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.
System components
High-capacity
stackers
The high-capacity stacker (HCS) bins are located in the top half of
the feeder/stacker modules, accessed through double doors.
Two high-capacity stacker bins are standard, with up to two
additional bins available as options (providing up to four bins
total). Each bin holds up to 2500 sheets of 20 pound or 80 gsm
paper.
More High volume printer configurations
In addition, the high volume printer is available with three or four
feeder/stacker modules.
Figure 2-6. Printer with inverter feeder/stacker + feeder/
stacker + feeder/stacker
Figure 2-7. Printer with inverter feeder/stacker + feeder/
stacker + feeder/stacker + feeder/stacker
The illustrations above show a High volume printer configuration
with two feeder/stacker modules and a bypass transport, and a
printer with three feeder/stacker modules and a bypass transport.
With the bypass transport installed, the printer can support up to
three feeder/stacker modules, including the inverter feeder/
stacker.
DocuTech 128/155/180 HighLight Color Operator Guide 2-13
System components
Production publisher
The standard base components, special features, and
configurations of the Xerox DocuTech 180 HLC production
publisher printer are shown in the following figures.
Figure 2-8. Production publisher: Printer + 2-Tray or 3-Tray
1. Convenience tray
2. Interposer (2-Tray shown)
3. Finisher
4. Top tray
Convenience tray
The convenience tray provides an area to place documents or
other items while you are at the printer.
Interposer + stitcher/binder
2-14 DocuTech 128/155/180 HighLight Color Operator Guide
Interposer
NOTE: Production publisher configuration only.
The 2-Tray or 3-Tray Interposer module is located between the
print engine and the Finisher. The Interposer inserts blank or
preprinted sheets as required. Sheets fed from Tray 4 are not
imaged and feed directly into the finisher. Sheets from Tray 5 or
Tray 6 (Three-tray Interposer) can be set either to feed through
the Interposer via the print engine (passing through the Fuser) or
to deliver pre-printed stocks into the Finisher (post-Fuser).
Both models of Interposer have the ability to process ordered sets
fed from Tray 4. This makes it unnecessary to have additional
trays for each page type in a set. However, for jobs that include
pre-printed sheets that are not pre-collated or several jobs that
use ordered sets, Tray 5 and Tray 6 (3-Tray Interposer) can also
be set to feed directly into the Finisher (post-Fuser).
NOTE: Ordered sets can also be fed for imagining from Trays 1,
2, and 3.
System components
Two-tray Interposer
(production
publisher only)
The 2-Tray Interposer allows applications to utilize up to five trays
to feed different paper stocks. Both trays may be used to feed preprinted stocks (bypassing the Fuser). If just Tray 4 is used for
post-Fuser feeding, four pick points are available for imaging
(passing through the fuser).
The following lists the 2-Tray interposer components
1. Paper transport (lower)
2. Paper transport (upper)
3. Inserter tray
4. Feeder/inserter tray
Figure 2-9. 2-Tray Interposer (production publisher only)
DocuTech 128/155/180 HighLight Color Operator Guide 2-15
System components
3-Tray Interposer
(production
publisher only)
The 3-Tray Interposer allows applications to utilize up to six trays
to feed different paper stocks. All three trays may be used to feed
pre-printed stocks (bypassing the Fuser). If just Tray 4 is used for
post-Fuser feeding, five pick points are available for imaging
(passing through the fuser).
The following lists the 3-Tray interposer components
1. Paper transport (lower)
2. Paper transport (upper)
3. Inserter tray
4. Feeder / inserter tray (Tray 5)
5. Feeder / inserter tray (Tray 6)
Figure 2-10. 3-Tray Interposer (production publisher only)
2-16 DocuTech 128/155/180 HighLight Color Operator Guide
Finisher
NOTE: Production publisher configuration only
Figure 2-11. Finisher
System components
In the finisher, prints can be collated, and stitched or bound, as
required for a job. The following lists the finisher components:
1. Bindexer
2. Stitcher
3. Stacker
4. Binder
5. Binder tape reel
6. Stitcher wire spools
7. Top tray
The bindexer
NOTE: Production publisher configuration only
The bindexer is a three-bin sorter that collates the pages of each
print set. As the pages of the print set are fed to the bindexer, the
bindexer moves up and down to collate them.
The stitcher
NOTE: Production publisher configuration only
When the job requires stitched output, the stitcher cuts and inserts
the wire stitches into each print set. The stitch length is related to
such factors as the number of pages in the print set and the print
stock weight. A single stitch can be placed in the portrait or
landscape print position. Dual stitching is available for landscape
and portrait prints. Stitch placement can be changed through the
FreeFlow Print Server software.
NOTE: For more information about setting stitch placement, refer
to the on-line help system.
DocuTech 128/155/180 HighLight Color Operator Guide 2-17
System components
The stacker
NOTE: Production publisher configuration only
The stacker collects unfinished or finished stitched or bound jobs.
When the stacker is full, or the job is completed, the stacker door
opens and the stacker drawer that holds the prints comes out.
After the stacker drawer is unloaded, the system retracts the
drawer and closes the door. The stacker also can be unloaded
during the printing cycle to check the quality of the print sets by
changing the printer options.
NOTE: For more information, refer to the on-line help system.
The binder
NOTE: Production publisher configuration only
When a job requires bound output, a length of pre-glued paper
tape is placed on a heated surface called the binder platen. The
system aligns the pages of each print set before placing the set on
the tape. Binder flappers then press the tape to the sides of the
set. The combination of the heat in the binder and the pressure of
the flappers glues the tape to the set.
NOTE: For information about adjusting the binder tape
registration and the binder tape length, refer to the on-line help
system.
The top tray
NOTE: Production publisher configuration only
Prints are delivered to the top tray because the prints are
oversized or because the top tray was selected at the print server.
Bypass transport
Function of the
bypass transport
Paper stocks
supported on
bypass transport
DFA support The bypass transport meets the Xerox Document Feeding and
The bypass transport moves paper from the printer to a third-party
finisher such as a stitcher, booklet maker, tape binder, and so on.
By making selections on the user interface windows, you can
program the printer to send output to the bypass transport, which
feeds the output to the finishing equipment.
The bypass transport accepts all paper stocks on which the printer
can print, and it accommodates simplex and duplex printing.
Finishing Architecture (DFA) specifications. The system software
supports DFA. However, in order for the bypass transport to
function correctly, you need to set up finishing personality profiles
to identify your finishing device to the printing system. (The
customer support representative for your finishing device can give
2-18 DocuTech 128/155/180 HighLight Color Operator Guide
System components
you the information you need to create a personality profile for
your third-party finishing device.)
For information on marketing partners that provide solutions for
support and interface with finishers, contact your local Xerox sales
representative.
Bypass transport on the production publisher
Depending on the finisher configuration, the bypass transport is
located inside the finisher module on the Production publisher
configuration. Bypass transport function is the same as the
external bypass transport module.
NOTE: The Production publisher finisher is available with or
without the bypass transport.
Bypass transport on the High volume printer
Connected to the last feeder/stacker module. The bypass
transport option enables third-party finishing devices to interface
directly with the printing system. The bypass transport allows you
to customize your printer for increased efficiency and specialized
applications involving finishing.
NOTE: Systems configured with the external bypass transport
can have a maximum of two (2) feeder/stacker modules. See
figure 2-13.
7 by 10 inch enablement kit
The 7 by 10 inch enablement kit allows the printing system to print
on 7 by 10 inch/178 by 254 mm paper size, with throughput speed
of up to 206 PPM.
Paper paths
The paper path is the route that materials (paper, transparencies,
labels, and so on) follow through the printer from the feeder trays
to the output bins or finisher.
DocuTech 128/155/180 HighLight Color Operator Guide 2-19
System components
High volume printer paper path
The following figure shows the path the paper takes through the
high volume printer.
Figure 2-12. Route of paper through the high volume printer
1. Processor feeder tray 1
2. Processor feeder tray 2
3. High-capacity feeder tray 3
a. Side 1 of sheet leaving feeder tray
b. Drilled holes (on right edge)
c. Origin 0,0: portrait orientation
2-20 DocuTech 128/155/180 HighLight Color Operator Guide
4. High-capacity feeder tray 4
a. Side 1 of sheet leaving feeder tray
b. Drilled holes (on right edge)
c. Origin 0,0: portrait orientation
5. Paper inverter
6. Duplex inverter
7. Sample tray
8. High-capacity stacker bin A
a. Side 2 of sheet stacked in bin
b. Drilled holes (on left edge)
c. Origin 0,0: portrait orientation
9. High-capacity stacker bin B
a. Side 2 of sheet stacked in bin
b. Drilled holes (on left edge)
c. Origin 0,0: portrait orientation
System components
10. Purge tray
11. Bypass transport
a. Side 2 of sheet passing through bypass transport
b. Drilled holes (on left edge)
c. Origin 0,0: portrait orientation
DocuTech 128/155/180 HighLight Color Operator Guide 2-21
System components
Production publisher paper path
The following figure shows the path the paper takes through the
production publisher.
Figure 2-13. Route of paper through the production publisher
1. Processor feeder tray 1
2. Processor feeder tray 2
3. High capacity paper tray
4. Paper inserter tray
5. High capacity paper tray (Two-tray Interposer shown)
6. Duplex inverter
7. Purge tray
8. Bypass transport
9. Bindexer area
10. Bind area
11. Stitch area
12. Stacker area
Bypass transport paper path
The following figures show the paper path through the bypass
transport, viewed from the front of the printer.
2-22 DocuTech 128/155/180 HighLight Color Operator Guide
System components
High volume printer bypass transport paper path
Figure 2-14. Bypass transport paper path (high volume
printer configuration shown)
1. Sheet path
2. Exit rollers
3. Floor
DocuTech 128/155/180 HighLight Color Operator Guide 2-23
System components
The System
System Hardware
The basic hardware components of the DocuTech 128/155/180
HLC systems are the FreeFlow Print Server and the printer.
The FreeFlow Print Server
The FreeFlow Print Server is the connection between you and the
system. You communicate through the FreeFlow Print Server
software by selecting and managing the jobs displayed on the
screen and sending them to the printer for production. The system
also communicates messages and instructions to you on the Print
Server interface screen.
The print server consists of a specially-configured workstation and
uses proprietary Xerox hardware, firmware, and software.
Specifications can be obtained from your Xerox customer
representative or by accessing the Setup, System Configuration
feature on the FreeFlow Print Server user interface.
NOTE: Print server hardware configurations are subject to
change to keep up with advances in technology.
Print Server overview
The print server receives LCDS, IPDS, PostScript, and PCL data
streams from a mainframe host or a workstation client, processes
the data, and sends it to the printer. The print server also provides
the printer with print data and commands and receives status
information from the printer.
The print server consists of a workstation, which is run by the Sun
Solaris Operating environment. Also resident on the print server is
software which manages all printing, diagnostic, and
administrative functions on the printing system.
The FreeFlow Print Server software includes a full-color graphical
user interface, which enables you to interact with the printing
system to set up and configure the system, to set up and
implement system options, to run print jobs, etc.
Online Help (menus and buttons) provides access to online help
that contains information when requested.
2-24 DocuTech 128/155/180 HighLight Color Operator Guide
Accessing FreeFlow Remote Print Server remotely
FreeFlow Remote Print Server, a remote graphical user interface
(GUI), is available for installation from a CD. FreeFlow Remote
Print Server allows you to manage your FreeFlow Print Serverbased printers from a single PC or Sun workstation. You may set
your preferences from the remote client to disable or enable some
or all connections.
FreeFlow Remote Print Server allows you to configure the printers
that you want to manage, and provides real time status of the
printers. You may switch between the printers that you are
managing, but you can display only one printer GUI at a time.
The remote client GUI looks and functions the same as the local
FreeFlow Print Server GUI on the print server.
Moving the print server
To ensure consistent performance and avoid any damage to
equipment, follow these rules for placing the components of the
print server.
System components
Do:
Use the print server stand that comes with your printing system
equipment.
Keep the processor in an upright, vertical position.
Allow at least 6 inches / 152 mm of unobstructed space at the front
and rear of the processor, so the fan and vents are not blocked.
CAUTION: Do not place the monitor on top of the processor. Do
not block any fan or vent on the front, sides, or rear of the
processor.
Do not:
Do not place the monitor on top of the processor.
Do not allow any piece of equipment to blow warm air into the air
intake vents of the processor.
Do not place the processor on its side, or in any other position but
the upright, vertical position achieved by using the print server
stand.
Do not place the processor or monitor on top of the printer.
Tape drives overview
The DocuTech 128/155/180 HLC supports several types of tape
drives that may be used to load resources (forms, fonts, etc.) or to
submit offline LCDS print jobs.
A 26-track cartridge tape drive can be used only to import
resources to the system disk. A 9-track or 36-track tape drive can
be used to submit print jobs to the printer or to load resources.
DocuTech 128/155/180 HighLight Color Operator Guide 2-25
System components
The FreeFlow Print Server Tape Client software enables
transmission of data from a cartridge or open reel tape to the
FreeFlow Print Server via the Socket gateway.
The 4 GB external SCSI quarter inch cartridge (QIC) tape drive is
an external device. The cartridge tape drive connects to the print
server through the SCSI port on the processor back panel.
Like the diskette and DVD drives, this tape drive is not an input
source for print jobs or for any other data or application. You can
use it to load resource files, and the service representative uses it
to load system maintenance files or to save diagnostic
information.
36-track cartridge
tape drive
Figure 2-15. 26-track cartridge tape drive
An 18/36-track cartridge tape drive is an option. You can use this
drive to load resources and to submit offline LCDS print jobs.
Peripheral cabinet (9-track and 18/36-track tape drives)
Some Xerox customers may already have a peripheral cabinet
that houses a 9-track magnetic and an 18/36-track cartridge tape
drive. If a peripheral cabinet has either of the following 18-track
tape drives, they are not supported:
STK 4220 MOD 1 tape drive
STK 4220 MOD 2 tape drive
2-26 DocuTech 128/155/180 HighLight Color Operator Guide
Figure 2-16. Peripheral cabinet
1. 9-track magnetic tape drive
2. 18/36-track cartridge tape drive
System components
Paper sizing and print speed
The printer paper trays have edge guide sensors that detect paper
length and width. The system selects correct paper trays for the
print job based on the paper parameters, such as size, weight,
color, or coating, specified in the job as follows:
• If an exact match is found, the print job continues.
• If an exact match is not found, the operator can specify in the
job for the printer to do one of the following:
– Stop printing the job and print an error sheet.
– Print the data on an oversized sheet.
If you encounter any problems related to paper sizing, contact
your lead operator or Xerox service representative.
DocuTech 128/155/180 HighLight Color Operator Guide 2-27
System components
Long and short edge
feeding
To feed through the printer, the leading edge of the paper must be
at least 10 inches long. Therefore, the following standard sizes of
paper must be loaded so that sheets feed long edge first:
• 7 by 10 inch
•B5
•A4
•US letter
•B4
•US legal
The following papers, which have long edges greater than 14.33
inches / 364 mm must feed short edge first:
•A3
• US ledger or US tabloid
NOTE: JIS B4 can be fed either long edge or short edge first.
2-28 DocuTech 128/155/180 HighLight Color Operator Guide
3 Routine maintenance
This section describes the routine activities you perform to
maintain the reliability and productivity of your printer.
Cleaning and maintenance overview
Some printer components need to be cleaned periodically to help
keep the system operating reliably, and to ensure that the print
quality is consistent.
When supplies get low, an indicator will appear in the FreeFlow
Print Server window on the print server. You should respond to the
fault or message as soon as possible to avoid a printer shut down.
The system provides dry ink to the printer from a bottle located in
the printer. When the screen displays an “empty” message, a full
dry ink bottle must be installed.
Waste dry ink empties into a container located at the side of the
printer, under the toner filter. When this container becomes full, it
must be replaced.
Fuser lubricant must be added to the fuser reservoir in the printer
when a “low” message on the screen directs you to do so. Fill the
fuser reservoir at this time or the printer shuts down.
For information on cleaning the processor sensors, the reflecting
surfaces, and the finisher sensors, refer to the Problem solving
chapter.
NOTE: The DocuTech HLC fuser oil is a specially blended fuser
shield specifically for the DocuTech HLC systems.
CAUTION: The DocuTech HLC fuser shield must not be used in
any other Xerox product.
CAUTION: Use only the DocuTech HLC fuser shield in the
DocuTech HLC systems.
Necessary Precautions
For your own safety and to protect the system, it is important to
take the following precautions whenever you perform cleaning
and replacement tasks.
• Use only the cleaning and replacement supplies that are
approved or recommended by Xerox. If you use other
DocuTech 128/155/180 HighLight Color Operator Guide 3-1
Routine maintenance
supplies, you may damage the system.
• Keep supplies in stock as listed in the Service and supplies
chapter.
• Whenever you use or remove a part from the system, handle
the part carefully. Note any informative labels on the system.
• Keep atomized and aerosol sprays away from the system.
• Pour cleaning liquids onto a cloth. Do not pour or spray liquids
directly onto system parts.
• Before reinstalling a system part that has been cleaned with a
liquid, ensure that the part is dry.
• Always use a drop cloth when replacing the dry ink bottle,
highlight color container, or when adding fuser shield.
• Some parts of the system, such as the fuser, get hot during
operation. To ensure that you do not burn yourself, be careful
when working around these parts.
WARNING: The fuser can reach a temperature of approximately
425°F (218°C). Exercise care to prevent burns when working near
this area.
Finisher precaution
NOTE: Production publisher configuration only
The system uses stitcher wire from two spools located below the
stacker. Stitcher spool A is used for portrait, top corner stitches.
When stitcher spool A is empty, it must be replaced with a new
stitcher spool. Stitcher spool B is used for portrait dual stitches and
landscape stitches.
To replace stitcher spool B, contact the Customer Support Center;
refer to the section, “Calling for assistance”, in this guide.
To replace stitcher spool A, refer to the section, “Replacing the
stitcher spool A”, in this guide.
The system applies binder tape from a reel mounted in the binder
drawer in the finisher. You will need to replace the binder tape
periodically.
WARNING: All areas of the binder drawer, including the binder
tape, are approximately 425°F (218°C) and may cause a serious
burn to the operator. If the binder has been in a "Ready" condition,
allow the binder to cool for at least one hour before attempting to
clean the binder.
3-2 DocuTech 128/155/180 HighLight Color Operator Guide
Paper
Routine maintenance
You can add the same kind of paper to a tray when the supply is
low without stopping the printer. You must have the same paper or
stock loaded in two trays for the system to continue printing while
you are loading the other tray.
Storing paper
It is important to store paper correctly. Temperature and humidity
affect the way your printer processes paper.
Store paper in the cartons it came in. To reduce the possibility of
moisture absorption, always place cartons on a wooden pallet or
store them in a cabinet off the floor.
After removing the paper from its carton, always store it:
• In its wrapper
• On a flat surface
• In a closed cabinet
• In a cool, dry area
• In 68 to 76
• In 35% to 55% humidity
o
F. / 20 to 24.4o C.
Figure 3-1 Storing paper correctly
DocuTech 128/155/180 HighLight Color Operator Guide 3-3
Routine maintenance
Conditioning paper
Figure 3-2 Recommended temperature and humidity for
paper storage
Because temperature and humidity affect paper performance in
the printer, you need to condition paper before using it. To
condition paper, store it for a specified length of time in the same
type of environment as your printer.
The length of time you should condition your paper depends on
the amount of paper and the difference between the storage and
operating temperatures.
Use the following chart to determine the number of hours needed
to condition stacked cartons of paper.
NOTE: The numbers in the top two rows indicate the temperature
difference between the storage area and the operating
environment, not actual room temperatures.
3-4 DocuTech 128/155/180 HighLight Color Operator Guide
Table 3-1. Paper conditioning
Temperature difference between storage and
operating areas
Routine maintenance
Paper curl
Centigrade
Fahrenheit
10
5.5
o
o
o
15
20o25
8.5o11
o
o
13
o
30
17
o
o
40
22
o
o
50
26
o
o
Cartons Hours needed to condition the paper
1 4 8 1114172434
5 5 9 1215182535
10 8 141822273851
20 11 16 23 28 35 48 67
40 14 19 26 32 38 54 75
Example: If you want to move ten cartons of paper from a storage
area with a temperature of 90
o
temperature of 70
F. ( a 2 0
o
F. to an operating area with a
o
difference), you should do so at least
18 hours before using the paper.
Before the manufacturer cuts paper into sheets, it is stored on
large rolls. After it is cut and packaged, it retains some of the curl
from the rollers.
Although it is unnecessary to load paper with the curl facing up or
down, best results occur when you are consistent. For example, if
you open paper with the wrapper seam up, always load it in the
tray that way.
DocuTech 128/155/180 HighLight Color Operator Guide 3-5
Routine maintenance
Adding paper to tray 1 or 2
The following steps must be performed to add paper to tray 1 or 2.
1. Press the Tray unlock button on the front of the tray. Wait for
the red "Please wait" light to go off.
2. When the green "Ready to open" light comes on, pull the tray
out until it stops.
Steps 3 through 5 of loading paper into tray 1 or 2 are
illustrated in Figure 3-3.
3. Press the green release tab.
4. Lift the metal handle on the feed belt and remove any paper
under the belt.
5. Move the rear guide to the back of the tray.
Figure 3-3 Preparing the paper tray
NOTE: To load the paper correctly, refer to the label located
on the inside panel at the front of the paper tray. Remove any
damaged sheets from the top of the stack.
CAUTION: Do not load the paper above the red line. A jam could
occur if too much paper is loaded in the tray.
6. Load the required paper into the paper tray. Load paper with
the curl side facing down. Load Xerox paper with the package
wrapper seam side facing up.
NOTE: When loading drilled paper, be sure to fan the edge
where the holes are located.
7. Position the stack against the front right corner of the tray, as
shown in Figure 3-4. This is indicated by the green arrow on
the bottom of the tray.
3-6 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
For stock outside the recommended limits, refer to the
"Technical information" chapter in this guide.
Figure 3-4 Positioning the stack
8. Move the rear guide forward until it touches the edge of the
stack.
9. Lower the feed belt.
10. Close the tray slowly, but firmly, until it latches.
DocuTech 128/155/180 HighLight Color Operator Guide 3-7
Routine maintenance
Adding paper to trays 3, 4, 5, or 6
Using the custom transfer assist blade
Paper Tray 3 is used to supply the largest volume of paper
required for your jobs. Trays 3, 5 and 6 (3-tray Interposer only) can
also be used to supply oversized paper for special jobs. Paper in
Tray 4 is only used for post-process insertion.
These trays lower one ream at a time as paper is added. More
than one ream can be loaded by pressing the Tray unlock button
again after the tray is fully opened.
Follow the described steps in the previous section to add paper to
Trays 3, 4, 5 or 6.
The custom transfer assist blade in the printer assures good print
quality for your jobs. A kit is available allowing you to customize
the transfer assist blade for use with nonstandard paper sizes.
You cannot use the custom transfer assist blade for print jobs that
use more than one paper size. In addition, the following paper
lengths cannot use the blade:
In U.S. markets
Installing the
custom transfer
assist blade
Setting tray size with
the custom transfer
assist blade
– 11.1 to 11.4 inches/282 to 290 mm
– 11.8 to 12.1 inches/300 to 307 mm
– 13 to 13.5 inches/330 to 343 mm
In non-U.S. markets
– 11.1 inches to 11.4 inches/282 to 290 mm
– 11.8 inches to 12.1 inches/300 to 307 mm
NOTE: With these paper sizes, transfer efficiency may be
reduced.
CAUTION: To avoid damage to the photoreceptor, you must set
the tray size with the transfer assist blade.
The custom transfer assist blade comes in a package containing
detailed instructions. Be sure you follow the instructions carefully.
CAUTION: To prevent damage to the system, have your service
representative show you the procedure before you attempt to
customize and install a transfer assist blade for the first time.
When you are using the custom transfer assist blade, you must
set the tray length. Use the following two tables to determine the
tray length setting to use.
3-8 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
Table 3-2. Tray length settings for custom transfer assist blades (U.S. markets)
Paper Size Set Paper Size
11.5 to 11.7 inches/292 to 297 mm 11.7 inches/297 mm
12.1 to 12.9 inches/307 to 328 mm 13 inches/330 mm
13 to 13.9 inches/330 to 353 mm 14 inches/356 mm
Table 3-3. Try length settings fro custom transfer assist blades (Non-U.S. markets)
Paper Size Set Paper Size
10 to 10.9 inches/254 to 277 mm 11 inches/279 mm
11.5 to 11.6 inches/292 to 294 mm 11.7 inches/3297 mm
12.1 to 12.9 inches/307 to 328 mm 13 inches/330 mm
Adjusting for paper curl
Each sheet of paper has a natural curve called the curl. Storing or
using the paper under humid conditions may increase the curl.
When too much curl causes paper handling problems, adjust the
decurler in the processor. The decurler flattens the paper after
fusing.
Measuring the paper curl
1. Program and print five 1-sided, 8.5 x 11 inch (216 x 279 mm)
sheets to the top tray.
NOTE: Keep the image toward you, as shown in Figure 3-5.
2. Measure the amount of curl in the prints by holding the five
prints in the top center of the short edge.
DocuTech 128/155/180 HighLight Color Operator Guide 3-9
Routine maintenance
Figure 3-5 Measuring the paper curl
3. Place the bottom edge of the prints over the paper curl
measurement chart in this guide.
• If the print curl on the printed paper measures between +1
and - 2, do not change the decurler setting.
• If the curl is between +2 and +3, or - 3 and - 4, refer to the
procedure, "Adjusting the decurler lever," in this section.
NOTE: Superior performance for greater than substance 32
(120 g/m2) can be achieved between +1 and -1 curl.
3-10 DocuTech 128/155/180 HighLight Color Operator Guide
Note: Corners of
the sheets of paper
should not exceed
curl shown in this
chart.
Routine maintenance
Image
Move green
decurler lever
Figure 3-6 Measuring the paper curl
DocuTech 128/155/180 HighLight Color Operator Guide 3-11
Move green
decurler lever
Routine maintenance
Adjusting the decurler lever
Perform the following steps to adjust the decurler lever.
CAUTION: Do not use any paper that is not suitable for system
use.
1. Open the right door of the processor.
2. Locate the decurler lever in area 7 of the paper path, as shown
in the figure below.
Figure 3-7 Locating the decurler lever
3. If the print curl is +2 or more, move the green decurler lever to
the right.
4. If the print curl is -3 or more, move the green decurler lever to
the left.
5. 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.
3-12 DocuTech 128/155/180 HighLight Color Operator Guide
Maintaining the printer
A screen message is displayed when it is necessary to replace
system supplies. To ensure that the system runs efficiently,
replace the supplies as soon as possible.
Replacing the black dry ink bottle
When directed by a screen message, replace the black dry ink
bottle. If the bottle is not replaced, the printer will eventually stop,
and it will not operate until a new bottle is installed.
CAUTION: To prevent dry ink spills, remove the bottle only when
directed to do so by a message on the screen.
CAUTION: Do not use warm or hot water, or general cleaning
solvents to remove dry ink from your skin or clothing. The heat or
solvent will set the dry ink and make it difficult to remove.
Routine maintenance
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.
Replace the black dry ink bottle
The following steps must be performed to replace the black dry ink
bottle.
1. Open the front processor access door and locate the black dry
ink bottle at the left side of the processor.
2. Place a drop cloth on the floor under the dry ink bottle area.
3. Remove the empty bottle by grasping the bottle handle. With a
slow, firm motion, pull the bottle from the bottle guide.
a. Pull the empty dry ink bottle out until it stops.
b. Move the green handle to the unlatched position.
c. Remove the empty bottle and discard it.
DocuTech 128/155/180 HighLight Color Operator Guide 3-13
Routine maintenance
Figure 3-8 Removing the empty bottle
4. To insert a new bottle, place the bottle on the edge of the bottle
guide.
a. With a slow, firm motion push the bottle into the dispense
position over the hopper.
b. Turn a new bottle of dry ink upside down and shake the
bottle thoroughly to loosen the contents. Insert the full
bottle until it stops.
Figure 3-9 Inserting and latching the bottle
c. Slide the full bottle all the way into the system.
3-14 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
d. Hold the bottle in place with one hand and remove the
paper seal by pulling it toward you with the other hand.
Discard the seal along with the drop cloth.
Figure 3-10 Removing the paper seal
5. Close the processor access door.
NOTE: If any dry ink should get on your skin, wash with mild
soap and cold water.
Replacing the highlight color container
The highlight color container holds the color dry ink. When
directed by a screen message, replace the highlight color
container. If the highlight color container is not replaced, the
printer stops, and it will not operate until the highlight color
container is replaced.
CAUTION: Do not use warm or hot water, or general cleaning
solvents to remove dry ink from your skin or clothing. The heat or
solvent will set 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.
If any dry ink should get on your clothes, brushing with a dry paper
towel or a stiff-bristled brush may remove the ink. If not, launder
your clothes with detergent and cold water. Tell a commercial dry
cleaner that the spot is dry ink or "toner" so that they will not use a
solvent that will set the dry ink stain.
1. Open the front processor access door and locate the highlight
color container at the right side of the processor.
2. Place a drop cloth on the floor under the highlight color
container area.
DocuTech 128/155/180 HighLight Color Operator Guide 3-15
Routine maintenance
3. Remove the empty container by grasping its handle. With a
slow, firm motion, remove the container.
Figure 3-11 Highlight color container
4. Pull the container out until it stops.
5. Remove the container and discard it.
6. To insert a new bottle, place the bottle on the edge of the bottle
guide. With a slow, firm motion, push the bottle into the
dispense position over the hopper.
7. After the bottle is in the dispense position, remove the seal.
You may encounter some resistance.
8. Close the processor door.
3-16 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
Changing the highlight color Customer Changeable Units
The highlight color Customer Changeable Unit (CCU) consists of
the color dry ink bottle and supporting equipment. In order to
change the highlight color or to service the wire module, you need
to remove the highlight color CCU from the printer.
If you have more than one highlight color CCU, a CCU cart is
provided to allow you to change and store the CCU. If you have
only one highlight color CCU, a service cart is provided to allow
you to remove the CCU for service.
CAUTION: CCU carts should be used exclusively for changing
and storing CCUs. You should always have at least one empty
cart at your site if your printer has more than one color CCU. Do
not attempt to remove or install a CCU without a cart.
CAUTION: Do not remove the CCU after a hard stop, such as
caused by a paper jam, system crash or restart, or opening a door
during printing, without first allowing the system to cycle up and
continue processing for a proper recovery.
Removing the CCU using the CCU cart
To remove the highlight color CCU from the printer:
1. If the printer is not cycled down, Pause the system before you
open the doors and attempt to remove the CCU.
2. Open the printer doors and locate the color housing area in the
center of the printer.
3. Open the top cover of an empty cart.
4. Push the cart up to the printer, lining up the yellow knob on the
cart with the yellow recess on the printer inner cover.
5. Push the cart firmly against the printer until you can feel the
two latch together.
6. Make sure the cart is level.
a. If the cart is not level, loosen the locknut holding the height
adjustment knob in place.
b. Use the height adjustment knob to regulate the level.
DocuTech 128/155/180 HighLight Color Operator Guide 3-17
Routine maintenance
c. When the HLC unit is level, tighten the lock nut.
Figure 3-12 Leveling the cart
7. Push down firmly on the cart pedal until you hear or feel the
pedal catch. The pedal should stay locked down. The pallet
within the cart is raised.
8. Unlatch the CCU by turning the photoreceptor backup roller
handle clockwise for a quarter turn to an upright position.
3-18 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
5. Then, turn the yellow CCU handle a quarter turn clockwise.
Figure 3-13 Unlatching the CCU
9. Using the metal flange of the color CCU, pull the CCU out of
the printer until it is completely in the cart. The flange is
located directly below the bottle.
Figure 3-14 Removing the CCU from the printer
10. Push down firmly on the cart pedal until you hear or feel a
click. The pallet, which now contains the CCU, is lowered into
DocuTech 128/155/180 HighLight Color Operator Guide 3-19
Routine maintenance
the cart. If the pallet does not move, check that the CCU is all
the way out of the printer and push down on the pedal again.
Figure 3-15 Closing the top cover
11. Close the top cover and store it.
Inserting a CCU
To insert a CCU, follow these steps.
1. Open the top cover of the cart containing the new color CCU.
2. Push the cart up to the printer, lining up the yellow knob on the
cart with the yellow recess on the printer inner cover. Make
sure the cart is level.
Figure 3-16 CCU on cart
3-20 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
3. Push the cart firmly against the printer until you can feel the
two latch together.
4. Push down firmly on the cart pedal until you hear or feel the
pedal catch. The pedal should stay locked down. The pallet
containing the CCU is raised.
5. Using the CCU metal flange, firmly push the CCU into the
printer.
6. Turn the yellow CCU handle counterclockwise for a quarter
turn. If it does not turn, check that the CCU is firmly seated in
the printer.
Figure 3-17 Turning the backup roller handle
counterclockwise
7. Turn the photoreceptor backup roller handle counterclockwise
for a quarter turn.
8. Make sure that the CCU is completely inserted into the
machine to prevent photoreceptor damage.
9. Push down firmly on the cart pedal until you hear or feel a
click. If the pallet does not drop, check that the CCU is all the
way in the printer and the pallet is released, then push down
on the pedal again.
10. Remove the cart from the printer and close the cart top cover.
11. Close the printer doors.
12. Store the cart.
DocuTech 128/155/180 HighLight Color Operator Guide 3-21
Routine maintenance
Storing the cart and CCU
NOTE: If any dry ink gets on your hands, wash them with soap
and cold water. Heat sets the ink permanently. If any dry ink gets
on your clothes, brush them with a dry paper towel or a stiff
bristled brush. If this does not remove the ink immediately, launder
with detergent and cold water. Tell the dry cleaners that the spot is
dry ink for a printer, so they will not use a solvent that sets the
stain.
When you are not using a cart and CCU, store them in a dry, dustfree area that has little variation in temperature and humidity. The
storage area should have a similar temperature and humidity to
the printer room. Maintain the temperature in the range of 60 to
80° F/15 to 26 C° and a relative humidity of 30 to 65 percent.
Removing the CCU using the service stand
Use the service stand to withdraw the highlight color CCU from the
printer. Use this stand if you do not have a cart.
To set up the service stand:
1. If the printer is not cycled down, Pause the system before you
open the doors and attempt to remove the CCU.
2. Open the printer doors and locate the color housing area in the
center of the printer.
3. Place the service stand next to the developer housing.
4. By turning the jack screws, adjust the height of the front feet so
that the alignment pins in the service stand are positioned just
below the hole and the docking bracket. Tighten the lock nuts
on the jack screws to lock the jack screws in position.
Figure 3-18 Service stand
3-22 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
5. Slide the stand toward the machine to engage the pins with
the holes and the slot. The end of the service stand may need
to be lifted slightly to ensure pin engagement.
6. With the service stand in position against the machine and the
pins engaged in the docking bracket, engage the locking
mechanism by applying a force forward on the lever and
compressing the latch spring while turning it to the position
shown.
7. Locate the pin squarely to the machine by ensuring that the
two (2) locating pins in the service stand are in contact with the
docking bracket.
8. With the service stand properly located to the machine and
while observing the level, turn the rear jack screws to adjust
the height of the service stand so that it is level.
9. Tighten the lock nuts on the jack screws to lock the jack
screws in position.
10. Unlatch the CCU by turning the photoreceptor backup roller
handle clockwise for a quarter turn to an upright position.
Figure 3-19 Unlatching the CCU
DocuTech 128/155/180 HighLight Color Operator Guide 3-23
Routine maintenance
6. Then, turn the yellow CCU handle a quarter turn clockwise.
Figure 3-20 Removing the CCU from the printer
11. Using the metal flange of the color CCU, pull the CCU out of
12. To replace the CCU, reverse the above steps.
Adding fuser shield
When directed by a message, add fuser lubricant as soon as
possible. If it is not added, the printer stops after approximately
5,000 prints and not run until fuser shield is added. Please read
the important note below.
NOTE: In 2006, the formula for the DocuTech HLC fuser lubricant
was changed to provide better image quality and to prevent image
transfer. The new fuser formula is called Fuser Shield. The fuser
blend and the fuser shield CANNOT be intermixed in a DocuTech
HLC. To change from one fuser lubricant to another requires a
service call and cleaning or replacing components. The two fuser
formulas are identified with different color bottles and caps. Be
sure the color of the cap of the bottle you are filing from matches
the color of the cap already in the system. Fuser shield
description: blue bottle, white cap with black printing. Fuser blend
description: yellow bottle, black cap with white printing.
the printer until it is completely in the stand. The flange is
located directly below the bottle.
WARNING: The fuser area can reach temperatures of
approximately 425°F (218°C). Exercise care to prevent burns
when working in this area.
3-24 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
CAUTION: Fuser lubricant for other printers is not compatible.
Do not use DocuTech and DocuPrint fuser agent in a DocuTech
HLC system. Do not use DocuTech HLC fuser shield in a
DocuTech 61xx or DocuPrint 1xx system. The fuser lubricants are
not compatible and will contaminate the system.
1. Open the processor doors.
2. Place a drop cloth on the floor under the fuser area.
3. Open the fuser drawer.
a. Locate the fuser drawer.
b. Grasp the green handle on the fuser drawer and pull it out
until it stops.
Figure 3-21 Opening the fuser drawer
WARNING: Fuser lubricant contains silicone, which can cause
irritation upon contact with the eye. Make sure that you wash your
hands with soap and water after you finish this procedure.
CAUTION: Fuser lubricant can cause damage to the CCU if any
of the it is spilled into the unit. Use extra care to ensure that no
fuser lubricant is dripped into the CCU.
4. Wipe the fuser lubricant filler area to remove any residual
lubricant.
5. Fill the fuser lubricant reservoir.
a. Pull the fuser lubricant reservoir out until it stops.
b. Remove the reservoir cap by turning it counterclockwise.
DocuTech 128/155/180 HighLight Color Operator Guide 3-25
Routine maintenance
Figure 3-22 Preparing to add fuser blend
WARNING: Fuser lubricant spills cause the floor to be slippery. If
any fuser lubricant is spilled onto the floor, it must be removed
immediately.
c. Open a new box of fuser lubricant and remove a bottle.
Remove the cap from the bottle of fuser lubricant.
d. Carefully pour the fuser lubricant into the reservoir until the
level reaches the MAX line. Avoid spilling the fuser
lubricant or overfilling the reservoir.
CAUTION: Do not push the fuser lubricant bottle into the
reservoir with excessive force. There is an anti-splash seal in the
reservoir that could be damaged.
3-26 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
Figure 3-23 Adding the fuser blend
e. Replace the reservoir cap by turning it clockwise
approximately one full turn. Do not overtighten the cap.
f. Inspect the area around the fuser to ensure no fuser blend
was spilled. Clean as required.
g. Push the fuser blend reservoir in until it stops.
6. Push the fuser drawer in until it latches into place.
Figure 3-24 Closing the fuser drawer
DocuTech 128/155/180 HighLight Color Operator Guide 3-27
Routine maintenance
Waste containers
7. Close the processor doors.
The fuser blend message disappears after the system makes
approximately 20 prints.
The waste containers in the DT 128/155/180 HLC collect dry ink
and developer after it has been used by the printer. When a
container becomes full, it must be replaced or the printer
eventually stops printing. This section contains the procedures for
replacing the toner and developer waste containers.
Replacing the 128/155/180 HLC developer waste container
To replace the developer waste container:
1. Open the processor doors and locate the dry ink cartridge at
the lower center of the printer. The developer waste container
is located below and to the right of the color dry ink bottle.
Figure 3-25 HLC developer waste container
2. Using your right hand, grasp the container by the handle on
top. With your thumb, depress the latch located above the
frame of the machine. Lift the edge of the container from the
tray and remove. Unscrew the cap from the front of the waste
container and use it to close the open end of the waste
container.
3. Discard the waste material and container appropriately.
3-28 DocuTech 128/155/180 HighLight Color Operator Guide
4. Insert the new waste HLC developer waste container into the
transport assembly. Push the retainer out of the way with your
thumb. Continue seating the new waste container onto the tray
and release the container latch.
5. Close the processor doors.
Replacing the 128/155/180 toner waste bottle
To replace the toner waste bottle:
1. Open the HLC module door.
Routine maintenance
Figure 3-26 Opening the HLC module door
2. Remove the toner waste bottle.
3. Remove the flat cap from the top front of the bottle.
DocuTech 128/155/180 HighLight Color Operator Guide 3-29
Routine maintenance
Figure 3-27 Flat cap on waste bottle
4. Place the flat cap on the round bottle opening and snap it
down. This prevents spillage when discarding the bottle.
5. Discard the waste material and container by placing the
container in the trash.
6. Obtain a new bottle and open it, placing the cap at the front of
the bottle and snapping it down.
7. Insert the new bottle into the waste module.
Figure 3-28 Inserting a new waste bottle
8. Close the HLC module door.
3-30 DocuTech 128/155/180 HighLight Color Operator Guide
Wire Module Removal and Replacement
Replace the wire module only when directed to by the Customer
Support Center.
CAUTION: In the following instructions, do not pull on the locating
arm of the developer housing. A bent or damaged locating arm
can cause component damage or image quality artifacts.
Do no touch the Electrostatic Voltage (ESV) mounted to the top of
the developer housing when removing the wire module. The ESV
is fragile, and susceptible to damage from electrostatic discharge.
To remove the wire module:
1. Open the processor doors.
2. Using the CCU cart or service stand, slide the HLC developer
module out of the printer Refer to the procedures on using the
CCU cart or service stand.
Routine maintenance
Figure 3-29 Wire module retainer springs
3. Release the wire module retainer springs. There is one at
each end at the front and back of the developer housing.
CAUTION: Handle the wire module with care since the wires can
be damaged or broken easily. Do not touch the donor rolls.
Touching the roll surface with your fingers can contaminate the
surface, causing image quality problems.
To replace the wire module:
1. Position the wire module on the HLC developer module.
DocuTech 128/155/180 HighLight Color Operator Guide 3-31
Routine maintenance
2. Ensure that the brush on the wire module is at the toner bottle
end as shown in the figure below.
Figure 3-30 Wire module assembly brush location.
3. Snap the wire module retainer springs behind the tabs.
4. Slide the HLC developer module into the machine.
5. Latch the CCU into place.
6. Remove the cart or service stand.
7. Close the doors.
3-32 DocuTech 128/155/180 HighLight Color Operator Guide
Cleaning the system and its components
NOTE: Follow the procedures in this section only when directed
by Xerox Customer Support center personnel.
Cleaning tasks consist of the following:
• Cleaning the 18/36-track cartridge tape drive
• Cleaning the 26-track cartridge tape drive
• Cleaning the DVD drive
• Cleaning the diskette drive
• Cleaning the sensors and the reflecting surfaces
• Cleaning the display
• Cleaning the exterior surfaces of the system
Cleaning the 18/36-track cartridge tape drive
Routine maintenance
A cleaning cartridge is shipped with each 18/36-track cartridge
tape drive. This cartridge should be replaced after 500 uses.
When the tape drive needs to be cleaned, CLEAN appears in the
message display after a cartridge is unloaded and during a rewind
or locate operation.
NOTE: CLEAN is a status message, not an error message.
CAUTION: Never power off the tape drive without following the
cleaning procedure once the CLEAN message appears.
CAUTION: The cleaning cartridge must be undamaged and
clean.
To clean the 18/36-track cartridge tape drive read/write heads:
1. Remove any cartridge loaded in the tape drive.
2. Insert the cleaning cartridge.
The cleaning cycle takes approximately 15 seconds.
3. Remove the cleaning cartridge when it is unloaded.
4. Mark the usage on the tape label. Do not use a grease pencil.
You must clean the 18/36-track cartridge tape drive regularly to
keep it functioning properly.
DocuTech 128/155/180 HighLight Color Operator Guide 3-33
Routine maintenance
Cleaning the 26-track cartridge tape drive
Cleaning the DVD drive
The 26-track, or quarter inch cartridge (QIC) tape drive heads
should be cleaned at least once a week. If you use the drive for
eight hours or more per day, then you should clean the drive daily.
The process is simple and requires little time.
1. If there is a cartridge in the tape, remove it.
2. Insert the cleaning cartridge in the tape drive and close the
door. Cleaning begins automatically once the tape is inserted.
3. Allow the tape to run for approximately 30 seconds, then
remove it.
NOTE: Replace the foam pad on the cleaning cartridge after it
has been used three times. The cleaning cartridge itself can
be used 100 times.
Follow the DVD cleaning directions and recommended cleaning
frequency.
1. If there is a DVD disk in the drive, remove it.
2. Follow the directions to clean the DVD drive.
Cleaning the diskette drive
The floppy disk drive must be cleaned at recommended intervals
to prevent read and write disk errors.
To clean the diskette drive:
1. If there is a diskette in the floppy disk drive, remove it.
2. Insert the cleaning diskette into the disk drive.
3. Follow the directions on the cleaning diskette to clean the
diskette drive.
4. Remove the cleaning diskette.
3-34 DocuTech 128/155/180 HighLight Color Operator Guide
Cleaning the sensors and the reflecting surfaces
CAUTION: Never use abrasive materials or strong solvents when
cleaning sensors.
The following is a list of sensors to clean:
• Q850 and Q861 sensor
• Q1011/1009 sensor and mirror
• High Capacity Feeder/Stacker configuration
• Q1106 sensor
• Q1166 sensor
• Q1107 sensor
• Q1164 sensor
• Production publisher configuration (finisher sensors)
• Q1201 sensor
• Q1202 and Q1203 sensors
Routine maintenance
• Q1205, Q1206, and Q1207 sensors
• Q1213 sensor
• Q1221, Q1218, and Q1227 sensors
• Q1222 and Q1210 sensors
Cleaning the Q850 and Q861 sensor
1. Open the right and left doors of the printer and locate Area 4.
2. Raise the Area 4 green handle until it locks into place.
DocuTech 128/155/180 HighLight Color Operator Guide 3-35
Routine maintenance
Figure 3-31 Area 4 and green handle
3. Locate the Q850 and Q861 sensor.
Figure 3-32 Q850 and Q861 sensor
3-36 DocuTech 128/155/180 HighLight Color Operator Guide
4. Place a dry cleaning pad on the sensor and move it from left to
right to clean the sensor.
5. Lower the Area 4 green handle.
6. Close the printer doors.
Cleaning the Q1011/1009 sensor and mirror
1. Open the right and left doors of the printer and locate the
Q1011/1009 sensor.
Routine maintenance
Figure 3-33 Q1011/1009 sensor and mirror
2. Apply a small amount of lens and mirror cleaner to a cleaning
pad.
3. Wipe the sensor gently with the cleaning pad.
Cleaning the Q1106 and Q1166 sensors
NOTE: High volume printer configuration only
To access sensors Q1106 and Q1166, open the top cover of the
high capacity stacker.
To clean the sensors:
1. Brush or wipe the sensor windows lightly.
2. Remove any dust present in the area.
DocuTech 128/155/180 HighLight Color Operator Guide 3-37
Routine maintenance
Figure 3-34 Q1106 and Q1166 sensors
Cleaning the Q1107 sensor
NOTE: High volume printer configuration only
To access sensor Q1107, open the top cover of the high capacity
stacker.
To clean the sensor:
1. Brush or wipe the sensor windows lightly.
2. Remove any dust present in the area.
3-38 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
Cleaning the Q1164 sensor
NOTE: High volume printer configuration only
To access sensor Q1164, open the top cover of the last feeder/
stacker module, the one containing the purge tray.
To clean the sensor:
1. Brush or wipe the sensor windows lightly.
2. Remove any paper dust present in the area.
Figure 3-35 Q1107 sensor
DocuTech 128/155/180 HighLight Color Operator Guide 3-39
Routine maintenance
Figure 3-36 Q1164 sensor
Cleaning the display
The display should be cleaned as required.
Clean the display with a soft, lint-free cloth dampened with a glass
or lens and mirror cleaner. Do not spray the liquid directly onto the
display because it may cause damage.
Cleaning the exterior surfaces of the system
Clean the exterior surfaces of the printer daily, if possible.
Clean the exterior surfaces with a mild household detergent that
has been poured or sprayed onto a cloth lightly dampened with
water. Do NOT saturate the cloth; just dampen it.
CAUTION: Liquids must not be allowed to drip onto anything
electrical or mechanical. Also, never spray or pour any cleaner
directly onto the keyboard or the exterior surfaces of the system.
3-40 DocuTech 128/155/180 HighLight Color Operator Guide
Clearing or cleaning the finisher sensors
NOTE: Production publisher configuration only
Clearing the finisher sensors should be performed only when
directed by a Customer Support Center Representative.
NOTE: The finisher sensors are located under the processor top
cover, under the finisher top cover, and behind the finisher and
bindexer doors.
Use the following procedure to clear any obstructions from the
finisher sensors.
1. Fold a sheet of 8.5 x 11 inch (216 x 279 mm) paper, as shown
in figure 3-36.
Routine maintenance
Figure 3-37 Folding the paper
2. Use the folded sheet of paper to clear any obstructions in the
following sensor areas.
Clearing the Q1201 sensor
NOTE: Production publisher configuration only
Clearing the Q1201 sensor should be performed only when
directed by a Customer Support Center Representative.
1. Open the processor top cover.
NOTE: The Q1201 sensor is located under the processor top
cover on the right side.
2. Locate the Q1201 sensor, as shown in figure 3-37
DocuTech 128/155/180 HighLight Color Operator Guide 3-41
Routine maintenance
Figure 3-38 Locating the Q1201 sensor
3. Brush a folded sheet of paper under the sensor to clear any
obstructions.
4. Close the processor cover.
Clearing the Q1202 and Q1203 sensors
NOTE: Production publisher configuration only
Clearing the Q1202 and Q1203 sensors should be performed only
when directed by a Customer Support Center Representative.
1. Open the finisher top cover.
2. Locate the Q1202 and Q1203 sensors, as shown in figure 3-
38.
3-42 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
Figure 3-39 Locating the Q1202 and Q1203 sensors
3. Brush a folded sheet of paper under each sensor to clear any
obstructions, as shown in figure 3-39.
Figure 3-40 Clearing the Q1202 and Q1203 sensors
4. Close the finisher top cover.
DocuTech 128/155/180 HighLight Color Operator Guide 3-43
Routine maintenance
Cleaning the Q1222 and Q1210 sensors
NOTE: Production publisher configuration only
Cleaning the Q1222 and the Q1210 sensors should be performed
only when directed by a Customer Support Center
Representative.
1. Open the finisher top cover.
2. Look down at the rear section of the tilt bed area, as shown in
figure 3-40, to view the sensors.
Figure 3-41 Locating the Q1222 and Q1210 sensors
3. Locate the Q1222 and Q1210 sensors, as shown in figure 3-
41
3-44 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
Figure 3-42 Locating the Q1222 and Q1210 sensors
4. Wipe each sensor gently with a soft cloth to clean them.
5. Close the finisher top cover.
Clearing the Q1205, Q1206, and Q1207 sensors
NOTE: Production publisher configuration only
Clearing the Q1205, Q1206, and Q1207 sensors should be
performed only when directed by a Customer Support Center
Representative.
1. Open the finisher front doors.
2. Open the bindexer door.
3. Locate the Q1205, Q1206, and Q1207 sensors, as shown in
figure 3-42.
DocuTech 128/155/180 HighLight Color Operator Guide 3-45
Routine maintenance
Figure 3-43 Locating the Q1205, Q1206, and Q1207 sensors
4. Brush a folded sheet of paper across each sensor to clear any
obstruction.
5. Close the bindexer and finisher doors.
Clearing the Q1213 sensor
NOTE: Production publisher configuration only
Clearing the Q1213 sensor should be performed only when
directed by a Customer Support Center Representative.
1. Open the finisher doors.
WARNING: The top of the binder is approximately 425°F (218°C).
Do not touch the heated areas or you may get burned. If the
binder has been in a "Ready" condition, allow it to cool for at least
1 hour before continuing the procedure.
2. Grasp the green handle on the binder drawer. Pull the drawer
out until it stops.
3. Locate the Q1213 sensors, as shown in figure 3-43
3-46 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
Figure 3-44 Q1213 sensor
4. Brush a folded sheet of paper across the sensor to clear any
obstruction.
5. Close the binder drawer and the finisher doors.
Clearing the Q1221, Q1218, and Q1227 sensors
NOTE: Production publisher configuration only
Clearing the Q1221, Q1218, and Q1227 sensors should be
performed only when directed by a Customer Support Center
Representative.
1. Open the finisher front doors.
2. Locate the Q1221, Q1218, and Q1227 sensors, as shown in
figure 3-44.
DocuTech 128/155/180 HighLight Color Operator Guide 3-47
Routine maintenance
Figure 3-45 Locating the Q1221, Q1218, and Q1227 sensors
Cleaning the binder
NOTE: Production publisher configuration only
Keep the binder clean to prevent binder tape jams. Clean the
binder once a week, or as needed, and also when changing the
binder tape.
It is highly recommended that the binder be cleaned before the
binder warm-up cycle begins or before switching the system on.
The following steps must be performed to clean the binder.
WARNING: All areas of the binder drawer, including the binder
tape, are hot, approximately 425°F (218°C), and may cause a
serious burn. If the binder has been in a "Ready" condition, allow
the binder to cool for at least one hour before continuing the
procedure.
1. Open the finisher doors.
WARNING: A sharp edge on the plastic binder platen cleaner or
on the tape spool sometimes occurs as a result of removing the
cleaner. This sharp edge could cause finger cuts.
CAUTION
CAUTION: To avoid damage to the system, do not use any
liquids or any abrasive material to clean the binder. Use the plastic
binder platen cleaner on the tape reel or use a clean, lint-free
cloth.
3-48 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
2. Grasp the green handle on the binder drawer. Pull the drawer
out until it stops.
Figure 3-46 Opening the binder drawer
3. Perform the following steps:
a. Locate and remove the plastic binder platen cleaner from
the binder tape reel, as shown in the following figure.
Figure 3-47 Binder platen cleaner
b. If binder tape is in the area of the cleaner, pull the reel
slightly away from the tape to avoid tape damage.
c. Lift up on the cleaner and push down against the single
DocuTech 128/155/180 HighLight Color Operator Guide 3-49
Routine maintenance
Cleaning the binder tape guides
end tab. Move the cleaner back and forth until the end tab
breaks.
d. Continue to move the cleaner in the same manner until the
2-sided tabs break.
NOTE:
NOTE: Ensure that the following cleaning procedures are
performed in the order listed.
NOTE: Production publisher configuration only
The following steps must be performed to clean the binder tape
guides.
1. Use the binder platen cleaner to clean the surfaces and
grooves of the tape guides.
2. Ensure that all the glue is removed from the grooves on the
tape guides.
Figure 3-48 Cleaning the tape guides
Cleaning the binder platen
NOTE: Production publisher configuration only
The following steps must be performed to clean the binder platen.
3-50 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
1. Use the binder platen cleaner to clean the top and side
surfaces of the binder platen until all the glue is removed.
2. Ensure that the glue is removed from the grooves on the
binder platen surface, which align with the top and bottom
edges of the book.
Cleaning the flappers
NOTE: Production publisher configuration only
Using the binder platen cleaner, clean the top and side surfaces of
the binder flappers until all the glue is removed.
Figure 3-49 Cleaning the binder platen
DocuTech 128/155/180 HighLight Color Operator Guide 3-51
Routine maintenance
Cleaning the calipers
NOTE: Production publisher configuration only
Using the binder platen cleaner, clean the binder caliper surfaces
until all the glue is removed.
Figure 3-50 Cleaning the flappers
3-52 DocuTech 128/155/180 HighLight Color Operator Guide
Routine maintenance
Figure 3-51 Cleaning the calipers
Closing the binder
NOTE: Production publisher configuration only
Perform the following steps to close the binder.
1. Push in the binder drawer until it stops.
2. Close the finisher doors.
3. Place the platen cleaner in a safe place.
Replacing the stitcher spool A
NOTE: Production publisher configuration only
Use this procedure to replace stitcher spool A in the system.
Check stitcher spools A and B visually during the warm-up cycle.
Stitcher spool A is the spool on top, and stitcher spool B is the
spool on the bottom.
If spool B needs new wire, call the customer support center.
There is a label behind the stitcher panel that gives instructions for
replacing the stitcher spool A. Refer to this label if needed.
The following steps must be performed to replace the stitcher
spool A.
DocuTech 128/155/180 HighLight Color Operator Guide 3-53
Routine maintenance
1. Open the finisher doors.
2. Lift the stitcher panel, which is located directly above the
stitcher spools.
3. Pull the green stitcher head release handle forward and up
until it latches into place, as shown in figure 3-51.
Figure 3-52 Releasing the stitcher head
4. Remove the stitcher wire plug.
a. The stitcher wire plug is located above the binder area, as
shown in figure 3-52.
b. Press and hold down the release clip.
c. Pull the plug out of the stitcher head.
3-54 DocuTech 128/155/180 HighLight Color Operator Guide
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