sample tray, located on top of the printer, receives output such as transparencies, sample sheets from printing jobs, prints from system files such as forms, and wast e sheets that cannot be sent to the purge tray.

Monitor the sample tray and empty it when it contains 100 sheets. The system does not notify you when the tray is full.

Attention light

NOTE: High volume printer configuration only

An Attention light is mounted on top of the inverter module. Thi s light either blinks or modulates (alter nately 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 exi sts that needs attention soon. Flashing: The printer has stopped and requires your attention

immediately.

NOTE: When the Attention light starts flashing, an explanatory message appears on the controller screen.

Purge tray

NOTE: High volume printer configuration only

The purge tray is loc ated on top of the l ast f eeder/ st ack er module. Aborted sheets (for example, damaged sheets or sheets cleared after a paper jam) are sent to thi s tray. The purge tray should be emptied when it has received 100 sheets of p aper.

The system does not notify you when the tray is full.

2-10 DocuTech 128/155/180 HighLight Color Operator Guide

System components

Inverter feeder/stacker

NOTE: High volume printer configuration only

Each output feeder/st acker has offset ting cap ability and a cap acity 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 hol d only up to 1500 sheets of A3 or 11 by 17 inch papers , fo r s a fe ty re a s o n s.

Figure 2-4. High capacity stackers (HCS)

The stackers can stack the pri nted 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 less when stacking into a cont ainer.

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 lower s the stack for unloading. An offset mechanism offsets print ed sets toward the front or back of the HCS bin.

The elevator platform lowers under the following conditions:

• The bin capacity has been reached.

• A selection to lower the platform is entered at the printer control console or a user interface window.

• The job being printed reaches a designated unload boundary.

Each HCS bin has unlinked double doors to give you easy and safe access for unloading output from the printer.

The elevator bin platform automatically rises when the doors are closed after the stacker has been unloaded.

Bin control panels

on stackers

DocuTech 128/155/180 HighLight Color Operator Guide 2- 11

Each stacker bin has a control panel consisting of buttons and indicators.

System components

Figure 2-5. High capacity stacker bin control panel

1. Ready to Unload indicator on stacker bins

2. Please Wait ind icator on stacker bins

3. Bin Unload button on stacker

4. In Use indicator on stacker bin

Ready to Unload

indicator on stacker

bins

Please Wait

indicator on stacker

bins

Bin Unload button

on stacker

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.

• If the bin is in use when this button is pressed, the printed pages begin stacking i n the oth er stacker bin, if auto swit ching has been enabled.

• If the 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 cont ain the high-cap acity feeder trays and the stacker bins. The printer may have up to four feeder/ stacker modules (including t he inverter f eeder/stac ker), cont aining feeder trays 3, 4, 5, and 6, and stacker bins A, B, C, and D. Each module contains one high-capacit y feeder tray and one high capacity stacker bin.

High-capacity

feeders

2-12 DocuTech 128/155/180 HighLight Color Operator Guide

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 handl e 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 posit ion of the elevator to determine the fullness of the tray.

System components

High-capacity

stackers

The high-capacity st acker (HCS) bins are loc ated in the top half of the feeder/stacker modules, accessed through double doors.

Two high-capacity stacker bi ns are standard, with up to two additional bins available as options (providing up to four bins total). Each bin holds up to 2500 sheet s of 20 pound or 80 gsm paper.

More High volume printer configurations

In addition, the high volume printer is available with three or four feeder/stacker modules.

Figure 2-6. Printer with inverter feeder/stacker + feeder/ stacker + feeder/ stacker

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, speci al features, and configurations of the Xerox DocuTech 180 HLC production publisher printer are shown in the following figures.

Figure 2-8. Production publisher: Printer + 2-tray interposer + stitcher/binder

1. Convenience tray

2. Interposer

3. Finisher

4. Top tray

Convenience tray

The convenience tray provides an area to place documents or other items while you are at the printer.

2-14 DocuTech 128/155/180 HighLight Color Operator Guide

Interposer

NOTE: Production publisher configuration only

The two-tray Interposer module is located b etween the print engine and the Finisher. The Interposer inserts blank or preprinted sheets as required.

System components

Figure 2-9. Interposer (production publisher only)

The following lists the interposer components

1. Paper transport (lower)

2. Paper transport (upper)

3. Inserter tray

4. Feeder/inserter tray

DocuTech 128/155/180 HighLight Color Operator Guide 2- 15

System components

Finisher

NOTE: Production publisher configuration only

Figure 2-10. Finisher

In the finisher, prints can be collated, and stitched or bound, as required for a job. The following lists the finisher components:

1. Bindexer

2. Stitcher

3. Stacker

4. Binder

5. Binder tape reel

6. Sti tcher wire spools

7. Top tray

The bindexer

NOTE: Production publisher configuration only

The bindexer is a three-bin sorter that collates the pages of each print set. As the pages of the print set are fed to the bindexer, the bindexer moves up and down to collate them.

The stitcher

NOTE: Production publisher configuration only

When the job requires stitched output, the st itcher cut s and inserts the wire stitches into each print set. The stitch length is related to such factors as the number of pages in the print set and the print stock weight. A single stitch can be placed in the portrait or landscape print position. Dual stitching is available for landscape and portrait prints. Stitch placement can be changed through the DocuSP software.

NOTE: For more information about setti ng sti tch pla cement, refer to the on-line help system.

2-16 DocuTech 128/155/180 HighLight Color Operator Guide

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 stack er 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-li ne h elp 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 t he set on the tape. Binder flappers then press the tape to the sides of the set. The combination of the heat i n the binder and the pressure of the flappers glues the tape to the set.

Function of the

bypass transport

NOTE: For information about adjusting the binder tape

registration and the binder tape length, refer to the on-line help system.

The top tray

NOTE: Production publisher configuration only

Prints are delivered to the top tray beca use the pri n ts are oversized or because the top tray was selected on the screen.

The bypass transport device is no t available for this configuration (four feeder/stacker modules).

The printer is available in a Production configuration which includes a two-tray Interposer and the in -line Binder/Stitcher

Bypass tr ansport

The printing system is avail able in several confi gurations, and may be configured with a bypass transport.

The bypass transport moves paper from the stacker to a thirdparty 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

supported on

bypass transport

DocuTech 128/155/180 HighLight Color Operator Guide 2- 17

The bypass transport a ccepts all paper stocks on which the prin ter can print, and it accommodates simplex and duplex printing.

System components

DFA suppor t The bypass transport meets the Xerox Document Feeding and

Finishing Architecture (DFA) specifications. The system software supports DFA. However, in order for the bypass tr ansport to function correctly, you need to set up finishing personality profiles to identify your finishing device to the printing system. (The customer support represent ative for your finishing devi ce can give you the information you need to create a personality profile for your third-party finishing devi c e.)

For information on marketing partners that provide solutions for support and interface with finishers, contact your local Xerox sal es representative.

Bypass transport on the production publisher

Depending on the finisher configuration, the bypass transport is located inside the finisher module on the Pro duction publisher configuration. Bypass tr ansport function is the same as the external bypass transport module.

NOTE: The Production publisher finisher is available with or without the bypass transpor t.

Bypass transport on the High volume printer

Connected to the last feeder/stacker module. The bypass transport option enables third-party finishing devices to interface directly with the printing system. The bypass transport allows you to customize your printer for increased efficiency and specialized applications involving finishing.

NOTE: Systems configured with the external bypass transport can have a maximum of two (2) feeder/stacker modules. See figure 2-13.

7 by 10 inch enablement kit

The 7 by 10 inch enablement kit all ows the print ing system to pr int on 7 by 10 inch/178 by 254 mm paper siz e, with thro ughput speed of up to 206 PPM.

Paper paths

The paper path is the route that materials (paper, transp arencies, labels, and so on) follow through the printer f rom the feeder trays to the output bins or finisher.

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System components

High volume printer paper path

The following figure shows the path the paper takes through the high volume printer.

Figure 2-11. Route of paper through the high volume printer

1. Processor feeder tray 1

2. Processor feeder tray 2

3. High-capacity feeder tray 3 a. Side 1 of sheet leaving feeder tray b. Drilled holes (on right edge) c. Origin 0,0: portrait orientation

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System components

4. High-capacity feeder tray 4 a. Side 1 of sheet leaving feeder tray b. Drilled holes (on right edge) c. Origin 0,0: portrait orientation

5. Paper inverter

6. Duplex inverter

7. Sample tray

8. High-capacity stacker bin A a. Side 2 of sheet stacked in bin b. Drilled holes (on left edge) c. Origin 0,0: portrait orientation

9. High-capacity stacker bin B a. Side 2 of sheet stacked in bin b. Drilled holes (on left edge) c. Origin 0,0: portrait orientation

10. Purge tray

11. Bypass transport a. Side 2 of sheet passing through bypass transport b. Drilled holes (on left edge) c. Origin 0,0: portrait orientation

2-20 DocuTech 128/155/180 HighLight Color Operator Guide

System components

Production publisher paper path

The following figure shows the path the paper takes through the production publisher.

Figure 2-12. Route of p aper t hrough the pr oducti on publis her

1. Processor feeder tray 1

2. Processor feeder tray 2

3. High capacity paper tray

4. Paper inserter tray

5. High capacity paper tray

6. Duplex inverter

7. Purge tray

8. Bypass transport

9. Bindexer area

10. Bind area

11. Stitch area

12. Stac ker area

Bypass transport paper path

The following figures show the paper p ath through the bypass transport, viewed from the front of the printer.

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System components

High volume printer bypass transport paper path

Figure 2-13. Bypass transport paper path (high volume printer configuration shown)

1. Sheet path

2. Exit rollers

3. Floor

2-22 DocuTech 128/155/180 HighLight Color Operator Guide

The System

System Hardware

System components

The basic hardware components of the DocuTech 128/155/180 HLC systems are the DocuSP controller and the printer.

The DocuSP controller

The DocuSP controller is the connection between you and the system. You communicate through the DocuSP software by selecting and managing the jobs displayed on the screen and sending them to the printer for production. The system also communicates messages and instructions to you on the Print Services interface screen.

The controller consists of a specially-configured workstation and uses proprietary Xerox hardware, firmware, and software.

Speci fications can be obtained from your Xerox customer representative or by accessing the Setup, System Configuration feature on the DocuSP user interface.

NOTE: Controller hardware configurations are subject to change to keep up with advances in technology.

Controller overview

The controller receives LCDS*, IPDS, PostScri pt, and PCL data streams from a mainframe host or a workstation cli ent, processes the data, and sends it to the printer. The controller also provides the printer with print data and commands and receives status information from the printer.

The controller consists of a workstation, which is run by the Sun Solaris Operating environment. Also resident on the controller is the Document Services Platform application software, known as DocuSP software, which manages all printing, diagnostic, and administrative functions on the printing system.

The DocuSP software includes a full-c olor graphical user interface, which enables you to interact wi th the printi ng 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 wh en request ed.

NOTE: LCDS is not available on the Production publisher configuration at this time.

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System components

Accessing DocuSP remotely (Remote Workflow)

Remote Workflow, a remote graphical user interface (GUI), is available for installation from a CD. Remote Workflow allows you to manage your DocuSP-based printers from a single PC or Sun workstation. You may set your preferences from the remote client to disable or enable some or all connections.

Remote Workflow allows you to configure the printers that you want to manage, and provides real time status of the printers. You may switch between the printers that you are managing, but you can display only one printer GUI at a time.

The remote client GUI looks and functions the same as the local DocuSP GUI on the controller.

Moving the controller

To ensure consistent performance and avoid any damage to equipment, follow these rules for placi ng the components of the workstation controller .

Do:

Use the controller stand that comes with your printing system equipment.

Keep the processor in an upright, vertical positi on. Allow at least 6 i nches / 152 mm of unobstructed space at t he front

and rear of the processor, so the fan and vents are not blocked.

CAUTION: Do not place the monitor on top of the processor. Do not block any fan or vent on the front, sides, or rear of the processor.

Do not:

Do not place the monitor and processor on a desk or table top. Do not place the monitor on top of the processor. Do not allow any piece of equipment to blow warm air into the air

intake vents of the processor. Do not place the processor on its side, or in any other positi on but

the upright, vertical position achieved by using the controller stand.

Do not place the processor or monitor on top of the printe r.

Tape drives overview

The DocuTech 128/155/180 HLC supports several types of tape drives that may be used to load resources (forms, font s, etc. ) or to submit offline LCDS print jobs.

A 26-track cartridge tape dri ve 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.

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System components

The DocuSP Tape Client software enables transmission of data from a cartridge or open reel tape to the DocuSP controll er via the Socket gateway.

The 4 GB external SCSI quarter inch cartridge (QIC) tape drive is an external device. The cartridge tape drive connects to the controller through the SCSI port on the processor back panel.

Like the diskette and DVD drives, this tape drive is not an input source for print jobs or for any other data or application. You can use it to load resource files, and the servi ce representative uses it to load system maintenance files or to save diagnostic information.

36-track cartridge

tape drive

Figure 2-14. 26-track cartridge tape drive

An 18/36-track cartridge tape drive is an option. You can use this drive to load resources and to submit offline LCDS print jobs.

Peripheral cabinet (9-track and 18/36-t rac k tape drives)

Some Xerox customers may already have a peripheral cabinet that houses a 9-track magnetic and an 18/36-track cartr idge tape drive. If a peripheral cabinet has either of the following 18-track tape drives, they are not supported:

STK 4220 MOD 1 tape drive STK 4220 MOD 2 tape drive

DocuTech 128/155/180 HighLight Color Operator Guide 2- 25

System components

Figure 2-15. Peripheral cabinet

1. 9-track magnetic tape drive

2. 18/36-track cartridge tape dri ve

Paper sizing and print speed

The printer paper trays have edge gui de sensors that det ect paper length and width. The system select s correct paper trays for the print job based on the paper parameters, such as size, weight, color, or coating, specified in the job as follows:

• If an exact match is found, the print job continues.

• If an exact match is not found, the operator can specify in t he job for the printer to do one of the following:

– Stop pri nting the job and print an error sheet. – Print the data on an oversized sheet.

If you encounter any problems related to pa per sizing, contact your lead operator or Xerox service rep resentative.

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System components

Long and short edge

feeding

To feed through the printer, the l eading edge of t he p aper must be at least 10 inches long. Therefore, the following standard sizes of paper must be loaded so that sheets feed long edge first:

• 7 by 10 inch

•B5

•A4

• US letter

•B4

• US legal

The following papers, which have long edges greater than 14.33 inches / 364 mm must feed short edge first:

•A3

• US ledger or US tabloid

NOTE: JIS B4 can be fed either long edge or short edge first.

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System components

2-28 DocuTech 128/155/180 HighLight Color Operator Guide

3 Routine maintenance

This section describes the routine activities you perform to maintain the reliability and productivity of your printer.

Cleaning and maintenance overview

Some printer components need to be cleaned periodical ly to help keep the system operating reliably, and to ensure that the print quality is consistent.

When supplies get low, an indicator will appear in the DocuSP Print Services window on the DocuSP controller. You should respond to the fault or message as soon as possible to avoid a printer shut down.

The system provides dry ink to the printer from a bottle located in the printer. When the screen displays an “empty” message, a full dry ink bottle must be install ed.

Waste dry ink empti es 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 impo rtant to take the following precautions wheneve r you perform cleaning and replacement tasks.

• Use only the cleaning and replacement supplies that are

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Routine maintenance

approved or recommended by Xerox. If you use other supplies, you may damage the system.

• Keep supplies in stock as listed in the Service and supplies chapter.

• Whenever you use or remove a part from the system, handle the part carefully. Note any informative labels on the system.

• Keep atomized and aerosol sprays away from the system.

• Pour cleaning liquids onto a cl oth. Do not po ur or spr ay l iqui ds directly onto system par ts.

• Before reinstalling a system part that has been cleaned with a liquid, ensure that the part is dry.

• Always use a drop cloth when replacing the dry ink bottle, highlight color contai ner, or when adding fuser shield.

• 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 part s.

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. S tit cher spool B is used for port rait dual stitch es and landscape stitches.

To replace stitcher spool B, contact the Customer Support Center; refer to the section, “Calling for ass istance”, 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 binder 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.

3-2 DocuTech 128/1 55/180 High Light Col or Operat or Guide

Paper

Routine maintenance

You can add the same kind of paper to a tray when the supply is low without stopping the printer. You mu st have the s ame paper or stock loaded in two trays for the system to continue p ri nting 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

• In 35% to 55% humidity

F. / 20 to 24.4o C.

Figure 3-1 Storing paper correctly

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Routine maintenance

Conditioning paper

Figure 3-2 Recommended temperature and humidity for

paper storage

Because temperature and humidity affect paper performance in the printer, you need to condition paper before using it. To condition paper, store it for a specified length of time in the same type of environment as your printer.

The length of time you should condition your paper depends on the amount of paper and the dif fer ence 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 indic ate the te mperature difference between the storage area and the operating environment, not actual room temperatures .

3-4 DocuTech 128/1 55/180 High Light Col or Operat or Guide

Table 3-1. Paper conditioning

T e mperature difference between storage and operating areas

Routine maintenance

Paper curl

Fahrenheit Centigrade

5.5

20o25

8.5o11

30 17

40 22

50 26

Cartons Hours needed to condition the paper

1481114172434 5591215182535 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 car tons of p aper from a s torage area with a temperature of 90 temperature of 70

F. (a 20

F. to an operating area with a

difference), you should do so at least

18 hours before using the paper.

Before the manufacturer cuts paper into sheets, it is stored on large rolls. After it is cut and packaged, it ret ains some of the curl from the rollers.

Although it is unnecessary to load paper with the curl facing up or down, best result s occur when you are consistent. For example, if you open paper with the wrapper seam up, always load i t in the tray that way.

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Routine maintenance

Adding paper to tray 1 or 2

The following steps must be performed to add paper to tray 1 or 2.

1. Press the Tray unlock button on the front of the tray. Wait for the red "Please wait" light to go off.

2. When the green "Ready to open" light comes on, pull the tray out until it stops.

Steps 3 through 5 of loading paper into tray 1 o r 2 are illustrated in Figure 3-3.

3. Press the green release tab.

4. Lift the metal handle on the feed belt and remove any paper

under the belt.

5. Move the rear guide to the back of the tray.

Figure 3-3 Preparing the paper tray

NOTE: To load the paper correctly, refer to the label located

on the inside panel at the front of the paper tray. Remove any damaged sheets from the top of the stack.

CAUTION: Do not load the paper above the red li ne. A jam could occur if too much paper is loaded in the tray.

6. Load the required paper into the paper tray. Load paper with the curl side facing down. Load Xerox pap er with the package wrapper seam side facing up.

NOTE: When loading drilled paper, be sure to fan the edge where the holes are located.

7. 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.

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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.

Using the custom transfer assist blade

The custom transfer assist blade in the printer assures good print quality for your jobs. A kit is available allowing you to customize the transfer assist blade for use with nonstandard paper sizes.

You cannot use the custom transfer assist blade for print jobs that use more than one paper size. In addition, the following paper lengths cannot use the blade:

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Routine maintenance

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, tr ansfer efficiency may be reduced.

CAUTION: To avoid damage to the photoreceptor, you must set the tray size with the transfer assist blade.

Installing the

custom transfer

assist blade

Setting tray size with

the custom 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 procedur e before you attempt to customize and install a transfer assist blade for the first time.

When you are using the custom transfer assist blade, you must set the tray length. Use the following two tables to determine the tray length setting to use.

Table 3-2. Tray length settings for custom transfer assist blades (U.S. markets)

Paper Size Set Paper Size

11.5 to 11.7 inches/292 to 297 mm 11.7 inches/297 mm

12.1 to 12.9 inches/307 to 328 mm 13 inches/330 mm 13 to 13.9 inches/330 to 353 mm 14 inches/356 mm

Table 3-3. Try length settings fro custom transfer assist blades (Non-U.S. markets)

Paper Size Set Paper Size

10 to 10.9 inches/254 to 277 mm 11 inches/279 mm

11.5 to 11.6 inches/292 to 294 mm 11.7 inches/3297 mm

12.1 to 12.9 inches/307 to 328 mm 13 inches/330 mm

3-8 DocuTech 128/1 55/180 High Light Col or Operat or Guide

Adjusting for paper curl

Each sheet of paper has a natural curve call ed 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.

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.

Routine maintenance

Figure 3-5 Measuring the paper curl

3. Place the bottom edge of the prints over the p aper curl

measurement chart in this guide.

• If the print curl on the printed paper measures between +1

and - 2, do not change the decurler setting.

• If the curl is between +2 and +3, or - 3 and - 4, refer to the

procedure, "Adjusting the decurl er lever," in this section.

NOTE: Superior performance for greater than substance 32 (120 g/m2) can be achieved between +1 and -1 curl.

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Routine maintenance

Note: Corners of the sheets of pape r should not exceed curl shown in this chart.

Image

Move green decurler lever

Figure 3-6 Measuring the paper curl

3-10 DocuTech 128/155/180 HighLight Color Operator Guide

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 p ath, as shown

in the figure below.

Routine maintenance

Figure 3-7 Locating the decurler lever

3. If the print cur l is +2 or more, move the green decurler lever to

the right.

4. If the print curl is -3 or more, move the green decurler lever to the left.

5. If the decurler adjustment does not eliminate the paper curl problem, or for other curl problems, turn the stack of paper over in the paper tray.

6. If there is still a curl problem, perform steps 1 to 4 again. NOTE: A final solution to the curl problem may be to load a

new ream of paper.

7. Close the processor door.

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Routine maintenance

Maintaining the printer

A screen message is displayed when it is necessary to replace system supplies. To ensure that the system runs efficiently, replace the supplies as soon as possible.

Replacing the black dry ink bottle

When directed by a screen message, replace the black dry ink bottle. If the bottle is not replaced, the pri nter will eventually stop, and it will not operate until a new bottle is instal led.

CAUTION: To prevent dry ink spills, remove the bottle only when directed to do so by a message on the screen.

CAUTION: Do not use warm or hot water, or general cleaning solvents to remove dry ink from your skin or clot hing. The heat or solvent will set the dry ink and make it difficult to remove.

CAUTION: If any dry ink should get on your clothes, brushing with a dry paper t owel or a stif f -bris tled b rush may remove the i nk. If not, launder your clothes with detergent and cold water. Tell a commercial dry cleaner that the spot is dry ink or "t oner" so that they will not use a solvent that will set the dry ink stain.

Replace the black dry ink bottle

The following steps must be performed to replace the bl ack dry ink bottle.

1. Open the front processor acces s door and loc ate the b lack dry ink bottle at the left side of the processor.

2. Place a drop cloth on the floor under the dry ink bottle area.

3. 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.

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Routine maintenance

Figure 3-8 Removing the empty bottle

4. To insert a new bottle, place the bottle on the edge of the bottle

guide. a. With a slow, firm motion push the bottle into the dispense

position over the hopper.

b. Turn a new bottle of dry ink upside down and shake the

bottle thoroughly to loosen the contents. Insert the full bottle until it stops.

Figure 3-9 Inserting and latching the bottle

c. Slide the full bottle all the way into the system. d. Hold the bottle in place with one hand and remove the

DocuTech 128/155/180 HighLight Color Operator Guide 3- 13

Routine maintenance

paper seal by pulling it toward you with the other hand. Discard the seal along with the drop cloth.

Figure 3-10 Removing the paper seal

5. Close the processor access door. NOTE: If any dry ink should get on your skin, wash with mild

soap and cold water.

Replacing the highlight color container

The highlight color container hol ds the color dry ink. When directed by a screen message, replace the highlight color container. If the highlight col o r 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 clot hing. The heat or solvent will set the dry ink and make it diff icult 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, brus hing with a dry pa per 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 dr y 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 col or container area.

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Routine maintenance

3. Remove the empty container by grasping its handle. With a slow, firm motion, remove the container.

Figure 3-11 Highlight color container

4. Pull the container out until it stops.

5. Remove the container and discard it.

6. To insert a new bottle, place the bottle on the edge of the bottle

guide. With a slow, firm motion, push the bottle into the dispense position over the hopper.

7. After the bottle is in the dis pense position, remove the seal. You may encounter some resistance.

8. Close the processor door.

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Routine maintenance

Changing the highlight color Customer Changeable Units

The highlight color Customer Changeable Unit (CCU) consists of the color dry ink bottle and supporting equipment. In order to change the highlight color or to service the wire module, you need to remove the highlight color CCU from the printer.

If you have more than one highlight color CCU, a CCU cart is provided to allow you to change and store the CCU. If you have only one highlight color CCU, a service cart is provided to allow you to remove the CCU for service.

CAUTION: CCU carts should be used exclusive ly f or 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 cras h or rest art, or openi ng a door during printing, without firs t allowing the system to cycle up and continue processing for a proper recover y.

Removing the CCU using the CCU cart

To remove the highlight color CCU from the printer:

1. If the printer is not cycled down, Pause the system before you open the doors and attempt to remove the CCU.

2. Open the printer doors and locate the color housing area in the center of the printer.

3. Open the top cover of an empty cart.

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 is level. a. If the cart is not level, loosen the l ocknut holdi ng the height

adjustment knob in place.

b. Use the height adjustment knob to regulate the level.

3-16 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

c. When the HLC unit is level, tighten the lock nut.

Figure 3-12 Leveling the cart

7. Push down firmly on the cart pedal until you hear or feel the

pedal catch. The pedal should stay locked down. The pallet within the cart is raised.

8. Unlatch the CCU by turning the photoreceptor backup roll er handle clockwise for a quarter turn to an upright position.

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Routine maintenance

5. Then, turn the yellow CCU handle a quarter turn clockwise.

Figure 3-13 Unlatching the CCU

9. Using the metal flange of the color CCU, pull the CCU out of

the printer until it is completely in the cart. The flange is located directly below the bottle.

Figure 3-14 Removing the CCU from the printer

10. Push down firmly on the cart pedal until you hear or feel a

click. The pallet, which now contains the CCU, is lowered into

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Routine maintenance

the cart. If the pallet does not move, check that the CCU is all the way out of the printer and push down on the pedal again.

Figure 3-15 Closing the top cover

11. Close the top cover and store it.

Inserting a CCU

To insert a CCU, follow these steps.

1. Open the top cover of the cart containing th e 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.

Figure 3-16 CCU on cart

3. Push the cart firmly against the printer until you can feel the

two latch together.

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Routine maintenance

4. Push down firmly on the cart pedal until you hear or feel the pedal catch. The pedal should stay locked down. The pallet containing the CCU is raised.

5. Using the CCU metal flange, firmly push the CCU into the printer.

6. Turn the yellow CCU handle counter clockwise for a quarter turn. If it does not turn, check that the CCU is fir mly seated in the printer.

Figure 3-17 Turning the backup roller handle

counterclockwise

7. Turn the photoreceptor backup roller handle counterclockwise

for a quarter turn.

8. Make sure that the CCU is completely inserted into the machine to prevent photoreceptor damage.

9. Push down firmly on the cart pedal until you hear or feel a click. If the pallet does not drop, check that the CCU is all the way in the printer and the pallet is released, then push down on the pedal again.

10. Remove the cart from the printer and close the cart top cover.

11. Close the printer doors.

12. Store the cart.

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Storing the cart and CCU

NOTE: If any dry ink gets on your hands, wash them with soap

and cold water. Heat sets the ink permanently. If any dry ink gets on your clothes, brush them with a dry paper towel or a stiff bristled brush. If thi s 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, dustfree 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 withdr aw the highlight color CCU from the printer. Use this stand if you do not have a cart.

To set up the service stand:

Routine maintenance

1. If the printer is not cycled down, Pause the system before you open the doors and attempt to remove the CCU.

2. Open the printer doors and locate the color housing area in the center of the printer.

3. Place the service stand next to the developer housi ng.

4. By turning the jack screws, adjust the height of the front feet so

that the alignment pins in the service stand are positioned just below the hole and the docking bracket. Tighten the lock nuts on the jack screws to lock the jack screws in position.

Figure 3-18 Service stand

DocuTech 128/155/180 HighLight Color Operator Guide 3- 21

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 i n posit ion against the mac hine 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 t he service st and are in cont act with t he docking bracket.

8. With the service stand properly locat ed to the machine and while observing the level, turn the r ear 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.

Figure 3-19 Unlatching the CCU

3-22 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

6. Then, turn the yellow CCU handle a quarter turn clockwise.

Figure 3-20 Removing the CCU from the printer

11. Using the metal flange of the color CCU, pull the CCU out of

12. To replace the CCU, reverse the above steps.

Adding fuser shield

When directed by a message, add fuser lubricant as soon as possible. If it is not added, the printer stops after approximately 5,000 prints and not run until fuser shield is added. Please read the important note below.

NOTE: In 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 require s 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.

the printer until it is completely in the stand. The flange is located directly below the bottle.

WARNING: The fuser area can reach temperatures of approximately 425°F (218°C). Exercise ca re to prevent burns when working in this area.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 23

Routine maintenance

CAUTION: Fuser lubricant for other printers is not compatible. Do not use DocuTech and Do cuPrint 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.

Figure 3-21 Opening the fuser drawer

WARNING: Fuser lubricant contains silicone, which can cause

irritation upon cont act wit h the eye. Make sure t hat yo u wash your hands with soap and water after you finish this procedure.

CAUTION: Fuser lubricant can cause damage to the CCU if any of the it is spilled into the unit. Use extra care to ensure that no fuser lubricant is dripped into the CCU.

4. Wipe the fuser lubricant filler area to remove any residual lubricant.

5. Fill the fuser lubricant reservoir. a. Pull the fuser lubricant reservoir out until it stops. b. Remove the reservoir cap by turning it counterclockwise.

3-24 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Figure 3-22 Preparing to add fuser blend

WARNING: Fuser lubricant spills cause the floor to be slippery. If

any fuser lubricant is spille d onto the floor , it must be removed immediately.

c. Open a n ew box of fuser lubricant and remove a bottle.

Remove the cap from the bottle of fuser lubricant.

d. Carefully pour the fuser lubri cant into the reser voir 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 3- 25

Routine maintenance

Figure 3-23 Adding the fuser blend

e. Replace the reservoir cap by turning it clockwise

approximately one full turn. Do not overtighten the cap.

f. Inspect the area around the fus er to ensur e no fuser bl end

was spilled. Clean as required.

g. Push the fuser blend reservoir in until it stops.

6. Push the fuser drawer in until it latches into place.

Figure 3-24 Closing the fuser drawer

3-26 DocuTech 128/155/180 HighLight Color Operator Guide

Waste containers

Replacing the 128/155/180 HLC developer waste container

Routine maintenance

7. Close the processor doors. The fuser blend message disappears after the system makes

approximately 20 prints.

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 printi ng. T his secti on cont ai ns the procedure s for replacing the toner and developer waste containers.

To replace the developer waste container:

1. Open the processor doors and locate the dry ink cartri dge at the lower center of the printer. The developer waste container is located below and to the right of the color dry ink bottle.

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 locat ed above the frame of the machine. Lift the edge of the container from the tray and remove. Unscrew the cap from the front of the waste container and use it to close the open end of the waste container.

3. Discard the waste material and container appropriately.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 27

Routine maintenance

4. Insert the new waste HLC developer waste contain er into the transport assembly. Push the retainer out of the way with your thumb. Continue seating the new waste cont ainer onto the tray and release the container latch .

5. Close the processor doors.

Replacing the 128/155/180 toner waste bottle

To replace the toner waste bottle:

1. Open the HLC module door.

Figure 3-26 Opening the HLC module door

2. Remove the toner waste bottle.

3. Remove the flat cap from the top front of the bottle.

3-28 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Figure 3-27 Flat cap on waste bottle

4. Place the flat cap on the round bottle opening and snap it

down. This prevents spillage when discarding the bottle.

5. Discard the waste material and container by placing the container in the trash.

6. Obtain a new bottle and open it, placing the cap at the front of the bottle and snapping it down.

7. Insert the new bottle into the waste module.

Figure 3-28 Inserting a new waste bottle

8. Close the HLC module door .

DocuTech 128/155/180 HighLight Color Operator Guide 3- 29

Routine maintenance

Wire Module Removal and Replacement

Replace the wire module only when directed to by the Customer Support Center.

CAUTION: In the following i nstructions, do not pull on the locat ing arm of the developer housing. A bent or damaged locating arm can cause component damage or image quality artifacts.

Do no touch the Electrostati c Voltage (ESV) mount ed to the to p of the developer housing when removing the wire module. The ESV is fragile, and susceptible to damage from electrostatic discharg e .

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 Ref er to the procedures on using the CCU cart or service stand.

Figure 3-29 Wire module retainer springs

3. Release the wire module retainer springs. There is one at

each end at the front and back of the developer housing.

CAUTION: Handle the wire module with care since the wires can be damaged or broken easily. Do not touch the donor rolls. Touching the roll surface with your fingers can contaminate the surface, causing image quality problems.

To replace the wire module:

3-30 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

1. Position the wire module on the HLC developer module.

2. Snap the wire module retainer springs behind the tabs.

3. Slide the HLC developer module into the machine.

4. Latch the CCU into place.

5. Remove the cart or service stand.

6. Close the doors.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 31

Routine maintenance

Cleaning the system and its components

NOTE: Follow the procedures in this section only when directed

by Xerox Customer Support center personnel.

Cleaning tasks consist of the following:

• Cleaning the 18/36-track cartridge tape drive

• Cleaning the 26-track cartridge tape drive

• Cleaning the DVD drive

• Cleaning the diskette drive

• Cleaning the sensors and the reflecting surfaces

• Cleaning the display

• Cleaning the exterior surfaces of the system

Cleaning the 18/36-track cartridge tape drive

A cleaning cartridge is shipped with each 18/36-t rack 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 cart ridge is unl oaded and during a rewi nd or locate operation.

NOTE: CLEAN is a status message, not an error message.

CAUTION: Never power off the tape drive without following the

cleaning procedure once the CLEAN message appears. CAUTION: The cleaning cartridge must be undamaged and

clean.

To clean the 18/36-track cartridge tape drive read/write heads:

1. Remove any cartridge loaded in the tape drive.

2. Insert the cleaning cartridge.

The cleaning cycle takes approximately 15 seconds.

3. Remove the cleaning cartridge when it is unloaded.

4. Mark the usage on the tape label. Do not use a grease pencil.

You must clean the 18/36-track cartridge tape drive regularly to keep it functioning properly.

3-32 DocuTech 128/155/180 HighLight Color Operator Guide

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 dail y. The process is simple and requires little time.

1. If there is a cartridge in the tape, r e mov e it.

2. Insert the cleaning cartridge in the tape drive and close the

door. Cleaning begins automatically once the tape is inserted.

3. Allow the tape to run for approximately 30 seconds, then remove it.

NOTE: Replace the foam pad on the clea ning cart ridge af te r it has been used three times. The cleaning cartridge itself can be used 100 times.

Cleaning the DVD drive

Routine maintenance

Follow the DVD cleaning directions and recommended cleaning frequency.

1. If there is a DVD disk in the drive, remove it.

2. Follow the directions to clean the DVD drive.

Cleaning the diskette drive

The floppy disk drive must be cleaned at recommended intervals to prevent read and write disk errors.

To clean the diskette drive:

1. If there is a diskette in the floppy disk drive, remove it.

2. Insert the cleaning diskette into the disk drive.

3. Follow the directions on the cleaning diskette to clean the

diskette drive.

4. Remove the cleaning diskette.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 33

Routine maintenance

Cleaning the sensors and the reflecting surfaces

CAUTION: Never use abrasive materials or stro ng solv ents 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

• Q1106 sensor

• Q1166 sensor

• Q1107 sensor

• Q1164 sensor

• Production publisher configuration (finisher sensors)

• Q1201 sensor

• Q1202 and Q1203 sensors

• Q1205, Q1206, and Q1207 sensors

• Q1213 sensor

• Q1221, Q1218, and Q1227 sensors

• 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 int o place.

3-34 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Figure 3-30 Area 4 and green handle

3. Locate the Q850 and Q861 sensor.

Figure 3-31 Q850 and Q861 sensor

DocuTech 128/155/180 HighLight Color Operator Guide 3- 35

Routine maintenance

Cleaning the Q1011/1009 sensor and mirror

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.

1. Open the right and left doors of the printer and locate the

Q1011/1009 sensor.

Figure 3-32 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

NOTE: High volume printer configuration only

To access sensors Q1106 and Q1166, open the top cover of the high capacity stacker.

To clean the sensors:

1. Brush or wipe the sensor windows lightly.

2. Remove any dust present in the area.

3-36 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Figure 3-33 Q1106 and Q1166 sensors

Cleaning the Q1107 sensor

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.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 37

Routine maintenance

Cleaning the Q1164 sensor

NOTE: High volume printer configuration only

To access sensor Q1164, open the top cover of the last feeder/ stacker module, the one contai ning the purge tray.

To clean the sensor:

1. Brush or wipe the sensor windows lightly.

2. Remove any paper dust present in the area.

Figure 3-34 Q1107 sensor

3-38 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Figure 3-35 Q1164 sensor

Cleaning the display

The display should be cleaned as required. Clean the display with a sof t, lint- free cloth dampened with a gla ss

or lens and mirror cleaner . Do not spray the liquid dir ectly onto the display because it may cause damage.

Cleaning the exterior surfaces of the system

Clean the exterior surfaces of the prin ter daily, if possible. Clean the exterior surfaces with a mild household detergent that

has been poured or sprayed onto a cloth lightly dampened with water. Do NOT saturate the cloth; just dampen it.

CAUTION: Liquids must not be allowed to drip onto anythi ng electrical or mechanical. Also, never spray or pour any cleaner directly onto the keyboard or the exterior surfaces of the system.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 39

Routine maintenance

Clearing or cleaning the finisher sensors

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 process or top cover , under the finisher top cover, and behind the finisher and bindexer doors.

Use the following procedure to clear any obstructions from the finisher sensors.

1. Fold a sheet of 8.5 x 11 inch (216 x 279 mm) paper, a s shown in figure 3-36.

Figure 3-36 Folding the paper

2. Use the folded sheet of paper to clear any obstructions in the

following sensor areas.

Clearing the Q1201 sensor

NOTE: Production publisher configuration only

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

cover on the right side.

2. Locate the Q1201 sensor, as shown in figure 3-37

3-40 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Figure 3-37 Locating the Q1201 sensor

3. Brush a folded sheet of paper under the sensor to clear any

obstructions.

4. Close the processor cover.

Clearing the Q1202 and Q1203 sensors

NOTE: Production publisher configuration only

Clearing the Q1202 and Q1203 sensors should be performed only when directed by a Customer Support Center Representati ve.

1. Open the finisher top cover.

2. Locate the Q1202 and Q1203 sensors, as shown in figure 3-

38.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 41

Routine maintenance

Figure 3-38 Locating the Q1202 and Q1203 sensors

3. Brush a folded sheet of paper under each sensor to clear any

obstructions, as shown in figure 3-39.

Figure 3-39 Clearing the Q1202 and Q1203 sensors

4. Close the finisher top cover.

3-42 DocuTech 128/155/180 HighLight Color Operator Guide

Cleaning the Q1222 and Q1210 sensors

NOTE: Production publisher configuration only

Cleaning the Q1222 and the Q1210 sensors should be performed only when directed by a Customer Support Center Representative.

1. Open the finisher top cover.

2. Look down at the rear section of the tilt bed area, as shown in

figure 3-40, to view the sensors.

Routine maintenance

Figure 3-40 Locating the Q1222 and Q1210 sensors

3. Locate the Q1222 and Q1210 sensors, as shown in figure 3-

DocuTech 128/155/180 HighLight Color Operator Guide 3- 43

Routine maintenance

Figure 3-41 Locating the Q1222 and Q1210 sensors

4. Wipe each sensor gently with a soft cloth to clean them.

5. Close the finisher top cover.

Clearing the Q1205, Q1206, and Q1207 sensors

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.

3-44 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Figure 3-42 Locating the Q1205, Q1206, and Q1207 sensors

4. Brush a folded sheet of p aper a cross eac h se nsor t o cl ear any

obstruction.

5. Close the bindexer and finisher doors.

Clearing the Q1213 sensor

NOTE: Production publisher configuration only

Clearing the Q1213 sensor should be performed only when directed by a Customer Support Center Representative.

1. Open the finisher doors.

WARNING: The t op of the binder is appr oximately 425°F (218°C) .

Do not touch the heated areas or you may get burned. If the binder has been in a "Ready" condition, allow it to c ool for at least 1 hour before continuing the procedure.

2. Grasp the green handle on the binder drawer. Pull the drawer out until it stops.

3. Locate the Q1213 sensors, as shown in figure 3-43

DocuTech 128/155/180 HighLight Color Operator Guide 3- 45

Routine maintenance

Figure 3-43 Q1213 sensor

4. Brush a folded sheet of paper across the sensor to clear any

obstruction.

5. Close the binder drawer and the finisher doors.

Clearing the Q1221, Q1218, and Q1227 sensors

NOTE: Production publisher configuration only

Clearing the Q1221, Q1218, and Q1227 sensors should be performed only when directed by a Customer Support Center Representative.

1. Open the finisher front doors.

2. Locate the Q1221, Q1218, and Q1227 sensors, as shown in

figure 3-44.

3-46 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Figure 3-44 Locating the Q1221, Q1218, and Q1227 sensors

Cleaning the binder

NOTE: Production publisher configuration only

Keep the binder clean to prevent binder tape jams. Clean the binder once a week, or as needed, and also when changing the binder tape.

It is highly recommended that the binder be cleaned before the binder warm-up cycle begins or before switching the system on.

The following steps must be performed to clean the binder.

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 doors.

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

CAUTION: To avoid damage to the system, do not use any liquids or any abrasive material to clean the bi nder . Use the plast ic binder platen cleaner on the tape reel or use a clean, lint-free cloth.

2. Grasp the green handle on the binder drawer. Pull the drawer out until it stops.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 47

Routine maintenance

Figure 3-45 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 foll owing figure.

Figure 3-46 Binder platen cleaner

b. If binder tape is in the area of the cleaner, pull the reel

slightly away from the tape to avoid tape damage.

c. Lift up on the cleaner and push down against the single

end tab. Move the cleaner back and forth until the end tab breaks.

3-48 DocuTech 128/155/180 HighLight Color Operator Guide

d. Continue to move the cleaner in the same manner un til th e

2-sided tabs break.

NOTE:

NOTE: Ensure that the following cleaning procedures are performed in the order listed.

Cleaning the binder tape guides

NOTE: Production publisher configuration only

The following steps must be performed to clean the binder tape guides.

1. Use the binder platen cleaner to clean the surfaces and grooves of the tape guides.

2. Ensure that all the glue is removed from the grooves on the tape guides.

Routine maintenance

Figure 3-47 Cleaning the tape guides

Cleaning the binder platen

NOTE: Production publisher configuration only

The following steps must be performed to clean the binder pl aten.

1. Use the binder platen cleaner to clean the top and side surfaces of the binder platen until all the glue is removed.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 49

Routine maintenance

2. Ensure that the glue is removed from the grooves on the binder platen surface, which align with the top and bottom edges of the book.

Cleaning the flappers

NOTE: Production publisher configuration only

Using the binder platen cleaner , cl ean the top and side surfaces of the binder flappers until all the glue is removed.

Figure 3-48 Cleaning the binder platen

3-50 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

Cleaning the calipers

NOTE: Production publisher configuration only

Using the binder platen cleaner, clean the binder caliper surfaces until all the glue is removed.

Figure 3-49 Cleaning the flappers

DocuTech 128/155/180 HighLight Color Operator Guide 3- 51

Routine maintenance

Figure 3-50 Cleaning the calipers

Closing the binder

NOTE: Production publisher configuration only

Perform the following steps to close the binder.

1. Push in the binder drawer until it stops.

2. Close the finisher doors.

3. Place the platen cleaner in a safe place.

Replacing the stitcher spool A

NOTE: Production publisher configuration only

Use this procedure to replace stitcher spool A in the system. Check stitcher spools A and B visually during the warm-up cycle. Sti tcher 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 stitc her panel that gives instruct ions for

replacing the stitcher spool A. Refer to thi s label if needed. The following steps must be performed to replace the stitcher

spool A.

3-52 DocuTech 128/155/180 HighLight Color Operator Guide

Routine maintenance

1. Open the finisher doors.

2. Lift the stitcher panel, which is located directly above the

stitcher spools.

3. Pull the green stitcher head release handle forward and up until it latches into place, as shown in figure 3-51.

Figure 3-51 Releasing the stitcher head

4. Remove the stitcher wire plug.

a. The stitcher wire plug is located above the bi nder area, as

shown in figure 3-52. b. Press and hold down the release clip. c. Pull the plug out of the stitcher head.

DocuTech 128/155/180 HighLight Color Operator Guide 3- 53

Routine maintenance

Figure 3-52 Removing the stitcher wire plug

5. Perform one of the following steps:

• If there is no wire on the spool, use the wire cutters to pull

the remaining wire carefully out of th e tubing, as shown in

figure 3-53.

NOTE: The wire cutter tool needed to perform this procedure is located next to stitcher spool B.

3-54 DocuTech 128/155/180 HighLight Color Operator Guide

Xerox 128 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual