Xerox DocuTech 180, DocuTech 155, DocuTech 128 Operating Guide
October 2007
701P47034
DocuTech 128/155/180 HighLight Color
Operator
Guide
Prepared by:
Xerox Corporation
Global Knowledge and Language Services
800 Phillips Road Bldg. 845-17S
Webster, New York 14580
USA
©2007 by Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms and matters of copyrightable material and information
now allowed by statutory judicial law or hereinafter granted, including without limitation, material
generated
from the software programs displayed on the screen such as icons, screen displays, or looks.
Printed in the United States of America.
XEROX® and all Xerox product names mentioned in this publication are trademarks of XEROX
CORPORATION.
Other company trademarks are also acknowledged.
Changes are periodically made to this document. Changes, technical inaccuracies, and typographic
errors will be corrected in subsequent editions.
Document Version: 1.0 (July 2007)
Product Recycling and Disposal
If you are managing the disposal of your Xerox product, please
note that the product contains lead, mercury and other materials
whose disposal may be regulated due to environmental
considerations in certain countries or states. The presence of lead
and mercury is fully consistent with global regulations applicable
at the time that the product was placed on the market.
European Union
Some equipment may be used in both a domestic/household and
a professional/business application.
Domestic/Household Environment
Application of this symbol on your equipment is confirmation that
you should not dispose of the equipment in the normal household
waste stream.
In accordance with European legislation end of life electrical and
electronic equipment subject to disposal must be segregated from
household waste.
Private households within EU Member States may return used
electrical and electronic equipment to designated collection
facilities free of charge. Please contact your local disposal
authority for information.
In some Member States when you purchase new equipment your
local retailer may be required to take back your old equipment free
of charge. Please ask your retailer for information.
Professional/Business Environment
Application of this symbol on your equipment is confirmation that
you must dispose of this equipment in compliance with agreed
national Procedures.
In accordance with European legislation end of life electrical and
electronic equipment subject to disposal must be managed within
agreed procedures.
Prior to disposal please contact your local dealer or Xerox
representative for end of life take back information.
DocuTech 128/155/180 HighLight Color Operator Guide 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
Perchlorate Law Compliance Announcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Product Recycling and Equipment End-of-Life Disposal
Language Requirements for Xerox Customer Documentation . . . . . . . . . . . . . . . . . . . 1-8
2 System components
Electronic reprographics process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
FreeFlow Print Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
System Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Paper sizing and print speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
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
Adding paper to trays 3, 4, 5, or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Using the custom transfer assist blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Adjusting for paper curl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Adjusting the decurler lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Maintaining the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
DocuTech 128/155/180 HighLight Color Operator Guide
iii
Replacing the black dry ink bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Replacing the highlight color container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Changing the highlight color Customer Changeable Units . . . . . . . . . . . . . . . . . . . . . 3-17
Adding fuser shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Waste containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Wire Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Cleaning the system and its components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Cleaning the 18/36-track cartridge tape drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Cleaning the 26-track cartridge tape drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Cleaning the DVD drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Cleaning the diskette drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Cleaning the sensors and the reflecting surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Cleaning the Q850 and Q861 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Cleaning the Q1011/1009 sensor and mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Cleaning the Q1106 and Q1166 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Cleaning the Q1107 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Cleaning the Q1164 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Cleaning the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Cleaning the exterior surfaces of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Clearing or cleaning the finisher sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Clearing the Q1201 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Clearing the Q1202 and Q1203 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Cleaning the Q1222 and Q1210 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Clearing the Q1205, Q1206, and Q1207 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Clearing the Q1213 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Clearing the Q1221, Q1218, and Q1227 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Cleaning the binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Cleaning the binder tape guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Cleaning the binder platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Cleaning the flappers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Cleaning the calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Closing the binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Replacing the stitcher spool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Storing the binder tape reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Replacing the binder tape reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Adjusting the binder tape registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Replacing the Customer Replaceable Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
iv DocuTech 128/155/180 HighLight Color Operator Guide
5 Technical information
DocuTech printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Printer rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Paper tray capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Additional paper capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Printer satisfaction guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Stock satisfaction guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Using non-standard stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Paper stock rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Finisher satisfaction guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
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 guide is intended for Xerox DocuTech 128/155/180 HLC
operators whose job consists of the routine operation of this
printing system: operating each of the system components,
running print jobs, solving simple system problems, and
performing basic maintenance tasks, such as replenishing printer
supplies.
If you are a lead operator, or your job involves some programming
or systems administration tasks, as well as operating the
DocuTech 128/155/180 HLC system, use the on-line help system
and the other documents for the FreeFlow Print Server to
supplement the information in this guide.
Before using this guide, become familiar with its contents and
conventions.
WARNING: Both power cords with the printer must be
disconnected from the printer in order to completely power down
the machine.
Contents
This section lists the contents of this guide.
• “System components” contains an explanation of each of the
system components.
• “Routine maintenance” describes the routine activities you
perform to maintain the reliability and productivity of your
printer.
• “Problem solving” describes how the system informs you of
problems. When you know there is a system problem, you can
take measures suggested by the system to correct the
problem. You can also use the problem and solution tables in
this section to resolve recurring problems.
DocuTech 128/155/180 HighLight Color Operator Guide vii
Introduction
Conventions
• “Technical information” contains the hardware and software
capacity guidelines for the DocuTech 128/155/180 HLC
systems.
• “Supplies” lists the supplies that you might want to keep in
stock, and the information you need to order them.
This guide uses the following conventions:
• All caps and angle brackets–Within procedures, 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 <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 Platform Series
System Guide).
• Square brackets–Names of options you select are shown in
square brackets (for example, Select [Exit]).
• Quotes–Keywords you can enter as arguments appear in
quotes (for example, “US Letter”).
• Vertical bars–Alternatives to specified arguments are
separated by vertical bars (for example, -pdl <ps | hppcl | ascii
| 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 equipment safety notices related to
laser safety, ozone safety, and operation safety.
WARNING: Use of controls or adjustments, or performances
other than specified herein, may result in hazardous radiation
exposure.
The Xerox DocuTech 128/155/180 HLC models are certified to
comply with laser performance standards set by the U.S.
Department of Health, Education, and Welfare as Class 1 laser
products. This is a class of laser products that does not emit
hazardous radiation. This is possible only because the laser beam
is totally enclosed during all modes of customer operation.
When performing operator functions, laser warning labels may be
visible. These labels are to alert and remind the service
representative and are placed on or near panels or shields which
require a tool for removal.
THE PANELS TO WHICH THESE LABELS ARE FIXED OR
NEAR ARE NOT TO BE REMOVED BY ANYONE OTHER THAN
AUTHORIZED TRAINED PERSONNEL.
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 operation. The ozone
produced is dependent on copy volume and is heavier than air.
Providing the proper environmental parameters as specified in the
Xerox installation instructions ensures that concentration levels
meet safe limits.
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 grounded power source receptacle.
If in doubt, have the receptacle checked by a qualified
electrician.
• Do not use an adaptor plug to connect the system to an
electrical outlet that lacks a ground connection terminal.
WARNING: 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.
WARNING: Do not push objects into slots and openings on the
system. Making contact with a voltage point or shorting out a part
could result in fire or electrical shock.
• 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 system power, disconnect the power cables, and
call a service representative when any of the following
conditions occur:
1-2 DocuTech 128/155/180 HighLight Color Operator Guide
Safety notices
– The power cable is damaged or frayed.
– Liquid is spilled into the system.
– The system is exposed to water.
– Any part of the system is damaged.
• Always use materials and supplies specifically designed for
your Xerox equipment. Use of unsuitable materials may result
in poor performance and can possibly create a hazardous
situation.
• Never attempt any maintenance function that is not specifically
described in this Operator Guide.
• Never remove any covers or guards that are fastened with
screws. There are no operator-serviceable areas within these
covers.
• 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, approximation
of the laws of the member Stated related to electromagnetic
compatibility.
• March 9, 1999: Council Directive 1995/5/EC on radio
equipment and telecommunications terminal equipment and
the mutual recognition of their conformity.
A full declaration, defining the relevant directives and referenced
standards can be obtained from your Xerox Europe
representative.
WARNING: Changes or modification to this equipment not
specifically approved by Xerox Europe may void user’s authority
to operate the equipment. Shielded cables must be used with this
equipment to maintain compliance with the EMC Directive (89/
336/EEC).
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.
DocuTech 128/155/180 HighLight Color Operator Guide 1-3
Safety notices
WARNING: This system is certified manufactured and tested in
compliance with strict safety and radio frequency interference
regulations. Any unauthorized alteration which includes the
addition of new functions or the connections of external devices
may impact this certification. Please contact your local Xerox
Europe representative for a list of approved accessories.
Shielded cables must be used with this equipment to maintain
compliance with the EMC Directive (89/336/ EEC).
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 128/155/180 HighLight Color Operator Guide
Safety notices
In the event of problems, you should contact your local Xerox
representative in the first instance.
The product has been tested to and is complaint with TBR21, a
specification for terminal equipment for use on analogue switched
telephone networks in the European Economic Area.
The product may be configured to be compatible with other
country networks. Please contact your Xerox representative if it
needs to be reconnected to another country’s network.
There are no user-adjustable settings in the product.
NOTE: Although this product can use either loop disconnect
(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.
Electricity at Work Regulation - UK
The Electricity at Work Regulation applies only to England and
Wales.
The Regulation
The Electricity at Work Regulation 1989 came into force in
England and Wales on 1 April 1990. This 1989 Regulation places
a duty on all employers and self employed persons to ensure the
electrical systems in their premises are constructed, maintained
and operated in such a manner as to prevent, so far as reasonably
practical, danger. This includes ensuring all electrical equipment
connected to such electrical systems are safely constructed,
maintained and operated.
All Xerox equipment have been designed to exacting safety
standards. They have all undergone a variety of stringent safety
tests including earth bond, insulation resistance and electrical
strength tests. Xerox Europe manufacturing plants have been
awarded ISO 9000 quality certification and are subject to regular
audits by the British Standards Institution or equivalent national
standards body.
Xerox equipment which has been properly and regularly serviced
and maintained should not have to undergo additional specific
safety tests pursuant to the 1989 Regulation. Customers wishing
to complete safety testing should contact Xerox Europe Technical
Centre for advice prior to any test implementation.
Xerox equipment should, however, be properly and regularly
serviced and maintained at all times.
DocuTech 128/155/180 HighLight Color Operator Guide 1-5
Safety notices
Check your understanding
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 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 serviced and maintained by competent persons.
Xerox Europe Customer Service Engineers ensure Xerox
equipment is serviced and maintained to exacting Xerox safety
standards. If you would like your Xerox equipment to be serviced
and maintained to such high standards, please contact your local
Xerox Europe Customer Service Organization. They will be
pleased to assist you.
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 tests which may be completed by your
Xerox Europe Customer Service Organization. THESE TESTS
1-6 DocuTech 128/155/180 HighLight Color Operator Guide
Safety notices
MUST BE CARRIED OUT ONLY BY PERSONS WHO POSSESS
THE RELEVANT SKILL, KNOWLEDGE AND EXPERIENCE TO
CARRY OUT SUCH TESTS.
Please contact the Xerox Europe Customer Service Organization
for further information.
THE USE OF INAPPROPRIATE TEST PROCEDURES AND
TEST EQUIPMENT MAY PROVIDE MISLEADING RESULTS
AND MAY CAUSE DEATH, PERSONAL INJURY AND/OR
DAMAGE TO PROPERTY.
Question I would like to carry out my own safety tests on the Xerox
equipment in my premises.
Answer You may, of course, request such tests as you deem necessary to
satisfy yourself that your Xerox equipment is safe. Your Xerox
Europe Customer Support will be pleased to advise you on such
testing.
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 advised of such action to enable
such defects to be corrected.
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.
DocuTech 128/155/180 HighLight Color Operator Guide 1-7
Safety notices
Perchlorate Law Compliance Announcement
This announcement is required for all Xerox products which
contain perchlorate materials and are destined for the State of
California.
Product Recycling and Equipment End-of-Life Disposal Language Requirements for Xerox Customer Documentation
Xerox operates a worldwide equipment take back and reuse/
recycle program. Contact your Xerox sales representative (1-800ASK-XEROX) to determine whether this Xerox product is part of
the program. For more information about Xerox environmental
programs, visit www.xerox.com/environment.
If you are managing the disposal of your Xerox product, please
note that the product contains lamp(s) with mercury, and may
contain lead, Perchlorate and other materials whose disposal may
be regulated due to environmental considerations. The presence
of these materials is fully consistent with global regulations
applicable at the time that the product was placed on the market.
For disposal information, contact your local authorities. In the
United States, you may also refer to the Electronic Industries
Alliance web site: http://www.eiae.org/
Perchlorate Material - This product may contain one or more
perchlorate-containing devices, such as batteries. Special
handling may apply; please see http://www.dtsc.ca.gov/
HazardousWaste/Perchlorate/index.cfm.
1-8 DocuTech 128/155/180 HighLight Color Operator Guide
2 System components
The Xerox DocuTech HLC printers are electronic reprographics
systems. They are high volume printers available in multiple
configurations. These versatile, high performance printing
systems enable personal computers and other network-connected
devices (such as workstations and graphic scanners) to produce
documents incorporating graphics, forms, logos, signatures, and
fonts.
Electronic reprographics process
The Xerox DocuTech HLC system consists of a FreeFlow Print
Server and a DocuTech printer.
FreeFlow Print Server
DocuTech Printer
The FreeFlow Print Server accepts electronic print input created
by client software in ASCII, TIFF, HP PCL, PostScript, PPML,
LCDS, IPDS, VIPP or PDF format. This print input is passed on to
the system through a network connection. The Print Server
software performs the necessary data conversion, creating an
electronic file which is stored temporarily in a print queue on the
Print Server. This electronic image is then passed directly on to
the printer for production.
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 or 3-Tray Interposer and Finisher
The Xerox DocuTech HLC prints high quality, high resolution
documents in simplex or duplex mode at high production speeds,
from LCDS, PostScript, PCL, and other data streams. The system
can switch between printing different types of data streams
without a need for rebooting or reconfiguring software.
The printer supports:
• Duplex printing
• Media handling of multiple weights, sizes, and types
• Optional modules for enhanced finishing and output to thirdparty finishing devices
• Optional enabling of a third-party roll feeder
• Depending on your configuration: optional high-capacity
feeder/stacker modules, which provide additional feeder trays
and output bins
• Depending on your configuration: 2-Tray or 3-Tray Interposer
with a stape binder and stitcher
• High resolution of IPDS, LCDS, PostScript, and PCL data
streams (shown in the following table)
2-2 DocuTech 128/155/180 HighLight Color Operator Guide
Table 1. Data stream resolution
Data stream Input resolution
System components
Print resolution: DP128/155/180 HLC
IPDS 240 by 240 dpi or 300
by 300 dpi or 600 by
600 dpi
LCDS 300 by 300 dpi 600 x 2400 dpi (High volume printer only)
PostScript and PCL 300 by 300 dpi or 600
by 600 dpi
600 x 2400 dpi (High volume printer only)
600 x 2400 dpi (High volume printer)
600 x 600 dpi (Production publisher)
Data formats supported
The Xerox DocuTech 128/155/180 HLC can print the following
data formats:
• ASCII
• LCDS
•IPDS
•PCL
•PDF
•PostScript
•TIFF
• PPML
The system prints LCDS data from a mainframe host computer,
emulating an IBM 4245 or 3211 page printer. The printing system
can receive data over a channel through bus and tag cables, and
through the Socket Gateway or lpr using TCP/IP protocol.
The system prints IPDS data from a host computer, emulating an
IBM 3812, 3825, 3827, or 3935 printer. The printing system can
receive data through a channel card with bus and tag connectivity,
and through a TCP/IP interface using Ethernet.
The system also prints PostScript and PCL data submitted over a
network (Ethernet or AppleTalk) from a variety of clients:
• PCs (Windows and Windows XP)
• Sun workstations (UNIX)
• UNIX command line clients: lpr (including 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, store, condition, and load print media properly
in order to keep your printer running at optimum efficiency.
The printer functions best and produces the best print 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 standard 75 gsm paper. The
available stock that is closest in weight to 20 pound paper is 80
gsm.
The following special stocks can be used with the DocuTech 128/
155/180 HLC:
• Labels: Must be the type designed for high-speed printers and
must meet the specifications described in the section above.
Loading instructions are printed on all paper trays.
• Transparencies: Must be the type designed for high-speed
printers and must meet the specifications described in the
section above. Loading instructions are printed on all paper
trays.
• Colored paper: Available in a variety of colors, colored paper
has many uses, including calling attention to certain printed
material, separating special sections, or dividing chapters of a
report.
• Preprinted paper: May be letterhead, forms, or logos. Refer to
the Helpful Facts about Paper guide to verify that the
preprinting inks used on your stock are the kind formulated for
use in laser printers.
2-4 DocuTech 128/155/180 HighLight Color Operator 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: Has been pierced with one or more rows of
holes to permit easy tearing or separating into sections. Read
and follow the instructions on the ream packaging.
• Precut or full tabs.
• Carbonless paper: Is paper that is treated or coated to
produce an image under pressure (without the use of carbon
paper). 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 interface (GUI) on the print server enables you
to interact with the printing system. It contains windows, icons,
and menus through which you can issue commands and perform
operator and system administration tasks.
When the print server is powered on and booted, the FreeFlow
Print Server home screen displays.
DocuTech 128/155/180 HighLight Color Operator Guide 2-5
System components
System software and job flow
This section describes how the system software processes are
used as a typical job flows through the system.
NOTE: There are no job flow differences between the High
volume printer and the Production publisher configurations.
Figure 2-1. Job flow
1. Job
2. Input Queue
3. Decomposer
4. Output queue
5. Printer
Job
The job and the job ticket (if applicable) are received from the
network by one of the protocol gateways.
Input queue
The Job Pool Manager (JPM) process transfers the job into the
input queue. The virtual printer name and job attributes are
attached to the job. The job remains in the Input Queue until it can
be printed; for example, “held” and “faulted” jobs reside in the
input queue.
Decomposer
The Job Chooser reconciles the job attributes with the virtual
printer attributes. Once the job is ready for print, the Job Chooser
gives the job to the appropriate decomposer, PostScript or PCL.
2-6 DocuTech 128/155/180 HighLight Color Operator Guide
System components
Output queue
After decomposition, the job is stored in the output queue.
Printer
The marker transfers the job from the Output Queue to the printer.
After the job has successfully printed, it is removed from the
Output Queue and also from the Input Queue.
The printing process and job flow is different for PostScript, PCL,
TIFF, ASCII, PDF jobs (that is, non-LCDS or non-IPDS jobs) and
for LCDS or IPDS jobs.
PostScript, PCL,
TIFF, ASCII, LCDS,
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 print data file and the job request are
submitted to the selected queue. Jobs are processed by priority
within the designated queue once the job reaches the queue from
a given application.
The printer receives data from the print server and prints the
document according to the print options specified by the user. The
printer also stacks and collates the printed output.
The printer system is available in two configurations:
1. High volume printer with inverter feeder/stacker and up to
three feeder/stackers
2. Production publisher with either a 2-Tray, or 3-Tray interposer
and finisher
DocuTech 128/155/180 HighLight Color Operator Guide 2-7
System components
High volume printer
The components, special features, and configurations of the
Xerox DocuTech 128/155/180 HLC printer are shown in the
following figures.
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 example, to provide
different paper colors for specific pages.
The printing system may have up to six feeder/paper trays: two
processor feeder trays and two to four high-capacity trays. Four
addressable input trays are standard with the system, and two
additional high-capacity trays are optional.
2-8 DocuTech 128/155/180 HighLight Color Operator Guide
System components
Processor feeder/
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 10 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 in use. In each
tray, a control panel consisting of a button, indicators, and paper
level displays controls the elevator tray and indicates its status.
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 is 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, printing stops.
• If the tray is in use and selected as a backup tray, pressing the
Tray Unlock button causes the tray elevator to lower and the
tray to be unavailable for auto switching.
• If the tray elevator is in the raised position and the tray is not in
use or selected as a backup tray, pressing this button causes
the elevator to lower with no effect on printing operations.
This button functions when the Please Wait indicator is off.
DocuTech 128/155/180 HighLight Color Operator Guide 2-9
System components
Paper Level
indicators
Display the approximate quantity of paper in the tray. Each display
shows paper by quarter reams up to one ream, and then by full
reams. The green indicator appears above its Paper Level
indicator.
Sample tray
NOTE: High volume printer configuration only
The sample tray, located on top of the printer, receives output
such as transparencies, sample sheets from printing jobs, prints
from system files such as forms, and waste sheets that cannot be
sent to the purge tray.
Monitor the sample tray and empty it when it contains 100 sheets.
The system does not notify you when the tray is full.
Attention light
An Attention light is mounted on top of the inverter module. This
light either blinks or modulates (alternately brightens and dims)
when the printer requires operator attention. The light has three
states:
Off: No printer problems exist that require attention.
Steady light: A situation exists that needs attention soon.
Flashing: The printer has stopped and requires your attention
immediately.
NOTE: When the Attention light starts flashing, an explanatory
message appears on the print server screen.
Purge tray
NOTE: High volume printer configuration only
The purge tray is located on top of the last feeder/stacker module.
Aborted sheets (for example, damaged sheets or sheets cleared
after a paper jam) are sent to this tray. The purge tray should be
emptied when it has received 100 sheets of paper.
The system does not notify you when the tray is full.
2-10 DocuTech 128/155/180 HighLight Color Operator Guide
System components
Inverter feeder/stacker
NOTE: High volume printer configuration only
Each output feeder/stacker has offsetting capability and a capacity
of 2500 sheets of 20 pound or 80 gsm paper.
This capacity does not apply to 11 by 17 inch and A3 papers.
Because of the additional weight these large sheets add to the
bins, each bin is restricted to hold only up to 1500 sheets of A3 or
11 by 17 inch papers, for safety reasons.
Figure 2-4. High capacity stackers (HCS)
The stackers can stack the printed output in the bin three ways:
1. Directly onto the bin platform.
2. Into a container that is set on top of the bin platform.
NOTE: The stacking capacity is approximately 100 to 150 sheets
less when stacking into a container.
3. Onto a pallet without a container (for paper sizes 11 by 17 inches or A3 only).
Using the stacking windows on the user interface, you can select
the level to which paper will be stacked in the HCS.
A stacking elevator maintains the paper at the proper level for
stacking and lowers the stack for unloading. An offset mechanism
offsets printed sets toward the front or back of the HCS bin.
The elevator platform lowers under the following conditions:
• 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 indicator 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 in the other stacker bin, if auto switching
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 contain the high-capacity feeder trays
and the stacker bins. The printer may have up to four feeder/
stacker modules (including the inverter feeder/stacker), containing
feeder trays 3, 4, 5, and 6, and stacker bins A, B, C, and D. Each
module contains one high-capacity feeder tray and one high
capacity stacker bin.
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 handle paper sized from 8 by
10 inches / 203 by 254 mm to 17 by 14.02 inches / 432 by 356
mm.
Unlike the processor feeder trays, the HCF trays have Paper
Level switches, which detect the position of the elevator to
determine the fullness of the tray.
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