Xerox 61xx User Manual

Xerox Document Services Platform Series

DocuTech 61xx Operator Guide

701P38838
DocuSP version 3.6
August, 2002

Xerox Corporation
Global Knowledge and Language Services
800 Phillips Road
Building 845-17S
Webster, New York 14580
USA

© 2002 by Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms and matters of copyrighted material

and information now allowed by statutory or judicial law or hereinafter granted
including without limitation, material generated from the software programs that are
displayed on the screen such as styles, templates, icons, screen displays, looks, and
so on.

Printed in the U.S.A., U.K., and France.
XEROX, XEROX Europe, and XEROX Canada Limited, The Document Company, the

stylized X, and all names and identifying numbers used in connection with Xerox
products mentioned in this publication are trademarks of XEROX CORPORATION. All
non-Xerox brands and product names are trademarks or registered trademarks of
their respective companies. Other company trademarks are also acknowledged.

While the information in this Guide is correct at the time of this publication, Xerox
reserves the right at any time to change the information without notice. Changes are
made periodically to this document. Changes and technical updates will be added in
subsequent editions.

Table of Contents

1. Safety notices 1-1

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 1-5
Electricity at Work Regulation - UK 1-7

The Regulation 1-7

Check your understanding 1-7

Your responsibility 1-9

Additional queries 1-10

2. Certifications 2-1

FCC . . . USA 2-1

Radio frequency 2-1
Extra Low Voltage safety approval 2-1
Industry Canada requirements 2-2
European Union 2-3

3. Introduction 3-1

About this guide 3-1

Powering down the System 3-1

Contents 3-2

Conventions 3-2

4. System components 4-1

Electronic reprographic s proces s 4-1
The System 4-2

DOCUTECH 61XX OPERATOR GUIDE i

TABLE OF CONTENTS

System Hardware 4-2
The DocuSP controller 4-4
The Printer 4-5

The processor 4-5

The paper trays 4-6

The electrical module 4-6

The dry ink cartridge 4-6

The photoreceptor 4-6

The laser 4-7

The fuser agent reservoir 4-7

The inverter (duplex tray) 4-7

The decurler lever 4-7

The ground fault protector 4-7

The interposer 4-8

Upper entrance transport 4-9
Upper vertical transport 4-9
Upper turn transport 4-9
Tray 4 4-9
Upper exit transport 4-9
Tray 5 4-9
Lower entrance transport 4-10
Lower turn transport 4-10
Lower exit transport 4-10
Lower vertical transport 4-10
Loop transports 4-10

The finisher 4-10

The bindexer 4-11
The stitcher 4-12
The stacker 4-12
The binder 4-12
The top tray 4-12

The paper paths 4-13

ii DOCUTECH 61XX OPERATOR GUIDE

TABLE OF CONTENTS

5. Routine maintenance 5-1

Adding paper 5-1

Adding paper to tray 1 or 2 5-1

Adding paper to trays 3, 4, or 5 5-3
Cleaning and maintenance overview 5-5
Precautions you should take 5-6
Cleaning the binder 5-7

Cleaning the binder tape guides 5-9

Cleaning the binder platen 5-10

Cleaning the flappers 5-11

Cleaning the calipers 5-12

Closing the binder 5-13
Maintaining the printer 5-13

Replacing the dry ink cartridge 5-13

Replacing the dry ink waste container 5-17

Adding fuser agent 5-20

Replacing the stitcher spool A 5-24

Storing the binder tape reels 5-31

Replacing the binder tape reel 5-33
Adjusting the binder tape registration 5-38
Adjusting the heavy paper levers 5-41
Adjusting for paper curl 5-42

Measuring the paper curl 5-42

Adjusting the decurler lever 5-46

6. Problem solving 6-1

How problems are displayed 6-1
Printer faults and fault windows 6-2
When a fault occurs 6-2
Resolving a recurring problem 6-2

Resolving a processor problem 6-3

Resolving an interposer problem 6-7

Resolving a finisher problem 6-7
Clearing a binder tape fault 6-9

DOCUTECH 61XX OPERATOR GUIDE iii

TABLE OF CONTENTS

Clearing a stitcher spool A fault 6-10
Customer Support Center directed tasks 6-15

Cleaning the processor sensors and the reflecting surfaces 6-15

Cleaning the Q861 sensor 6-15
Cleaning the Q1009 sensor and mirror 6-16

Clearing or cleaning the finisher sensors 6-17

Clearing the Q1201 sensor 6-18
Clearing the Q1202 and Q1203 sensors 6-19
Cleaning the Q1222 and Q1210 sensors 6-21
Clearing the Q1205, Q1206, and Q1207 sensors 6-22
Clearing the Q1213 sensor 6-23
Clearing the Q1221, Q1218, and Q1227 sensors 6-24

Clearing the camming motor 6-25

Calling for assistance 6-27

Recording the problem 6-27

7. Technical information 7-1

DocuTech 61xx hardware requirements 7-1

Power consumption 7-1
Heat output 7-2

DocuTech 61xx printer specifications 7-2

Printer rates 7-2
Paper tray capacities 7-3
Additional paper capacities 7-5

DocuTech 61xx printer satisfaction guides 7-6

Stock storage 7-6
Improving the feeding reliability 7-6
Stock satisfaction guides 7-8

Using various stocks 7-11
Using non-standard stock 7-14

Finisher satisfaction guides 7-15

Paper stock rotation 7-19

Background 7-19

iv DOCUTECH 61XX OPERATOR GUIDE

TABLE OF CONTENTS

Limitations 7-20

8. Supplies 8-1

Supplies to keep in stock 8-1

Supplies ordered from the Supply Order Representative 8-1

Supplies ordered from the Parts Marketing Representative 8-1
Ordering supplies 8-2

DOCUTECH 61XX OPERATOR GUIDE v

TABLE OF CONTENTS

vi DOCUTECH 61XX OPERATOR GUIDE

TABLE OF CONTENTS

DOCUTECH 61XX OPERATOR GUIDE vii

TABLE OF CONTENTS

viii DOCUTECH 61XX OPERATOR GUIDE

System safety

Laser safety

1. Safety notices

WARNING

Use of controls or adjustments, or performances other than
specified herein, may result in hazardous radiation
exposure.

The Xerox DocuTech M od els 61 00 , 6 115, 6135, 61 55, an d 6 180
are certified to comply with laser performance standa rds set by
the U.S. Departme nt of He alth, Educa tion, and Welfare as Class
1 laser products. This is a class of laser products that does not
emit hazardous radi ation. This is possible only b ecause the la ser
beam is totally encl osed durin g all mod es of customer operation .

When performing operator functions, laser warning labels may
be visible. These labels are to alert and remind the service
representative a nd are place d on or ne ar panels or shiel ds 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.

DocuTech 61xx Operator Guide 1-1

Safety notices

Ozone safety

Operation safety

This product produces ozone duri ng nor ma l oper ati o n. Th e
ozone produced is dependent on copy volume and is heavier
than air. Providing the proper environmental parameters as
specified in the Xerox installation instructions ensures that
concentration levels meet safe limits.

Your Xerox equipment and supplies have been designed and
tested to meet strict safety requirements. These include safety
agency examination and approval, and compliance to
established environmental standards. Attention to the following
notes ensures the continued 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 ground ed power sour ce receptacle.
If in doubt, have the receptacle checked by a qualified
electrician.

• Do not use an adaptor plug to connect the system to an

electrical outlet that lacks a ground connection terminal.

WARNING

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 mechanical interlocks.

1-2 DocuTech 61xx Operator Guide

Safety notices

WARNING

Do not push objects into slots and openings on the system.
Making contact with a vo ltage point 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 . Disconn ect the system power
cable from the el ectrical outlet and call a Service
Representative.

• Do not place containers of coffee or other liquids on the

system.

• Switch off the system power, disconnect the power cable,

and call a Service Representative when any of the following
conditions occur:

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

• Always use materials and supplies specifically designed for

your Xerox equipment. Use of unsuitable materials may
result in poor performance and can possibly creat e a
hazardous situation.

• Never attempt any maintenance function that is not

specifically described in this Operator Guide.

• Never remove any covers or guards that are fastened with

screws. There are no op erator-service able 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 Confo rmity with the following applicable
Directives of the European Union as of the dates indicated
below.

DocuTech 61xx Operator Guide 1-3

Safety notices

January 1, 1995: Co uncil Directive 73/23/EEC amended by
Council Directive 93/68/EC, Approximation o f the laws of the
member states related to low voltage equipment.

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

March 9, 1999: Coun cil D ire cti ve 1 995 /5/EC on radio equipment
and telecommunicati on s termi na l equ i pmen t and the mutu al
recognition of their conformity.

A full declaration, defining the relevant directives and referenced
standards can be obtained from your Xerox Ltd. representative.

1-4 DocuTech 61xx Operator Guide

Safety notices

WARNING

Changes or modification to this equipment not specifically
approved by Xerox Europe may void user’s authority to
operate the equipment. Shielded cables must be used with
this equipment to maintain compliance with the EMC
Directive (89/336/EEC).

WARNING

The is a Class A product. In a domestic environment this
product may cause radio interference in which case the
user may be required to take adequate measures.

WARNING

This system is certified manufactured and tested in
compliance with str ict safety and radio frequency
interference regulations. Any unauthorized alteration which
includes the addition of new functions or the connections of
external device s may impact this cer ti9fication. 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 ne twork (PSTN) in accordance wi th Directive
1999/5/EC.

The product has been desi gned to wor k with the n ational PS TNs
and compatibles PBXs of the following countries:

DocuTech 61xx Operator Guide 1-5

Safety notices

•Austria

• Belgium

• Denmark

•France

• Finland

•Germany

•Greece

•Iceland

•Ireland

•Italy

• Luxembourg

• Netherlands

•Norway

•Portugal

• Spain

•Sweden

• Switzerland

• United Kingdom
In the event of problems, you should contact your local Xerox

representative in the first instance.
The product has been tested to and is complaint with TBR21, a

specification for terminal equipment for use on analogue
switched telephone networks in the European Economic Area.

The product may be configured to be compatible with other
country networks. Please contact your Xerox representative if it
needs to be reconnect ed to another co untry’s netw ork. There ar e
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 external control software or to
external control apparatus not authorized by Xerox, will
invalidate its certification.

1-6 DocuTech 61xx Operator Guide

Electricity at Work Regulation - UK

The Electricity at Work Regulation applies only to England and
Wales.

The Regulation

The Electricity at Work Regulation 1989 came into force in
England and Wales on the 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 ens uring all
electrical equipment connected to such electrical systems are
safely constructed, maintained and operated.

All Xerox equipment have been designed to exacting safety
standards. They have all undergone a variety of stringent safety
tests including earth bond, insulation resistance and electrical
strength tests. Xerox Europe manufacturing plants have been
awarded ISO 9000 qual ity certif ication and are subject to re gular
audits by the British Standards Institution or equivalent national
standards body.

Safety notices

Xerox equipment which h as been properly and reg ularly 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. The
address of the X erox Technical Centre is provided in the
previous section, European Union declaration of conformity.

Xerox equipment should, howeve r, be properly an d regularly
serviced and maintained at all times.

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?

DocuTech 61xx Operator Guide 1-7

Safety notices

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 prevent, so far
as reasonably practicable, danger. This includes ensuring all
electrical products connected to such electrical systems are
safely constructed, maintained and operated.

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 electrical systems in their

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

manufacturers or suppliers of such electrical systems.
However, rest assured that all Xerox equipment which Xerox
Europe and its authorized distributors supply to customers
conforms with all the relevant safety legislation and 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 serv iced and maintained by c ompetent 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 stand ards, please cont act 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?

1-8 DocuTech 61xx Operator Guide

Safety notices

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 tests which may be completed by your
Xerox Europe Customer Service Organization. THESE TESTS

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

Please contact the Xerox Euro pe Customer Service
Organization for further information.

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

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

temperament in my premises.

Answer You may, of course, request such tests as you deem necessary

to satisfy yourself that your Xerox eq uipmen t is safe. Your Xerox
Europe Customer Supp ort 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 which details the
results of all tests completed.

In the event of any defect being noted, the Xerox equipment will
be switched off and disconnected from the supply until the defect
has been corrected. You will be advise d of such act ion to ena ble
such defects to be corrected.

Your responsibility

YOU MUST ENSURE THAT YOUR XEROX EQUIPMENT IS
SAFE AT ALL TIMES.

DocuTech 61xx Operator Guide 1-9

Safety notices

Additional queries

Please contact the Xerox Europe Technical Centre or your
authorized Xerox representative if you have any queries
regarding the information provided in this document.

1-10 DocuTech 61xx Operator Guide

FCC . . . USA

Radio frequency

2. Certifications

This equipment ha s been tested and found to comply with the
limits for a Class A digita l device , pur suant to Par t 15 o f the FCC
Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is
operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequ ency energy and , if
not installed and u sed in accor dance with the instruction manual,
may cause harmful interference in which case the user will be
required to correct the interference, at his own expense.

Changes or modifications to this equipment not expressly
approved by Xerox Corporation may void the authority granted
by the FCC to operate this equipment. If requ ested, provide
these numbers to the telephone company.

Extra Low Voltage safety approval

The Xerox DocuTech M od els 61 00 , 6 115, 6135, 61 55, an d 6 180
are in compliance with various governmental agencies and
national safety regulations. All system ports meet the
requirements for Extr a Low Voltage (ELV) circuits for co nn ecti on
to customer-owned devices and networks.

Additions of customer-owned or third-party accessories attached
to the system must meet or exceed the requirements listed
above.

Since this system consists of several modules requiring external
connection, it must be installed per the Xerox Installation
procedure.

DocuTech 61xx Operator Guide 2-1

Certifications

Industry Canada requirements

Notice: The Canadian Industry Canada label identifies certified
equipment. This certification means that the equipment meets
certain telecommunications network protective, operational, and
safety requirements. The Department does not guarantee the
equipment wi ll operate to the user’s satisfaction.

• Before installing this equipment, users should ensure that it is

permissible to be connected to the facilities of the local
telecommunications company. The equipment must also be
installed using an acceptable method of connection. In some
cases, the company's inside wiring associated with a single
line individual service may be extended by means of a
certified conne ctor assembly (tele phone extension cor d). The
customer should be aware that compliance with the above
conditions may not prevent degradation of service in some
situations.

• Repairs to certified equipment should be made by an

authorized Canadian maintenance facility designated by the
supplier. Any repairs or alterations made by the user to this
equipment, or equipment malfunctions, may give the
telecommunications company cause to request the user to
disconnect the equipment.

• Users should ensure for their own protection that the

electrical ground connections of the power utility, telephone
lines and internal metallic water pipe system, if present, are
connected together. This precaution may be particularly
important in rural areas.

WARNING

Users should not attempt to make such connections
themselves, but should contact the electric inspection
authority or electrician, as appropriate.

• The Load Number (LN) assigned to each terminal device

denotes the percenta ge of the tot al load to be con nected to a
telephone loop which is used by the device, to prevent
overloading. The t ermination on a loop may consist of any
combination of devices subject only to the requirement that
the total of the Load Numbers of all the devices does not
exceed 100.

2-2 DocuTech 61xx Operator Guide

European Union

Certifications

WARNING

This is a Class A product. In a domestic environment, this
product may cause radio interference, in which case the
user may be required to take adequate measures.

Changes of modifi cations to this equipment not specifically
approved by Xerox Europe may void the user’s authority to
operate this equipment.

Shielded cables must be used with this equipment to maintain
compliance with the EMC Directive (89/336/EEC).

WARNING

In order to allow this equipment to operate in proximity to
Industrial, Scientific, and Medical (ISM) equipment, the
external radiation from ISM equipment may have to be
limited or special mitigation measures taken.

DocuTech 61xx Operator Guide 2-3

Certifications

2-4 DocuTech 61xx Operator Guide

About this guide

3. Introduction

The DocuTech 61xx Operator Guide is one of a number of
publications which make up the Xerox Document Services
Platform Series.

The guide is intended for Xerox DocuTech 6100, 6115, 6135,
6155, or 6180 operators whose job consists of the routine
operation of this printing system: operating each of the system
components, running print jobs, so lving simple system problems,
and performing basic maintenance tasks, such as replenishing
printer supplies.

If you are a lead operator, or your job involves some
programming or systems administration tasks, as well as
operating the DocuTech 61xx system, use the on-line help
system and the other documents in the Xerox Document
Services Platform Series to supplem ent the information in the
DocuTech 61xx Operator Guide.

Users should have an understanding of the operations of the
DocuSP controller and be familiar with Solaris and basic UNIX
commands.

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

Powering down the System

If it is necessary to power down the system, refer to the on-line
help, the Common Controller System Guide, or contact the
System Administrator. Never switch off the printer power switch
or the circuit breakers unless y ou are instructed to do so in the
System Guide.

DocuTech 61xx Operator Guide 3-1

Introduction

Contents

This section lists the contents of this guide.

• Chapter 1, "System components," describes each hardware

component in detail.

• Chapter 2, "Routine maintenance," describes routine

cleaning, maintenance, and adjustments of the DocuTech
61xx printer.

• Chapter 3, "Problem solving," describes how to solve some

specific problems that may occur and provides instructions
on placing servic e calls.

• Chapter 4, "Technical information," contains the hardware

and software capacity gui delines for the DocuTech 61xx
system. It includes the satisfaction guides for paper trays
and stocks.

• Chapter 5, "Supplies," contains general information about

supplies and how to order supplies for the DocuTech 61xx
system.

Conventions

This guide uses the following conventions:

• All caps and angle brackets–W ithin procedure s, the names of

keys are shown in all caps within angle brackets (for
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 <Patte r n>).

• 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 Platform Series
System Guide).

• Square brackets–Names of options you select are shown in

square brackets (for example, Select [Exit]).

• Quotes–Keywo r ds you can enter as arguments appear in

quotes (for example, "USLetter").

3-2 DocuTech 61xx Operator Guide

Introduction

• Vertical bars–Alternatives to specified arguments are

separated by vertical bars (for example, -pdl <ps | hppcl |
ascii | tiff>).

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

CAUTION

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

WARNING

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

DocuTech 61xx Operator Guide 3-3

Introduction

3-4 DocuTech 61xx Operator Guide

4. System components

The basic hardware components of the DocuTech 6100, 6115,
6135, 6155, and 6 180 are the Do cuSP control ler and the pr inter .
After a brief review of the process involved in electronic
reprographics, this section introduces each of the system
components.

Electronic reprographics process

The Xerox DocuTech 6100, 6115, 6135, 6155, and 6180 are
electronic reprographics systems. They ar e high volume printers
that create images electronically. These versatile, high
performance printing systems enable personal computers and
other network-connected devices (such as workstations and
graphic scanners) to produce docum ents incorporat ing graph ics,
forms, logos, signatures, and fonts.

The Xerox DocuTech 61xx systems consist of a DocuSP
controller and a 6100, 6115, 6135, 6155, or 6180 printer. They
accept electronic print input created by client software in ASCII,
TIFF, HP PCL, PostScript, or PDF format. This print input is
passed on to the system through a network connection. The
DocuSP software performs the necessary da ta conversion,
creating an electronic file which is stored temporarily in a print
queue on the DocuSP contro l ler. This electronic image is then
passed directly on to the printer for production.

The DocuTech 6100 prints up to 96 prints per minute using 8.5 x
11 inch (216 x 279 mm) stock. With 17 x 11 inch (432 x 279 mm)
stock, the print rate is 57 prints per minute.

The DocuTech 611 5 prints up to 1 1 5 prints per minute usin g 8.5 x
1 1 inch (216 x 279 mm) stock. With 17 x 11 inch (432 x 279 mm)
stock, the print rate is 57 prints per minute.

The DocuTech 6135 prints up to 135 prints per minute using 8.5
x 11 inch (216 x 279 mm) stock. With 17 x 11 inch (432 x 279
mm) stock, the print rate is 57 prints per minute.

DocuTech 61xx Operator Guide 4-1

System components

The System

System Hardware

The DocuTech 6155 prints up to 155 prints per minute using 8.5
x 11 inch (216 x 279 mm) stock. With 17 x 11 inch (432 x 279
mm) stock, the print rate is 77 prints per minute.

The DocuTech 6180 prints up to 180 prints per minute using 8.5
x 11 inch (216 x 279 mm) stock. With 17 x 11 inch (432 x 279
mm) stock, the print rate is 77 prints per minute.

Prints per minute vary, depending on paper size, for all printers.
Refer to the "Technical information" chapter of this guide for

more detailed information.

The basic hardware components o f t he DocuTech 61xx systems
are the DocuSP controller and the printer. The DocuSP
controller is a Sun platform. The printer consists of a processor
and a finisher , with an optional interposer available for the 6100,
6115, and 6135.

NOTE: Refer to "The interposer" section of this chapter and
figure 4-2 for more detailed information on the interposer.

4-2 DocuTech 61xx Operator Guide

Figure 4-1. DocuTech 6100/6115/6135 system hardware

System components

1. Sun platform with DocuSP software

2. DocuTech 6100/6115/6135 printer

3. Processor

4. Finisher

For the DocuTech 6155 and 6180, the printer consists of a
processor, an interposer, and a finisher.

DocuTech 61xx Operator Guide 4-3

System components

Figure 4-2. DocuTech 6155/6180 system hardw are

1. Sun platform with DocuSP software

2. DocuTech 6155/6180 printer

3. Processor

4. Interposer

5. Finisher

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 four components of the DocuSP controller are the
processor, the monitor, the keyboard, and the mouse.

NOTE: For more information on the DocuSP controller, refer to
the DocuSP on-line help system.

4-4 DocuTech 61xx Operator Guide

The Printer

The Xerox DocuTech 6100, 6115, or 6135 printer consists of the
processor, the interposer (optional), and the finisher. The Xerox
DocuTech 6155 or 6180 consists of the processor, the
interposer, and the finisher. These modules work together to
produce collated or uncollate d, unfinished, stitched or bound
prints as required.

The processor

The processor is the part of the system that produces the prints
of your documents.

Figure 4-3. Processor components

System components

2

34

5

87

1

69

1. Paper trays

2. Electrical module

3. Dry ink cartridge

4. Photoreceptor, located behind a panel

5. Laser, located behind a panel

6. Fuser agent reservoir

7. Inverter

DocuTech 61xx Operator Guide 4-5

System components

The paper trays

The electrical module

8. Decurler lever

9. Dry Ink Waste container

There are three paper trays wh ich can hold dif ferent sizes, types,
and colors of stock for printi ng jobs. Pa per tray cap acities ar e as
follows:

Tray 1: 1,100 sheets of substance 20 (75 g/m2)
Tray 2: 600 sheets of substance 20 (75 g/m2)
Tray 3: 2,600 sheets of substance 20 (75 g/m2)

The system circuit breakers are located behind the door of the
electrical module . To remove all power from the printe r, all three
circuit breakers must be in the down position. For the printer to
operate properly, all three circuit breakers must be in the up
position.

The dry ink cartridge

Dry ink is the material that forms the black image on prints. Dry
ink is contained in the dry ink cartridge. When directed by a
message on the controller, you must replace the dry ink
cartridge.

For dry ink cartridge replacement, refer to the "Routine
maintenance" chapter.

The photoreceptor

In the xerographic process, the image to be printed is first
developed on the photoreceptor. When print stock is brought
into contact with the photoreceptor, the image is transferred to
the print stock.

4-6 DocuTech 61xx Operator Guide

The laser

A laser is used to create an i nvisible image on the photor eceptor .
The electroni c master of a job communicates instructions to the
laser, causing the laser to switch on and off to create the image.

The fuser agent reservoir

Fuser agent is used t o p re ven t pa pe r that is passing through the
fuser from sticking to the fuser roll. Fuser agent is contained in
the fuser agent reservoir. When directed by a message on the
controller, you must add fuser agent to the reservoir.

For fuser agent repl acem ent, r efer t o the "Ro utin e mainte nance "
chapter.

The inverter (duplex tray)

System components

When 2-sided prints are made, the side one image is put on the
paper first. The paper with the side one image is then moved to
the duplex inverter, where the paper is turned over. The paper
then moves through the paper path again to have the side two
image applied.

The decurler lever

Too much curl in paper can cause paper handling problems.
Adjusting the decurler lever should correct most of the curl
problems.

For the decurler lever adjustments, refer to the "Routine
maintenance" chapter.

The ground fault protector

Some processors are equipped with a ground fault protector.
This device is located on the back panel of the processor. The
device has circuit breakers associated with it. When the device
senses an electrical fault in the processor, it will shut off the
processor power. If your processor has more than one power
cord, there will be a ground fault pr otector for each power cord.

DocuTech 61xx Operator Guide 4-7

System components

In the event of an unexpected loss of processor power, you
should check the status of the ground fault protector. No red
light is visible when the device is in its normal state and the
power is on. When the device has trip ped, a red i ndicator light is
on, and the white-handled circuit breakers are in the off position.

The interposer

The interposer is designed to improve productivity through the
use of two additional paper trays.

Figure 4-4. Interposer components

The following lists the components of the interposer:

1. Upper entrance transport

2. Upper vertical transport

3. Upper turn transport

4-8 DocuTech 61xx Operator Guide

System components

4. Tray 4

5. Upper exit transport

6. Tray 5

7. Lower entrance transport

8. Lower turn transport

9. Lower exit transport

10.Lower vertical transport

11.Loop transports

Upper entrance transport

The upper entrance transport receives the print from the
processor.

Upper vertical transport

The upper vertical transport takes the sheet from tray 4.

Upper turn transport

The upper turn transport inserts the sheet from tray 4 into the
upper transport.

Tray 4

Tray 4 ho ld s up to 550 sheets of substance 20 (75 g/ m2 ) paper.
The paper from this tra y can be fed onl y in to the upper transport
paper path to the finisher, bypassing the fuser.

Upper exit transport

The upper exit transport delivers the prints from the processor , or
the sheets from trays 4 or 5, to the finisher.

Tray 5

Tray 5 holds up to 260 0 sheets of substan ce 20 (75 g/m2 ) paper .
The paper from this tray can be fed into the pr ocessor for printing
or can be bypassed through the loop transports to insert sheets
directly to the finisher.

DocuTech 61xx Operator Guide 4-9

System components

Lower entrance transport

The lower entrance transport receives sheets from tray 3 to the
processor.

Lower turn transport

The lower turn transport inserts sheets from tray 5 into the lower
exit transport.

Lower exit transport

The lower exit transport delivers sheets from tray 5 in the
Interposer or from tray 3 in the finisher, to the processor.

Lower vertical tran sport

The lower vertical transport t akes the sheet from tray 5. If the job
is programmed to bypass the processor, it will divert the sheets
to the loop transports. If the job is programmed to feed the paper
from tray 5 to the processor, it will deliver the sheets to the lower
turn transport.

The finisher

Loop transports

The loop transports deliver sheets from tray 5 and inserts them
in the upper transport paper path.

In the finisher, prints can be collated, and stitched or bound, as
required for a job.

4-10 DocuTech 61xx Operator Guide

Figure 4-5. Finisher components

System components

The following lists the finisher components:

1. Bindexer

2. Stitcher

3. Stacker

4. Binder

5. Binder tape reel

6. Stitcher wire spool s

7. Top tray

The bindexer

The bindexer is a th ree-bin so rter th at collates t he pag es 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.

DocuTech 61xx Operator Guide 4-11

System components

The stitcher

When the job requires stitched output, the stitcher cuts and
inserts the wire stitches into each pr int set. The stitch length is
related to such factors as the number of pages in th e print set
and the print stock weight. A single stitch can be placed in the
portrait or landscap e print posi tion. Du al stitching is availa ble for
landscape and portrait prints. Stitch placement can be changed
through the DocuSP software.

NOTE: For more information about setting stitch placement,
refer to the on-line help system.

The stacker

The stacker collects unfinished or finished stitched or bound
jobs. When the stacker is full , or the job is completed, the
stacker door opens and the stacker drawer that holds the prints
comes out. After the stacker drawer is unloaded, the system
retracts the drawer an d closes the do or . The stacker also can b e
unloaded during the printing cycle to check the quality of the print
sets by changing the printer options.

NOTE: For more information, refer to the on-line help system.

The binder

When a job requires bound output, a length of pre-glued paper
tape is placed on a he ated su rf ace call ed the b inde r plate n. The
system aligns the pages of each print set before placing the set
on the tape. Binder flappers then press the tape to the sides of
the set. The combination of the heat in the binder and the
pressure of the flappers glues the tape to the set.

NOTE: For information about adjusting the binder tape
registration and the binder tape length, refer to the "Routine
maintenance" chapter in this guide.

The top tray

Prints are delivered to the top tray because the prints are
oversized o r because the t op tray was selected on the screen.

NOTE: Refer to the satisfaction guides in the "Technical
information" chapter of this guide to find the top tray paper
capacity for various stock weights.

4-12 DocuTech 61xx Operator Guide

The paper paths

The path that the print stock takes as it moves through the
Processor and Finisher depends on the requirements of the job
and if there is an Interposer.

Figure 4-6. Paper path areas

System components

The numbers in fi gure 4-6 identify the following paper path
areas:

• Areas 1 to 4 - The stock leaves a paper tray and is fed to the

photoreceptor.

• Areas 5 to 10 - The syst em prints an image o n one side of the

stock. If the job requires 2-sided printing, the system turns
the page over and feeds it back to the photoreceptor.

• Areas A to H - This is the interposer area. Paper travels

through this area if paper is fed from trays 1, 4 or 5 and also
to pass paper from area 10 (through F and H) to the finisher.

• Areas 11 and 12 - If the prints are t o be fed to the to p tray, the

system delivers the prints through the top tray slot.

• Areas 13 to 16 - The prints enter the bindexer and are

collated, if desired.

• Areas 17 to 19 - The prints are stitched in area 17, or bound

in area 18, if desired, and placed on the stacker in area 19.

If a paper jam occurs, the system displays a message on the
controller that shows the number of the area where the jam
occurred.

NOTE: For information about clearing a paper jam, refer to the
"Problem solving" chapter of this guide.

DocuTech 61xx Operator Guide 4-13

System components

4-14 DocuTech 61xx Operator Guide

Adding paper

Adding paper to tray 1 or 2

5. Routine maintenanc e

This chapter describes the routine activities you perform to
maintain the relia bility and productivity of your printer.

You can add the same kind of p ap er to a tr ay wh en the sup pl y i s
low without stopping the printer. You must have the same paper
or stock loaded in two trays for the system to continue printing
while you are loading the other t ray.

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

2.

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

2. When the green "Read y to open" ligh t comes on, pull the tray
out until it sto ps.

Steps 3 through 5 of loading pape r into tray 1 or 2, are
illustrated in figure 5-1.

3. Press the green release ta b.

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.

DocuTech 61xx Operator Guide 5-1

Routine maintenance

Figure 5-1. Preparing the paper tray

NOTE: To load the paper correctly, refer to the label located
on the inside panel at the front of the pap er tray. Remove any
damaged shee ts from the top of the stack.

CAUTION

Do not load the pap er above the r ed line. A ja m could occur i f too
much paper is loaded in the tray.

6. Load the required paper into the paper tray. Load paper with
the curl side facin g down. Load Xe rox paper w ith the package
wrapper seam side facing up.

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

7. Position the stack ag ai nst th e front right corner of the tray, as
shown in figure 5-2. This is indicated by the green arrow on
the bottom of the tray.

5-2 DocuTech 61xx Operator Guide

Figure 5-2. Positioning the stack

Routine maintenance

For stock outside the recommended limits, refer to the
"Technical information" chapter in this guide.

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.

Adding paper to trays 3, 4, or 5

Paper tray 3 or 5 is used to supply the largest volume of paper
required for your jobs. These trays can also be used to supply
oversized paper for sp eci a l j obs. P ap er in tray 4 is only used for
post-process insertion.

These trays lower one ream at a time as paper is added. More
than one ream ca n be lo aded by p ressing the Tray unlock button
again after the tray is fully opened.

The following steps must be performed to add paper to tray 3, 4
or 5.

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

NOTE: If the tray is not pulled out all of the way, the tray
elevator will not go down as paper is added.

DocuTech 61xx Operator Guide 5-3

Routine maintenance

2. When the green "Read y to open" ligh t comes on, pull the tray
out until it sto ps.

3. Move the rear and side gu ides away fr om the pap er stack, as
shown in figure 5-3.

Figure 5-3. Moving the guides

NOTE: To load the paper correctly, refer to the label located
on the inside panel at the front of the paper tray. For
information on loading different types of stock, refer to the
"Technical information" chapter in this guide. Remove any
damaged shee ts from the top of the stack.

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

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

5. Position the stack against the front left corner of the tray, as
shown in figure 5-4. This is indicated by the green arrow on
the bottom of the tray.

5-4 DocuTech 61xx Operator Guide

Figure 5-4. Positioning the stack

Routine maintenance

6. Move the rear and side guides until they touch the paper
stack.

7. Close the tray slowly, but firmly, until it latches.

Cleaning and maintenance overview

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

When supplies g et 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.

Refer to the System Guide for information on clearing faults.
The system provides dry ink to the printer from a cartridge

located in the printer. When the screen displays a low dry ink
message, a full dry ink cartridge should be installed.

Waste dry ink empties into a container located at the bottom of
the printer. When this container becomes full, it must be
replaced.

Fuser agent must be added to the fuser agent reservoir in the
printer when a message on the screen directs you to do so.

DocuTech 61xx Operator Guide 5-5

Routine maintenance

The system uses stitcher wire from two spoo ls locate d be low the
stacker . Stitcher spoo l A is used for portrait, top corner stitches.
When stitcher spool A is empty, it must be replaced with a new
stitcher spool. Stitcher spool B is used for portrait dual stitches
and landscape stitches.

To replace stitcher spool B, if you have not been trained in
eXcellerate, contact the Customer Support Center; refer to the
section, “Calling for assistance”, in this gu ide.

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

During operation, the binder heats the tape to 425°F (218°C).
To avoid injury, use special care when you remove or
replace the binder tape.

For information on cleaning the processor sensors, the reflecting
surfaces, and the finisher sensors, refer to the appropriate
sections in this booklet.

Precautions you should take

For your own safety and to protect the system, it is important to
take the following precautions whenever you perform cleaning
and replacement tasks.

• Use only the cleaning and replacement supplies that are
approved or recommended by Xerox. If you use other
supplies, you may damage the system.

• Keep supplies in stock as listed in the section, “Supplies to
keep in stock”, in this guide.

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

• Keep atomized and aerosol sprays away from the system.

• Pour cleaning liquids onto a cloth. Do not pour or spray
liquids directly onto system parts.

• Before reinstalling a syst em part that has be en cleaned with a
liquid, ensure that the part is dry.

5-6 DocuTech 61xx Operator Guide

Routine maintenance

• Always use a dro p cloth when r eplaci ng the d ry ink cartri dge,
dry ink waste container, or when adding fuser agent.

• Some parts of the system, such as the fuser, get hot during
operation. To ensure that you do not burn your self, be careful
when working around these parts.

WARNING

The fuser can reach a tem p erature of approximately 425°F
(218°C). Exercise care to prevent burns when working near
this area.

• To prev ent injury to yourself, always use special care when
using the wire cutters.

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.

Cleaning the binder

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 4 25°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.

DocuTech 61xx Operator Guide 5-7

Routine maintenance

WARNING

A sharp edge on the plastic binder platen cleaner or on the
tape spool sometimes occurs as a result of removing the
cleaner. This sharp edge could cause finger cuts.

CAUTION

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

2. Grasp the green ha ndle on the bin der drawer. Pull the drawer
out until it sto ps.

Figure 5-5. Opening the binder drawer

3. Perform the following steps:
a. Locate and remove the plastic binder platen cleaner from

the binder tape reel, as shown in the following figure.

5-8 DocuTech 61xx Operator Guide

Figure 5-6. Binder platen cleaner

Routine maintenance

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.

d. Continue to move the cleaner in the same manner until

the 2-sided tabs break.

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

Cleaning the binder tape guides

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.

DocuTech 61xx Operator Guide 5-9

Routine maintenance

Figure 5-7. Cleaning the tape guides

Cleaning the binder platen

The following steps must be performed to clean the binder
platen.

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

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.

5-10 DocuTech 61xx Operator Guide

Figure 5-8. Cleaning the binder platen

Routine maintenance

Cleaning the flappers

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

DocuTech 61xx Operator Guide 5-11

Routine maintenance

Figure 5-9. Cleaning the flappers

Cleaning the calipers

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

5-12 DocuTech 61xx Operator Guide

Figure 5-10. Cleaning the calipers

Routine maintenance

Closing the binder

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 clean er in a safe place.

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 possi ble.

Replacing the dry ink cartridge

When directed by a screen message, replace the dry ink
cartridge. If the cartridge is not replaced, the printer will
eventually stop, and it will not operate until a new cartridge is
installed.

DocuTech 61xx Operator Guide 5-13

Routine maintenance

CAUTION

T o pr event dry ink spills, remove the cartridg e only when directe d
to do so by a message on the screen.

The following steps must be performed to replace the dry ink
cartridge.

CAUTION

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

CAUTION

If any dry ink should get on your clothes, brushing with a dry
paper towel or a stiff-bristled brush may remove the ink. If not,
launder your clothes with detergent and cold water. Tell a
commercial dry cleaner that the spot is dry ink or "toner" so that
they will not use a solvent that will set the dry ink stain.

1. Open the processor doors and locate the dry ink cartridge at
the left side of the processor.

2. Place a d r op cloth on the floor under the dry ink cartridge
area.

3. Remove the empty cartridge, as shown in figure 5-11.
a. Pull the empty dry ink cartridge out until it stops.
b. Move the green handle to the unlatched position.
c. Remove the empty cartridge and discard it.

5-14 DocuTech 61xx Operator Guide

Routine maintenance

Figure 5-11. Removing the empty cartridge

4. Install a new dry ink cartridge, as shown in figures 5-12 and
5-13.

a. Turn a new cartridge of dry ink upside down and shak e

the cartridge thoroughly to loosen the contents.
b. Insert the full cartridge until it stops.
c. Move the green handle to the latched position.

DocuTech 61xx Operator Guide 5-15

Routine maintenance

Figure 5-12. Inserting and latching the cartridge

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

paper seal by pulling it toward you with the other hand.

Discard the seal along with the drop cloth.

Figure 5-13. Removing the paper seal

5. Close the processor doors.

5-16 DocuTech 61xx Operator Guide

NOTE: If any dry ink should get on your skin, wash with mild
soap and cold water.

Replacing the dry ink waste container

When directed by a screen message, replace the dry ink waste
container. If the dry ink waste container is not replaced, the
printer will eventually stop, and it will not operate until the dry ink
waste container is replaced.

Do not tip the waste container.

Do not use warm or hot water, or general cleaning solvents to
remove dry ink from your skin or clothing. The heat or solvent
will set the dry ink and make it difficult to remove. If any dry ink
should get on your skin, wash with mild soap and cold water.

Routine maintenance

CAUTION

CAUTION

If any dry ink should get on your clothes, brushing with a dry
paper towel or a stiff-bristled brush may remove the ink. If not,
launder your clothes with detergent and cold water. Tell a
commercial dry cleaner that the spot is dry ink or "toner" so that
they will not use a solvent that will set the dry ink stain.

1. Open the processor doors and locate the dry ink waste
container.

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

3. Remove the full waste container from the system.
a. Grasp the tab on the dry ink waste container and pull the

container out slowly, as shown in figure 5- 14.

DocuTech 61xx Operator Guide 5-17

Routine maintenance

Figure 5-14. Removing the full waste container

b. Remove the cap from the top of the full dry ink waste

container.

c. Place the removed cap over the opening on the end of the

full dry ink waste container, as shown in figure 5-15.

d. Do not remove the cap on the new container.

5-18 DocuTech 61xx Operator Guide

Routine maintenance

Figure 5-15. Placing the cap on the waste container

e. Slide a new , e mpty dry ink waste contain er all the way into

the system until the container stops, as shown in figure 5-

16.

Figure 5-16. Inserting the new, empty container

4. Close the processor doors.

DocuTech 61xx Operator Guide 5-19

Routine maintenance

Adding fuser agent

When directed by a message, add fuser agent as soon as
possible. If fuser agent is not added, the printer will stop after
approximately 5,000 prints. It will not run until fuser agent is
added.

WARNING

The fuser area can reach temperatures of approximat el y
425°F (218°C). Exercise care to prevent burns when
working in this area.

CAUTION

Fuser lubricant for other printers may not be compatible. Order
and use fuser agent only for the printer.

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 draw er.
b. Grasp the green handle on the fuser drawer and pull it out

until it stops.

5-20 DocuTech 61xx Operator Guide

Figure 5-17. Opening the fuser drawer

Routine maintenance

WARNING

Fuser agent contains silicone, which can cause irritation
upon contact with the eye. Make sure that you wash your
hands with soap and water after you finish this procedure.

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

DocuTech 61xx Operator Guide 5-21

Routine maintenance

Figure 5-18. Preparing to add fuser agent

WARNING

Fuser agent spills cause the floor to be slippery. If any
fuser agent is spilled onto the floor, it must be removed
immediately.

c. Open a new box of fuser agent and remove the bottle.

Remove the cap from the bottl e of fuser agent.

d. Carefully pour the fuser agent into the reservoir until the

level reaches the MAX line.

5-22 DocuTech 61xx Operator Guide

Figure 5-19. Adding the fuser agent

Routine maintenance

e. Replace the reser voir cap by turning it cl ockwise.

CAUTION

Do not push the fuser agent bottle into the reservoir with
excessive force. There is an anti-splash seal in the reservoir
that could be damaged.

f. Push the fuser agent reservoir in until it stops.

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

DocuTech 61xx Operator Guide 5-23

Routine maintenance

Figure 5-20. Closing the fuser drawer

6. Close the processor doors.

The fuser agent message will disappear after the system makes
approximately 20 prints.

Replacing the stitcher spool A

Use this procedure to replace stitcher spool A in the system.
Check stitcher spools A and B visually d uring the warm-up cycle.
Stitcher spool A is the spool on top, and stitcher spool B is the

spool on the bottom.
If spool B needs new wire, call the customer support center.

Refer to the section, "Calling for assistance," in this guide.
There is a label behind the stitcher panel that gives instructions

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

spool A.

1. Open the finisher doors.

2. Lift the stitcher panel, which is located direct ly above the
stitcher spools.

3. Pull the green stitcher head release handle forward and up
until it latches into place, as shown in figure 5-21.

5-24 DocuTech 61xx Operator Guide

Routine maintenance

Figure 5-21. Releasing the stitcher head

4. Remove the stitcher wire plug .
a. The stitcher wire pl ug is located ab ove the binder are a, as

shown in figure 5-22.
b. Press and hold down the release clip.
c. Pull the plug out of the stitcher head.

Figure 5-22. Removing the stitcher wire plug

5. Perform one of the following steps:

DocuTech 61xx Operator Guide 5-25

Routine maintenance

• If there is n o wir e on the spoo l, use th e wir e cutte rs to p ull

the remaining w ire car eful ly ou t of th e tubi ng, as shown in

figure 5-23.

NOTE: The wire cutter tool needed to perform this

procedure is located next to stitcher spool B.

Figure 5-23. Removing the wire from the tubing

• If there is wire on the spool, hold it on the spool and

carefully rewind the remaining wire out of the tubing and

onto the stitcher spool, as shown in figure 5-24.

5-26 DocuTech 61xx Operator Guide

Routine maintenance

Figure 5-24. Rewinding the remaining wire

6. Insert the plug into th e measur ing bracket, as shown in figure
5-25.

Figure 5-25. The measuring bracket

7. Release and remove stitcher spool A.
a. Locate the green pin release handle under spool B, as

shown in figure 5-26.

DocuTech 61xx Operator Guide 5-27

Routine maintenance

Figure 5-26. Removing the stitcher spool pin

b. Pull and hold the handle forward and remove the pin.
c. Release the handle and remove stitcher spool A.

8. Install the new stitcher spool.
a. Slide the new stitcher spool into position with the paper

wrapper still in place.

b. Replace the stitcher spool pin. Push it down until it locks

into place, as shown in figure 5-27.

5-28 DocuTech 61xx Operator Guide

Figure 5-27. Replacing the pin

Routine maintenance

9. Remove any damaged wire.

WARNING

Hold the wire on the spool to prevent eye injury and to
keep the wire from unwinding.

a. Locate the end of the wire on the new spool.
b. Using the wire cutters, carefully cli p any bent or twisted

wire from the lead end of the wire.

c. Hold onto the end of the wire and carefully remove the

paper wrapper, as shown in figure 5-28.

DocuTech 61xx Operator Guide 5-29

Routine maintenance

Figure 5-28. Removing the paper wrapper

NOTE: Hold the wire between the thumb and forefinger
of both hands.

10.Feed the wire slowly into the tubing until the wire extends
from the stitcher plug, as show n in figure 5-29.

Figure 5-29. Feeding the wire

11.Remove the stitcher plug from the measuring bracket.

5-30 DocuTech 61xx Operator Guide

Routine maintenance

12.Slowly and carefully pull about 3 feet (1 meter) of wire from
the spool.

13.Cut the wire, leaving about 2 inches (51mm) of wire
extending from the end of the stitcher plug.

14.Insert the plug into the measuring bracket.

15.Continue to feed the wire until it touches the ba ck plate of th e
measuring bracket.

16.Push the green stitcher head release handl e down and back.

17.Pull the plug from the measuring br acket.

18.Insert the plug into the stitcher head until the plug snaps into
place.

19.Place the wire cutters in the storage bracket.

NOTE: Ensure that the wire cutters are not touching the
stitcher spools. This can prevent the stitcher wire from
feeding proper ly.

20.Lower the stitcher panel.

NOTE: Ensure that the stitcher panel has been lowered.
The stacker will not deliver prints if the stitcher panel is left in
the up position.

21.Close the finisher doors.

Storing the binder tape reels

Binder tape contains paper that makes the tape sensitive to the
same conditions that affect paper, especial ly moisture. Figure 5­30 shows good storage conditions for the binder tape.

DocuTech 61xx Operator Guide 5-31

Routine maintenance

Figure 5-30. Storing binder tape in a cool, dry place

Perform the following steps to store the binder tape wheels.

1. Always store binder tape in a dry place cooler than 90°F
(32°C).

2. Keep stored rolls in their original unopened containers.

3. Use rolls with older dates first. Save the or iginal foil
containers for reuse in storing partially used rolls.

4. Place partially used rolls of binder tape in their original
resealable foil containers. Ensure that the edge is sealed
tightly.

Figure 5-31. Storing the binder tape

5. Store the partially used rolls of binder tape in a dry place
cooler than 90°F (32°C).

5-32 DocuTech 61xx Operator Guide

Refer to the pro cedure, Repla cing the binder tape r eel, in t his
guide for information on how to remove and replace the
binder tape reel.

Replacing the binder tape reel

Use this procedure to replace the binder tape in the system.
To ensure proper binding and to red uce bi nder ta pe jams, do not

leave binder tape in the system when the binder is not in use.
If necessary, refer to the label on the binder for instructions on

how to replace the binder tape.
The following steps must be performed to replace the binder

tape wheel.

All areas of the binder drawer, including the binder tape, are
hot, approximately 425°F (218°C), and may cause serious
burns. If the binder has been in a "Ready" condition, allow
the binder drawer to cool at least one hour before
continuing the procedure.

Routine maintenance

WARNING

1. Open the finisher doors.

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

Figure 5-32. Opening the binder drawer

3. Remove the tape from the drive roll.

DocuTech 61xx Operator Guide 5-33

Routine maintenance

a. Lift the pressure roll release handle and remove the tape

from the drive roll.

Figure 5-33. Removing the tape

b. Rewind the tape onto the tape reel.

4. Slide the tape reel off the tape reel drive.
a. Move the reel retainer in the center of the reel to the

horizontal unlocked position.

Figure 5-34. Unlocking the reel

b. Remove the tape reel.

NOTE: Ensure that the larger center hole in the reel
faces the drive.

5. Slide the new tape reel onto the tape reel drive.

5-34 DocuTech 61xx Operator Guide

Routine maintenance

a. If necessary, rotate the tape reel slightly until it clicks into

position.

NOTE: The tape will not feed properly if the retainer is not
locked.

b. Move the reel retainer to the locked position.

Figure 5-35. Locking the reel

NOTE: Ensure that the tape passes through the binder
tape sensor.

6. Follow the instructions on th e binder tape load ing label and
thread the tape through the tape feeder.

DocuTech 61xx Operator Guide 5-35

Routine maintenance

Figure 5-36. Threading the tape through the tape feeder

Tape
Sensor

7. Thread the tape around the drive roll to the edge of the
pressure roll.

Figure 5-37. Threading the tape to the pressure roll

8. Turn the g re en knob cl ockwi se un ti l the tap e extends at least
2 inches (51mm) beyond the tape guides.

5-36 DocuTech 61xx Operator Guide

Figure 5-38. Feeding the tape manually

Routine maintenance

9. Cut the tape.
a. Lift up on the gree n tape cutter handle, as show n in figure

5-39.

b. Remove the cut pie ce of tape.

Figure 5-39. Cutting the tape

10.Close the binder drawer.

DocuTech 61xx Operator Guide 5-37

Routine maintenance

11. Close the finisher doors.

Adjusting the binder tape registration

The binder tape knob is used to align the registration of the
binder tape to the top edge of a bound book.

This procedure has no effect on the length of the tape, but you
should perform this procedure before adjusting the tape length.

To adjust the length, refer to the on-line help.
Perform the followi ng step s to ad ju st th e bi n der ta pe r eg istr ation.

1. Ensure that the tape guides are clean and free of glue
residue.

Refer to the procedure, "Cleaning the binder," in this section.

2. Determine the adjustment amount for the top edge of the
book.

3. Open the finisher doors.

4. Measure the dista nce be tween t he top o f the b inder tape and
the top of the book.

5. Locate the black binder tape knob on the front of the binder
drawer.

5-38 DocuTech 61xx Operator Guide

Routine maintenance

Figure 5-40. Locating the binder tape knob

The knob is spring loaded and moves in increments to
change the location of the binder tape. Each increment
equals a change of 0.1mm, up or down, on the edge of the
book. One full rotation of the knob is equal to 0.04 inch
(1mm).

6. Pull the knob toward you to rotate it for the adjustment.

7. Adjust the tape position by performing one of the following
steps:

• Pull the knob and rotate it clockwise to move the tape

toward the top edge of the book, as shown in figure 5-41.

DocuTech 61xx Operator Guide 5-39

Routine maintenance

Figure 5-41. Adjusting the tape position up

• Pull the knob and rotate it counterclockwise to move the

tape toward the bottom edge of the book.

Figure 5-42. Adjusting the tape position down

8. Close the finisher doors.

9. Run a test binder job to check your adjustment.

10.Perform the procedure again as needed.

5-40 DocuTech 61xx Operator Guide

Adjusting the heavy paper levers

This system can handle a variety of papers. Some heavier
weight paper or longer paper may cause skewing problems.
Adjust the heavy paper levers to prevent this skewing.

Adjust the heavy paper levers when you have skewed prints.
Perform the following steps to adjust the heavy paper levers.

1. Open the right door of the processor.

2. Open the left door of the processor.

3. Locate the black heavy paper levers behind area 4 and area

2.

4. Raise the heavy paper levers.
a. Pull the silver latch release toward you.
b. Raise the lef t and right bl ack levers to the ve rtical position,

as shown in figure 5-43.

Routine maintenance

Figure 5-43. Raising the levers

5. Run the print job.

6. When the print job has been completed, lower the heavy
paper lever.

a. Pull the silver latch release toward you.

DocuTech 61xx Operator Guide 5-41

Routine maintenance

b. Lower the left and right black levers to the horizontal

position, as shown in figure 5-44.

Figure 5-44. Lowering the levers

7. Close the processor door.

Adjusting for paper curl

Each sheet of paper has a natural curve called the curl. Storing
or using the paper under humid conditions may i ncrease the curl.
When too much curl cau ses pape r handli ng prob lems, ad just the
decurler in the processor. The decurler flattens the paper after
fusing.

Measuring the paper curl

1. Program and print fi ve 1-si de d, 8 .5 x 11 inch (216 x 279 mm)
sheets to the top tray.

NOTE: Keep the image toward you, as shown in figure 5-45.

2. Measure the amount of curl in the prints by holding the five
prints in the top center of the short edge.

5-42 DocuTech 61xx Operator Guide

Figure 5-45. Measuring the paper curl

Routine maintenance

3. Place the bottom edge of t he prints over the paper curl
measurement chart in this guide.

• If the pri nt curl on the printed paper m easures be tween +1

and - 2, do not change the decurler setting.

• If the cur l is bet ween +2 and +3 , or - 3 a nd - 4, ref er t o the

procedure, "Adjusting the decurler lever," in this secton.

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

DocuTech 61xx Operator Guide 5-43

Routine maintenance

5-44 DocuTech 61xx Operator Guide

RECOMMENDED

CAUTION

Routine maintenance

NOTE: Corners of the
sheets of paper should not
exceed the curl shown in
this chart. See the example
above.

Note:

-4

-3

-2 -1

Image

+4

+3

+2

FLAT +1

Move Green Decurler
lever left

Move Green
Decurler lever
right

DocuTech 61xx Operator Guide 5-45

Routine maintenance

Adjusting the decurler lever

Perform the following steps to adjust the decurler lever.

CAUTION

Do not use any paper that is not suitable for system use.

1. Open the right door of the processor.

2. Locate the decurler lever in area 7 of the paper path, as
shown in figure 5-46.

Figure 5-46. Locating the decurler lever

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

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

5. 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.

5-46 DocuTech 61xx Operator Guide

6. Problem solving

The system is designed to help you find and solve problems as
they happen. The system detects hardware and software
problems, disp lays error or fault m essages and screens, and
sounds an alert tone (if it is enabled) when a problem needs to
be correcte d.

This section of the operator guide describes how the system
informs you of problems. When you know there is a system
problem, you can take measures suggested by the system to
correct the problem. You can also use the problem and solution
tables in this section to resolve recurring problems. Included are
detailed procedures that are re quired to resolve some of the
problems.

If you are not able to correct a problem, or you have a question
about system operation, you should call the Customer Support
Center. If the Customer Support Representative cannot solve
your problem over the phone, a Service Representative will be
dispatched.

How problems are displayed

Hardware problems show themselves by way of messages,
document misfeeds, paper jams, poor prints, fa ult codes, and
system components that do not operate correctly.

Software prob lems usually show up as messages in the status
area of the screen or as fault codes on the fau lt frames. Some
software problems affect hardware behavior. For example, the
printer may operate without producing any prints. This is a
condition called "dead cycling."

DocuTech 61xx Operator Guide 6-1

Problem solving

Printer faults and fault windows

When the printer needs attention, it is called a fault. There are
three types of faults: those that require immediate attention,
those that provide information, and those that require service.

Examples of faul ts that would require immediate attention are
misfeeds in the paper path or paper jams.

Examples of fa ults that are informational are lo w stitcher wire
and low dry ink. If this type of fault is not resolved, a fault
requiring immediate attention will result eventually.

When a fault occurs

When a fault occurs in the printer an indicator will app ea r on the
DocuSP Print Services window and a Printer Faults message will
appear.

NOTE: The printers also have an attention light on top of the
finisher module. A flashing light indicates a fault requiring
immediate attention; a steady light indicates a fault that can be
cleared at a later time.

Refer to the on-line help or System Guide for additional
information on printer faults.

Resolving a recurring problem

If you have a recurring hardware or software problem, perform
the following activities:

• Find the problem in the Problem column of the problem
solving charts in this guide.

The hardware charts are separated into resolving a
processor or finisher problem.

• Follow the instructions in the Suggested solutions column of
the problem solving charts in this guide.

6-2 DocuTech 61xx Operator Guide

Remember that the fuser and binder area surfaces are hot.
Proceed with caution when clearing all jams.

Resolving a processor problem

Table 6-1. Resolving a processor problem

Problem Suggested solutions

Problem solving

WARNING

Paper tray elevator
fails to rise or lower

Paper path jams Check the area where the jams are occurring to ensure that the paper path

Ensure that the stock is loaded properly in the paper trays, with the rear
and side guides against the stock stack.

If the elevator fails to rise or lower in paper tray 1 or 2, latch the paper
feeder by pressing down on the green dot inside the tray.

Do not slam the trays closed. Push the trays in slowly but firmly.
Ensure that all misfed stock has been removed from the immediate area of

the paper trays.

is clear of paper and other obstructions.
If a jammed sheet of paper tears when being removed, ensure that you

have removed all of the sheet pieces.
Ensure that the paper path baffles are in the correct seated position.
Ensure that the stock is loaded properly in the trays, with the rear and side

guides against the stack.
Ensure that the stock is not loaded above the bottom of the red line in the

paper tray.
Ensure that the stock has no bent corners, or tears, and that the edges are

straight. Remove any damaged sheets.
Repeated jamming may be due to a paper curl problem that can be

resolved by adjusting the decurler lever. Refer to the procedure, "Adjusting
for paper curl," in this guide.

Paper weight less than substance 20 (75 g/m2) will require careful setting
of the decurler. Refer to the procedure, "Adjusting for paper curl," in this
guide.

Fan the stock thoroughly.
Ensure that the stock is within the limitations described in the satisfaction

guides in the "Technical information" chapter.
Paper weight less than substance 20 (75 g/m2) will require careful storage

and handling. Refer to the "Technical information" chapter.

DocuTech 61xx Operator Guide 6-3

Problem solving

Table 6-1. Resolving a processor problem

Paper misfeeds and
multifeeds

Missing sheets in a set
immediately after a
jam.

Ensure that the stock is loaded properly in the paper trays, with the rear
and side guides against the stack.

Ensure that the stock is not loaded above the bottom of the red line in the
paper tray.

Ensure that the stock has no bent corners, or tears, and that the edges are
straight. Remove any damaged sheets.

Check the sheets in the bottom of the paper tray for damage. If they are
damaged, discard the sheets.

Ensure that the stock to be fed out of the paper tray is not excessively
curled. Refer to the procedure, "Adjusting for paper curl," in this guide.

If the misfeeds are occurring in the paper tray, ensure that the paper feeder
is latched by pressing down on the green dot inside the tray.

Fan the stock at all four corners. Change it if it has uneven edges or if it
was not drilled properly.

The stock should be kept in the original wrapper and stored correctly.
Refer to the "Technical information" chapter.

Ensure that the stock is within the limits described in the "T echnical
information" chapter.

After recovering from a jam, an incomplete set may be purged and the set
reprinted. Check the prints to ensure that you are not confusing the
purged output with the completed set.

Printer is dead cycling;
it is running, but not
making any prints

If the printer is running, but not making any prints, and no message is
displayed on the screen, open a processor door to stop the printer. If this
problem repeats, refer to the procedure, "Calling for assistance," in this
guide.

6-4 DocuTech 61xx Operator Guide

Table 6-1. Resolving a processor problem

Fuser jams WARNING

The fuser surfaces are hot. To avoid injury, proceed with caution
when removing all jams. Use a piece of paper to remove jammed
sheets from the fuser.

The jammed sheets in the fuser require careful handling because they may
not be fused properly.

Images that extend all the way to the edge of the prints may cause
increased frequency of jams. Do not place dense images to be printed at
the right or left lead and trail edges of the paper. This may cause fuser
jams.

If the above adjustment does not resolve the problem, contact the Site
Administrator to access the Lead Edge Screening feature on the Printer
Switches window.

There are three settings available in the Lead Edge Screening feature:

• Use the Off setting when it is necessary to print all of the document.

• Use the Standard setting when the documents have narrow black lines
or no dark areas on the lead edge. This is the system default setting
and is the recommended setting.

Problem solving

• Use the Stress setting when the system is experiencing fuser jams and
the Standard option is selected.

• Use the Erase All Edges setting when the system is experiencing jams
and the image prints to the edges of the paper.

Holes are on the
wrong side of the
prints

Paper curl Adjust the decurler. Refer to the procedure, "Adjusting for paper curl," in

Fault Code P10-216 This is a printer problem. Switch the printer off and on. Allow a minimum

Ensure that the stock is loaded correctly. Refer to the label on the tray.

this guide.

of 30 seconds between switching the printer off and switching the printer
back on.

DocuTech 61xx Operator Guide 6-5

Problem solving

Table 6-1. Resolving a processor problem

Processor p ower is off
unexpectedly

The processor or the DocuSP controller may have an electrical problem. If
the DocuSP controller has an electrical problem, it may shut off the power
to the processor.

1. Determine if the DocuSP controller power and the processor power are
off.

If the controller’s screen is blank and the power-indicator light is not
blinking, the controller power is off. Refer to the System Guide.

If the paper tray lights are out, the power to the processor is off.
Proceed with step 2.

2. Determine if the processor has a ground fault protector. If there is not a
ground fault protector installed, refer to the procedure "Calling for
assistance," in this guide.

3. If the processor has a ground fault protector, determine whether the
protector has shut off the power.

If the red light is visible on the protector, proceed with step 4.
If the red light is not visible, something other than the protector has

shut off the power. Refer to the problem "Processor power is off
unexpectedly, and the ground fault protector did not trip," in this
section.

4. Press the reset button on the processor ground fault protector.

Processor p ower is off
unexpectedly, and the
ground fault protector
did not trip

If the red light switches off, proceed with step 5.
If the red light does not switch off, or immediately switches on again,

refer to the procedure, "Calling for assistance", in this guide.

5. Switch the white-handled circuit breakers near the protector to the on
(up) position.

If the power comes on, proceed with step 6.
If the circuit breakers immediately switch off again, refer to the

procedure, "Calling for assistance,"in this guide.

6. Select the Reset icon on the fault frame. This should clear the fault.

7. Clear any other faults that may be declared. Do not clear the paper
path unless directed to do so. The system will maintain job integrity.

8. If the power repeatedly swi tc hes off unexpecte dly, refer to the
procedure, "Calling for assistance," in this guide.

Select the Reset icon on the fault frame.
Call for maintenance or electrical assistance within your facility in order to

determine whether power is available at the electrical panel box within your
facility.

Do not clear the paper path unless directed to do so. The system will
maintain job integrity.

6-6 DocuTech 61xx Operator Guide

Resolving an interposer problem

Table 6-2. Resolving an interposer problem

Problem Suggested solutions

Problem solving

Repeated jams in
interposer

Follow the jam clearance diagram in the Printer Fault Clearance window
carefully to ensure all paper has been cleared.

Make sure the stock in trays 4 and 5 have been loaded correctly . Refer to
the Satisfaction guides in chapter 4, “Technical Information”, for information
on loading stock in trays 4 and 5.

Make sure the stock in trays 4 and 5 meet the specifications for these trays
as indicated in the Satisfaction guides in chapter 4, “Technical Information”.

Resolving a finisher problem

Table 6-3. Resolving a finisher problem

Problem Suggested solutions
Repeated jams in area

14 (bindexer)

The bindexer contains three bins used by the system to sort sets. The
capacity of each bin is 125 sheets of substance 20 (75 g/m2) or 0.5 inch
(13 mm) thickness.

Include inserts and covers when considering the output capacity of the
bindexer.

125 sheets of substance 20 (75 g/m2) is equal to approximately:
104 sheets of substance 24 (90 g/m2)

Jammed binder tape,
such as binder tape
sticking together, or
cosmetic defects in
the bound book

Binder tape not
positioned correctly on
the top edge of the
output prints

78 sheets of substance 32 (120 g/m2)
47 sheets of substance 110 (200 g/m2).
Check that the sets in the bindexer are less than 0.5 inch (13 mm) thick.
If the set exceeds 0.5 inch (13 mm) thickness, reprogram the job for fewer

sheets or reduce the number of heavy-weight sheets.
When running collated, unfinished sets, the maximum sheet capacity of the

bindexer can be set between 50 and 125.
When running anything other than collated, unfinished sets, the maximum

sheet capacity of the bindexer will remain at 125.
Replace the tape reel with a new reel using the procedure, "Replacing the

binder tape reel," in this guide.
Refer to the binder tape reel storage information in this guide.

Adjust the binder tape registration using the procedure, "Adjusting the
binder tape registration," in this guide.

DocuTech 61xx Operator Guide 6-7

Problem solving

Table 6-3. Resolving a finisher problem

Binder tape is too long
or too short on the
bottom edge of the
output prints

Loose binder tape
along the spine of the
completed bound
book

Repeated tape
feeding problems,
such as binder tape
not unwinding from
the reel

Stitcher fault codes
displayed in the fault
frame

Fault Code P12-218
Fault Code P12-219

Adjust the binder tape length using the procedure entitled "Adjusting the
binder tape registration" in the "Routine maintenance" chapter.

If an adjustment is made to the binder tape length during a job, it will not
take effect until the next job is printed. If it is necessary to adjust the binder
tape length during a job, adjust it using the procedures in the on-line help.

This is a symptom of excessive moisture in the tape. Replace the tape reel
with a new reel using the procedure, "Replacing the binder tape reel," in
the "Routine maintenance" chapter.

Refer to the binder tape storage guidelines in this guide.
If the binder tape is sticking together, or if there are cosmetic defects in the

bound book, replace the tape reel with a new reel using the procedure,
"Replacing the binder tape reel," in the "Routine maintenance" chapter.

Refer to the binder tape storage information in this guide.
Refer to the binder cleaning information in this guide.
Refer to information on calling the Customer Support Center in this guide.
Select the [Finishing] button on the Printer Manager window. Deselect

[Stitcher] on the Finishing window and refer to the procedure, "Calling for
assistance," in this guide.

Stitcher A problems. Perform the procedure, "Clearing a stitcher spool A
fault," in this guide.

Stitcher B problems. Refer to information on calling the Customer Support
Center in this guide.

Poor stitch quality or
short stitches

Reliable stitching can be expected with up to 65 sheets of substance 20
(75 g/m2) or 0.28 inch (7 mm) thick sets. Less reliable stitching can be
expected with over 70 sheets of substance 20 (75 g/m2).

Running intermixed stock heavier than substance 20 (75 g/m2) will reduce
the capacity of the stitcher.

To avoid short clinches, use the stitch override only when using a
lightweight paper. Stitch override allows the system to run beyond the
stitching limit. The system will shut down at 125 sheets.

Reduce the stock weight to enable the stitching of more sheets per set.
Refer to the satisfaction guides in the "Technical information" chapter.

6-8 DocuTech 61xx Operator Guide

Table 6-3. Resolving a finisher problem

Problem solving

Sheets are spil ling out
of the top tray

The capacity of the top tray is 500 sheets of substance 20 (75 g/m2) or 2
inches (51 mm) in height. When intermixed stock or paper heavier than
substance 20 (75 g/m2) is being run, the capacity of the top tray is
reduced.

500 sheets of substance 20 (75 g/m2) is equal to approximately:
415 sheets of substance 24 (90 g/m2)
310 sheets of substance 32 (120 g/m2)
225 sheets of substance 110 (200 g/m2)
If using any paper heavier than substance 20 (75 g/m2) or intermixed stock

of different weights, unload the top tray before the count in the tray reaches
its capacity lim it.

Refer to the satisfaction guides in the "Technical information" chapter.

Clearing a binder tape fault

Perform the following to clear a binder tape fault.

1. Open the finisher doors.

2. Open the top cover.

WARNING

The binder tape adhesive is hot, approximately 425°F
(218°C). Allow the binder to cool for 5 minutes with the
finisher doors and top cover open before touching the
binder tape.

3. Follow the instructions on the screen to det ermine the area
(17 or 18) that should be cleared.

4. If area 17 is displayed and the binder tape is present, stop
and follow the WARNING. Remove the binder tape and
paper. Proceed to step 6.

5. If area 17 is displayed and the binder tape is not present,
follow the instructions on the area 17 label and remove all
paper.

6. Ensure that area 17 is clear of all binder tape adhesive. If th e
area is not clear, clean the binder using the procedure,
"Cleaning the binder," in this guide.

DocuTech 61xx Operator Guide 6-9

Problem solving

WARNING

The binder tape adhesive is hot, approximately 425°F
(218°C). Allow the binder to cool for 5 minutes with the
finisher doors and top cover open before touching the
binder tape.

7. If area 18 is not displayed, proceed to step 10.

8. If area 18 is displayed an d the entir e binder tap e length is n ot
aligned with the tape feeder assembly, stop and follow the
WARNING. Proceed to step 10.

9. If area 18 is displayed and the entire binder tape length is
aligned with the tape feeder assembly, proceed to step 10.

10.Remove the binder tape.
1 1.Ensure that area 18 is clear of all binder tape adhe sive. If it is

not, clean the binder using the procedure, "Cleaning the
binder," in the "Routine maintenance" chapter.

12.Close the finisher doors.

13.Close the top cover.

Clearing a stitcher spool A fault

Repeated jams in area 17 may be caused by the following
problems:

• Stitcher wire not feeding properly

• A kink in the stitcher wire

1. Open the finisher doors.

2. Lift the stitcher panel, which is located direct ly above the
stitcher spools.

NOTE: If the spool is empty, replace the stitcher spool A using
the procedure , "Replacing the stitcher spool A," in the "Routine
maintenance" chapter.

3. Ensure that there is wire on the spool.

4. Pull the green stitcher head release handle forward and up
until it latches into place, as shown in figure 6-1.

6-10 DocuTech 61xx Operator Guide

Problem solving

Figure 6-1. Stitc h er head release handle

5. Remove the stitcher wire plug .
a. The stitcher wire pl ug is located ab ove the binder are a, as

shown in figure 6-2.
b. Press and hold down the release clip.
c. Pull the plug out of the stitcher head.

Figure 6-2. Removing the stit cher wire plug

6. Remove any damaged wire.

DocuTech 61xx Operator Guide 6-11

Problem solving

a. Using the wire cutters, slowly and carefully pull

approximately 3 feet (1 meter) of wire out of the stitcher

plug.
b. The wire cutter tool needed to perform this procedure is

located next to stitcher spo ol B, as sho wn in the l ower l eft

corner of figure 6-1.
c. Cut the wire carefully, leaving approximately 2 inches (50

mm) of wire extending from th e sti tche r plug, as shown i n

figure 6-3.

Figure 6-3. Cutting the wire

7. Insert the plug into th e measur ing bracket, as shown in figure
6-4.

6-12 DocuTech 61xx Operator Guide