XEROX N2025 User Manual
DocuTech 61xx Production Publisher Family
701P48388
February 19, 2008
Operator HandyBook
The purpose of this HandyBook is to provide a quick reference for the operator. It does not
replace the Operator Guide or other Xerox supplied reference materials.
More information is available at www.Xerox.com. The Operator Guide is available for download
as well.
Prepared by:
Xerox Corporation BGO/PSG/PDU/Cost Productivity
800 Phillips Road, 207-02Z
Webster, New York 14580
USA
© 2008 Xerox Corporation. All rights reserved. Xerox® and the sphere of connectivity design are trademarks of
Xerox Corporation in the US and/or other countries.
Changes are periodically made to this document. Changes, technical inaccuracies, and typographic
errors will be corrected in subsequent editions
Table of Contents
Table of Contents......................................................................3
1. System Hardware.................................................................7
Processor Components................................................................................................................ 8
Interposer Components................................................................................................................ 9
Finisher Components ................................................................................................................. 10
Paper Path Areas ....................................................................................................................... 11
2. Paper Trays & Loading Media...........................................13
Paper Tray & Finisher Capacities............................................................................................... 13
Adding Paper to Tray 1 or 2 ....................................................................................................... 16
Adding Paper to Trays 3, 4, or 5................................................................................................. 18
Loading Transparencies............................................................................................................. 19
Re-Loading Tabs........................................................................................................................ 19
Adding Inserts............................................................................................................................. 20
Satisfaction Guides..................................................................................................................... 21
Satisfaction Guide for Paper Trays 1 and 2 .................................................................. 21
Satisfaction Guide for Paper Tray 3.............................................................................. 22
Satisfaction Guide for Paper Tray 4.............................................................................. 23
Satisfaction Guide for Paper Tray 5.............................................................................. 23
Satisfaction Guide for 2-Sided Printing ......................................................................... 24
Satisfaction Guide for Various Stocks........................................................................... 24
Satisfaction Guide for Stitcher....................................................................................... 26
3. Recommended Shift Preventative Maintenance Plan ....27
4. Replacing Consumables ...................................................29
Add Fuser Agent........................................................................................................................ 29
Replace Stitcher A Wire ............................................................................................................. 31
Replace the Binder Tape Reel................................................................................................... 34
Replace the Toner (Dry Ink) Bottle.............................................................................................37
Replace the Toner (Dry Ink) Waste Container........................................................................... 38
Order Supplies, Consumables, and Parts.................................................................................. 40
5. Machine Maintenance........................................................41
Adjusting for Paper Curl ............................................................................................................. 41
Adjusting the Heavy Paper Levers............................................................................................. 44
Adjust the Binder Tape Registration........................................................................................... 46
Enable a Paper Tray for Clean up..............................................................................................47
Enable or Disable the Binder...................................................................................................... 47
Enable or Disable the Stacker....................................................................................................48
Enable or Disable the Stitcher....................................................................................................48
Modify the Bindexer Capacity Number.......................................................................................49
Modify the Lighter / Darker Setting.............................................................................................49
Stop a Job From Printing at the Printer...................................................................................... 50
6. Problem Solving.................................................................51
COMMON FAULT CODES & CASE .......................................................................................... 52
PROBLEM LISTING AND SOLUTIONS, LISTED by CASE NUMBER ..................................... 55
Solutions in Alphabetical Order.................................................................................................. 66
Clean Finisher Entrance Sensor (Q1201).................................................................................. 68
Clean the Bin A Bindexer Sensor (Q1205)................................................................................. 71
Clean the Bin B Bindexer Sensor (Q1206)................................................................................. 72
Clean the Binder Tape Guide Sensor (Q1213).......................................................................... 73
DT6180 HandyBook
Clean the Bindexer Sensors (Q1205, Q1206, Q1207)............................................................... 74
Clean the Bins Exit Sensors (Q1222)......................................................................................... 75
Clean the Front Stack (Q1227), Rear Stack Height (Q1218), and Set Path (Q1221) Sensors. 77
Clean the Fuser (Q1010) and Prefuser Sensors (Q1009) ......................................................... 80
Clean the Post Inverter (Q1202) and Output Transport (Q1203) Sensors ................................ 82
Clean the Pre-Fuser Sensor (Q1009) ........................................................................................ 84
Clean the Registration Transport Sensor (Q861).......................................................................85
Clean the Set Path Sensor (Q1221)........................................................................................... 86
Clean the Tape Binder Area.......................................................................................................89
Clear Paper Jams in Areas 11, 12, 13, and 14 .......................................................................... 91
Clear Paper Jams in Areas 11, 12, and 13 ................................................................................ 94
Clear Paper Jams in Areas 13, 14, and 15 ................................................................................ 97
Clear Paper Jams in Areas 17 and 18 ..................................................................................... 100
Clear the Entire Paper Path From the Paper Trays to the Finisher ......................................... 102
Clear the Fault in the Printer Fault Clearance Window............................................................ 102
Clear the Paper Jam in Area 4................................................................................................. 103
Clear the Paper Jam in Areas 11, 14, 17, and 18.................................................................... 103
Clear the Paper Jam in Areas 12, 13, 14, and 15.................................................................... 107
Clear the Paper Jam in Areas 3 and 4..................................................................................... 111
Clear the Paper Jam in Areas 5 and 6..................................................................................... 112
Clear the Paper Jam in Areas 7, 6, and 5................................................................................ 113
Clear the Paper Jam in Areas 8 and 9..................................................................................... 115
Clear the Paper Jam in Areas 8, 11, 12, and 13...................................................................... 116
Clear the Paper Jams in Areas 16 and 17 ............................................................................... 119
Clear the Paper Jams in Areas 17 and 19 ............................................................................... 121
Clear the Paper Jams in Areas 7, 6, 5, 4, and 2 ...................................................................... 123
Clear the Stitcher A Fault ......................................................................................................... 125
Fan the Paper, Turn the Paper Over, and Reload ................................................................... 127
If Paper is Jammed in the Fuser, Release the Camming Motor Brake....................................127
If Printing to the Edges of the Paper Stock, set Lead Edge Screening to Stress .................... 128
If the Job is Sent From a DigiPath, Clean the Document Glass on the DigiPath..................... 129
Lower the Decurler Baffle Above Area 7.................................................................................. 129
Open and Close the Area 3 and 4 Baffles Securely................................................................. 130
Open and Close the Area 4 Baffle Securely............................................................................. 130
Open and Close the Area 9 Baffle Securely............................................................................. 131
Open and Close the Finisher Top Cover and the Finisher Front Doors................................... 131
Perform an Immediate Shutdown at the DocuSP..................................................................... 132
Power OFF, Reset the Printer Circuit Breakers, Then Power ON........................................... 132
Power OFF, Then Power ON the Printer.................................................................................. 133
Push Down on the Stacker Safety Door...................................................................................134
Read the Meter.........................................................................................................................135
Release the Camming Motor Brake......................................................................................... 135
Remove Paper From Interposer Areas B1 and B2................................................................... 137
Reset the White Power Switch................................................................................................. 138
Select Reset / Restart From the Fault Frame........................................................................... 138
Tap on the Toner (Dry Ink) Cartridge to Loosen the Toner...................................................... 139
Use A New Ream of Paper ...................................................................................................... 139
7. Perform Printer Functions...............................................141
1. Add a Font to the DocuSP Controller.................................................................................. 142
2. Allow Main, Aux, Auto, or Unspecified to be Used as Stock Names .................................. 143
3. Backup VIPP Files Before an Upgrade............................................................................... 144
4. Check the Systems Queue Output Location and Finishing Selections...............................145
5. Clear the Faulted Job.......................................................................................................... 146
6. Create a New Queue........................................................................................................... 147
7. Delete a Job in Job Manager............................................................................................... 148
DT6180 HandyBook
8. Disable Stock Size Checking............................................................................................... 149
9. Display all Active Machine Faults........................................................................................ 150
10. Enable and Bring On-line an External Finisher................................................................. 151
8. Programming Features....................................................153
Add Binding to a Job ................................................................................................................ 153
Enable Duplex Mode................................................................................................................ 153
Enable Offset Stacking.............................................................................................................154
Export the Accounting Log ....................................................................................................... 155
Program Image Shift for a Job.................................................................................................. 156
Program Paper Tray 5 as a Non-Fusing Tray.......................................................................... 156
Program Tabs...........................................................................................................................157
Program the PCL Paper Stock Sequences to Pull From a Specific Paper Tray at the Printer 158
Uncheck the Job Ticket in Job Forwarding .............................................................................. 161
Setup Job Forwarding for Printer to Printer in DocuSP............................................................ 162
9. Sensor Maps.....................................................................165
Paper Handling Module Sensor Locations............................................................................... 165
Inverter Sensor Locations......................................................................................................... 166
Finisher Sensor Locations........................................................................................................ 167
Interposer Sensor Locations..................................................................................................... 168
DT6180 HandyBook
System Hardware
DT6180 HandyBook 6
System Hardware
1. System Hardware
DT6180 HandyBook 7
Processor Components
System Hardware
Processor Components
1. Paper trays
2. Electrical module
3. Dry ink cartridge
4. Photoreceptor, located behind a panel
5. Laser, located behind a panel
6. Fuser agent reservoir
7. Inverter
8. Decurler lever
9. Dry Ink Waste container
DT6180 HandyBook 8
Interposer Components
System Hardware
Interposer Components
1. Upper entrance transport
2. Upper vertical transport
3. Upper turn transport
4. Tray 4
5. Upper exit transport
6. Tray 5
7. Lower entrance transport
8. Lower turn transport
9. Lower exit transport
10.Lower vertical transport
11. Loop transports
DT6180 HandyBook 9
Finisher Components
System Hardware
Finisher Components:
1. Bindexer
2. Stitcher
3. Stacker
4. Binder
5. Binder tape reel
6. Stitcher wire spools
7. Top tray
DT6180 HandyBook 10
System Hardware
Paper Path Areas
The numbers in figure 4-6 identify the following paper path are as follows:
• Areas 1 to 4 - The stock leaves a paper tray and is fed to the photoreceptor.
• Areas 5 to 10 - The system prints an image on one side of the stock. If the job requires
2-sided printing, the system turns the page over and feeds it back to the photoreceptor.
• Areas A to H - This is the interposer area. Paper travels through this area if paper is fed
from trays 1, 4 or 5 and also to pass paper from area 10 (through F and H) to the finisher.
• Areas 11 and 12 - If the prints are to be fed to the top tray, the system delivers the prints
through the top tray slot.
• Areas 13 to 16 - The prints enter the bindexer and are collated, if desired.
• Areas 17 to 19 - The prints are stitched in area 17, or bound in area 18, if desired, and
placed on the stacker in area 19.
DT6180 HandyBook 11
Paper Trays & Loading Media
DT6180 HandyBook 12
Paper Trays & Loading Media
2. Paper Trays & Loading Media
Paper Tray & Finisher Capacities
Stock Weight (all trays)
Tray 1 Stock sizes
Tray 1 Capacity
Tray 2 Stock sizes
Tray 2 Capacity
Tray 3 Stock sizes
Tray 3 Capacity
Tray 4 Stock sizes
Tray 4 Capacity
DT6180 HandyBook 13
Substance 16 to 110 (60 to 200 g/m2)
• US Letter (8 1/2 x 11 inches)
• US Legal (8 1/2 X 14 inches)
• 9 x 11 inches
• A4
• 8 1/2 x 13 inches
• 223 x 297 mm
• Custom (Width = 8 to 9 inches (203 to 229 mm), Length = 10
to14 inches (254 to 356 mm))
1100 sheets, substance 20 (75 g/m2)
• US Letter (8 1/2 x 11 inches)
• US Legal (8 1/2 x 14 inches)
• 9 x 11 inches
• A4
• 8 1/2 x 13 inches
• 223 x 297 mm
• Custom (Width = 8 to 9 inches (203 to 229 mm), Length = 10 to
• 14 inches (254 to 356 mm))
600 sheets, substance 20 (75 g/m2)
• US Letter (8 1/2 x 11 inches)
• US Legal (8 1/2 x 14 inches)
• US Ledger (17 x 11 inches)
• 9 x 11 inches
• A3
• A4
• 8 1/2 x 13 inches
• 223 x 297 mm
• ISO B4
• JIS B4
• Custom (Width = 8 to 17 inches (203 to 432 mm), Length = 10
to14.33 inches (254 to 364 mm))
2600 sheets, substance 20 (75 g/m2)
• US Letter (8 1/2 x 11 inches)
• US Legal (8 1/2 x 14 inches)
• US Ledger (17 x 11 inches)
• 9 x 11 inches
• A3
• A4
• 8 1/2 x 13 inches
• 223 x 297 mm
• ISO B4
• JIS B4
• Custom (Width = 8 to 17 inches (203 to 432 mm), Length = 10
to14.33 inches (254 to 364 mm))
550 sheets, substance 20 (75 g/m2), post-process only
Paper Trays & Loading Media
Tray 5 Stock sizes
Tray 5 Capacity
Inverter Stock sizes
Top Tray Stock Sizes
Top Tray Capacity
Stacker Stock Sizes
Stacker Capacity
Stitcher Stock Sizes
Capacity
Stitches per spool
Binder Stock sizes
Binder Capacity
Binds per spool
Bindexer Capacity
Sheets are spilling out
of the top tray
• US Letter (8 1/2 x 11 inches)
• US Legal (8 1/2 x 14 inches)
• US Ledger (17 x 11 inches)
• 9 x 11 inches
• A3
• A4
• 8 1/2 x 13 inches
• 223 x 297 mm
• ISO B4
• JIS B4
• Custom (Width = 8 to 17 inches (203 to 432 mm), Length = 10 to
• 14.33 inches (254 to 364 mm))
2600 sheets, substance 20 (75 g/m2), pre or post-process
8 x 10 inches to 17 x 11 inches (203 x 254 mm to 432 x 279 mm)
8x10 inches to 17 x 11 inches (203 x 254 mm to 432 x 279 mm)
500 sheets, substance 20 (75 g/m2)
8 x 10 inches to 9 x 14 inches (203 x 254 mm to 229 x 356 mm)
3000 sheets (1500 inboard and 1500 outboard), substance 20
(75 g/m2)
8 x 10 inches to 9 x 14 inches (203 x 254 mm to 229 x 356 mm)
See Satisfaction Guide for Stitcher
2 to 70 sheets, substance 20 (75 g/m2)
Approximately 35,000
8.5 x 11 inches (216 x 279 mm)
15 sheets (7 sheets with index covers) to 125 sheets of
substance 20 (75 g/m2) or equivalent thickness
Approximately 425
The bindexer contains three bins used by the system to sort sets.
The
capacity of each bin is 125 sheets of substance 20 (75 g/m2) or 0.5
inch
(13 mm) thickness.
Include inserts and covers when considering the output capa city of
the
bindexer.
125 sheets of substance 20 (75 g/m2) is equal to approximately:
104 sheets of substance 24 (90 g/m2)
78 sheets of substance 32 (120 g/m2)
47 sheets of substance 110 (200 g/m2).
Check that the sets in the bindexer are less than 0.5 inch (13 mm)
thick.
If the set exceeds 0.5 inch (13 mm) thickness, reprogram the job for
fewer
sheets or reduce the number of heavy-weight sheets.
When running collated, unfinished sets, the maximum sheet capacity
of the
bindexer can be set between 50 and 125.
When running anything other than collated, unfinished sets, the
maximum
sheet capacity of the bindexer will remain at 125.
The capacity of the top tray is 500 sheets of substance 20 (75 g/m2)
or 2
inches (51 mm) in height. When intermixed stock or paper heavier
DT6180 HandyBook 14
Paper Trays & Loading Media
than
substance 20 (75 g/m2) is being run, the capacity of the top tray is
reduced.
500 sheets of substance 20 (75 g/m2) is equal to approximately:
415 sheets of substance 24 (90 g/m2)
310 sheets of substance 32 (120 g/m2)
225 sheets of substance 110 (200 g/m2)
If using any paper heavier than substance 20 (75 g/m2) or
intermixed stock
of different weights, unload the top tray before the count in the tray
reaches
its capacity limit.
Refer to the satisfaction guides in the "Technical information"
chapter.
DT6180 HandyBook 15
Paper Trays & Loading Media
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.
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.
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.
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 below. This is
indicated by the green arrow on the bottom of the tray.
DT6180 HandyBook 16
Paper Trays & Loading Media
Move the rear guide forward until it touches the edge of the stack.
Lower the feed belt.
Close the tray slowly, but firmly, until it latches.
DT6180 HandyBook 17
Paper Trays & Loading Media
Adding Paper to Trays 3, 4, or 5
1. Press the Tray unlock button on the front of the tray. Wait for the red "Please wait" light to
go off.
NOTE: If the tray is not pulled out all of the way, the tray elevator will not go down as
paper is added.
2. When the green "Ready to open" light comes on, pull the tray out until it stops.
3. Move the rear and side guides away from the paper stack, as shown below.
4. Load the required paper into the paper tray. Load paper with the curl side facing down.
Load Xerox paper with the package wrapper seam side facing up.
NOTE: When loading drilled paper, be sure to fan the edge where the holes are located.
5. Position the stack against the front left corner of the tray, as shown below. This is
indicated by the green arrow on the bottom of the tray.
6. Move the rear and side guides until they touch the paper stack.
7. Close the tray slowly, but firmly, until it latches.
DT6180 HandyBook 18
Paper Trays & Loading Media
Loading Transparencies
The following are the different types and usage of transparencies for Paper Trays 1, 2 and 3.
• Transparencies with a 13 mm (0.5 inch) white stripe should be loaded with the white
stripe to the right if you are using Paper Trays 1 and 2. Load the shiny side up for
optimum performance.
• Removable stripe transparencies: Do not load more than 50 removable-stripe
transparencies into Paper Trays 1 and 2. With the white stripe to the right, place the
transparencies on top of approximately 50 sheets of paper in the tray. Do not run as
inserts to a bound job. Printing is not allowed on inserts.
• High speed transparencies with paper backing: Run these types of transparencies from
Paper Trays 1 and 2 with the paper side down, and from Paper Tray 3 with the paper
side up.
Re-Loading Tabs
For DocuSP version 3.X or higher:
There are two methods to replenish tab stock in the paper trays.
Option 1:
1. Open the paper tray where the tab stock is loaded.
2. Remove any tabs so that there is a full bank of tabs on top of the stack.
3. Add additional tab stock.
4. Close the paper tray.
Option 2:
1. Open the paper tray where the tab stock is loaded.
2. Add additional tab stock to the bottom of stack.
3. From the DocuSP for DocuTech 2000 series 61XX screen, select [Printer Manager].
Information about each paper tray will be displayed.
4. Select the line that has the information about the paper tray you are adding tab stock to.
A menu will be displayed.
5. Select [Properties] from the menu. The Tray Properties window will be displayed.
6. Select the check box next to [Set Sequence Position]. The box below the Set Sequence
Position box will become active.
7. Enter the number of tabs remaining in the bank of tabs on top of the stack in the paper
tray. For example, if there are three tabs remaining on top of the stack in the tray, enter
the number [3] in this box.
8. Select the check box next to [Check Override Programming] in the lower, left corner of
the window.
9. Select [OK].
10. Close the paper tray.
For DocuSP version 2.X or lower:
1. Open the paper tray where the tab stock is loaded.
2. Remove any tabs so that there is a full bank on top of the stack.
3. Add additional tab stock.
4. Close the paper tray.
DT6180 HandyBook 19
Paper Trays & Loading Media
Adding Inserts
For DocuSP 4.x and above:
Creating inserts differs from slip sheets in that they separate pages of a job while slip sheets
separate one job from another. Inserts may also be pre-printed stock or forms.
NOTE: Inserts may not be programmed for a job with covers if the inserts affect the cover
printing. For example, inserts are not allowed between pages printed on the front and back of a
cover. An insert request takes precedence over an exception page request. When two or more
special pages are programmed (covers, inserts, or exception pages) image ordering conflict s may
occur. Make sure that programmed options do not conflict.
1. From the DocuSP screen, logon as a System Administrator. See the Related Items
below for additional information.
2. Under Managers on the left, under the Job button, right-click on your job and select
[Properties] from the menu.
3. Click on the [Special Pages] tab.
4. Click on the [Inserts] button, and then click on [Add Inserts] button. The Insert screen will
be displayed.
5. If the insert is to be the first page, enter 0 (zero) in the After Pages field, and then the
number of inserts required in the Pages field. The result will be the insert being the first
page in the job.
6. Click on the [Add Insert] button.
7. Click on [Close].
8. Click [OK].
DT6180 HandyBook 20
Satisfaction Guides
Satisfaction Guide for Paper Trays 1 and 2
Stock Reliable feeds may be
expected
Size 8 x 10 inches to 9 x 14
inches (203 x 254 mm to
229 x 356 mm)
Weight Substance 20 to 110 (75 to
200 g/m2)
Capacity Tray 1 - 1100 sheets,
substance 20 (75 g/m2)
Tray 2 - 600 sheets,
substance 20 (75 g/m2)
Type or
condition
Xerographic bond paper in
good condition
Drilled stock, fanned
thoroughly
Tab stock in perfectly flat
condition
Less reliable feeds may be
expected
Stock smaller than 8 x 10
Substance 16 to 19 (60 to 72
g/m2)
For greater capacity, use
Slightly curled paper
Intermixed weights
Transparencies
Label stock
Adhesive drafting film
Paper with reinforced edges
Paper Trays & Loading Media
Suggested alternatives
inches cannot be used.
For stock larger than 9 x 14
inches (229 x 356 mm), refer
to the tray 3 satisfaction
guide.
Weights outside the limits
shown are not
recommended.
Substance 110 (200 g/m2)
must be long grain. Do not
use short grain.
Tray 3.
Do not use excessively
curled paper
Substance 110 (200 g/m2)
must be long grain. Do not
use short grain.
Use transparencies with a
white stripe.
Freshly printed offset prints,
use tray 3.
Refer to the “Using various
stocks” section for any stock
not defined in this guide.
DT6180 HandyBook 21
Satisfaction Guide for Paper Tray 3
Stock Reliable feeds may be
expected
Size 8 x 10 inches to 17 x 11
inches (203 x 254 mm to
432 x 279 mm)
Weight Substance 16 to 110 (60 to
200 g/m2)
Capacity 2600 sheets, substance
20 (75 g/m2)
Type or
condition
Xerographic bond paper in
good condition
Drilled stock, fanned
thoroughly
Less reliable feeds may be
expected
Smaller or larger sizes
Weights outside the limits
Slightly curled paper
Intermixed weights
Xerox vellum
Full cut tabs
Label stock
Adhesive drafting film
Paper with reinforced edges
Paper Trays & Loading Media
Suggested alternatives
cannot be used.
shown are not
recommended.
Substance 110 (200 g/m2)
must be long grain except 17
x 11 inch (432 x 279 mm)
substance 110 (200 g/m2)
which must be short grain.
Do not use excessively
curled paper
Substance 110 (200 g/m2)
must be long grain. Do not
use short grain.
Precut tabs - use tray 1 or 2.
Transparencies with a white
stripe, use tray 1 or 2.
Freshly printed offset prints,
use tray 3.
Refer to the “Using various
stocks” section for any stock
not defined in this guide.
DT6180 HandyBook 22
Satisfaction Guide for Paper Tray 4
Stock Reliable feeds may be
expected
Size 8 x 10 inches to 17 x 11
inches (203 x 254 mm to
432 x 279 mm)
Weight Substance 16 to 110 (60 to
200 g/m2)
Capacity 550 sheets, substance 20
(75 g/m2)
Type or
condition
Xerographic bond paper in
good condition
Drilled stock, fanned
thoroughly
Less reliable feeds may be
expected
Smaller or larger sizes
Weights outside the limits
Slightly curled paper
Intermixed weights
Xerox vellum
Full cut tabs
Label stock
Adhesive drafting film
Paper with reinforced edges
Paper Trays & Loading Media
Suggested alternatives
cannot be used.
shown are not
recommended.
Substance 110 (200 g/m2)
must be long grain except 17
x 11 inch (432 x 279 mm)
substance 110 (200 g/m2)
which must be short grain.
Do not use excessively
curled paper
Substance 110 (200 g/m2)
must be long grain. Do not
use short grain.
Refer to the “Using various
stocks” section for any stock
not defined in this guide.
Satisfaction Guide for Paper Tray 5
Stock Reliable feeds may be
expected
Size 8 x 10 inches to 17 x 11
inches (203 x 254 mm to
432 x 279 mm)
Weight Substance 16 to 110 (60 to
200 g/m2)
Capacity 2600 sheets, substance
20 (75 g/m2)
Type or
condition
Xerographic bond paper in
good condition
Drilled stock, fanned
thoroughly
DT6180 HandyBook 23
Less reliable feeds may be
expected
Suggested alternatives
Smaller or larger sizes
cannot be used.
Weights outside the limits
shown are not
recommended.
Substance 110 (200 g/m2)
must be long grain except 17
x 11 inch (432 x 279 mm)
substance 110 (200 g/m2)
which must be short grain.
Slightly curled paper
Intermixed weights
Xerox vellum
Full cut tabs
Label stock
Adhesive drafting film
Do not use excessively
curled paper
Substance 110 (200 g/m2)
must be long grain. Do not
use short grain.
Refer to the “Using various
stocks” section for any stock
not defined in this guide.
Paper with reinforced edges
Paper Trays & Loading Media
Satisfaction Guide for 2-Sided Printing
Stock Reliable feeds may be
expected
Size 8 x 10 inches to 17 x 11
inches (203 x 254 mm to
432 x 279 mm)
Weight Substance 16 to 110 (60 to
200 g/m2)
Substance 110 (200 g/m2)
must be long grain.
Type or
condition
Xerographic bond paper in
good condition
Drilled stock, fanned
thoroughly
Less reliable feeds may be
expected
Suggested alternatives
17 x 11 inch (432 x 279 mm)
paper can only be sent to
the top tray.
Weights outside the limits
shown are not
recommended.
Slightly curled paper
Paper with reinforced edges
Do not use excessively
curled paper
Refer to the “Using various
stocks” section for any stock
not defined in this guide.
Satisfaction Guide for Various Stocks
Stock type Instructions for use
• Recycled Paper
• Substance 13 (49 g/m2) paper
• Substance 16 (60 g/m2) paper
• Substance 20 (75 g/m2) paper
• Card stock
• Xerox substance 65 (176 g/m2)
• Substance 110 (200 g/m2) long grain
(index)
• Xerox 4024, substance 20 (75 g/m2)
• 3 hole drilled
• 4 hole drilled
• 7 hole drilled
• Never-tear, 3 hole drilled
DT6180 HandyBook 24
Acceptable, but may increase paper dust
contamination problems in machine. Recommend
vacuum paper before installing in machine to
minimize paper dust.
Use trays 3,4,or 5.
Do not run 2-sided prints.
Load the paper with seam side down into tray 3.
Optimum satisfaction can be expected with 8.5 x
11 inch (216 x 279 mm) or larger paper.
Load paper with seam side up into trays 1 and 2;
seam side down into tray 3, 4, or 5.
Optimum satisfaction can be expected from tray
3, 4, or 5.
Load the paper with seam side up into trays 1
and 2; seam side down into trays 3, 4, and 5.
Card stock can be run from any tray.
Reduce set size if frequent paper jams or
bindexer jams occur. If collated unfinished,
another solution is to lower the value of the
bindexer capacity set in the SWITCHES mode.
Load the paper into trays 1 and 2 with holes to
the right; load the paper into trays 3, 4, and 5 with
holes to the left.
Use the Image Shift or Reduce/Enlarge options
to avoid printing near the holes.
Fan the paper and check the paper for loose
paper plugs before loading the paper into the
trays.
Load the paper into trays 1 and 2 with holes to
the right; load the paper into trays 3, 4, and 5 with
Paper Trays & Loading Media
Stock type Instructions for use
holes to the left.
Do not bind or run 2-sided prints.
• Never-tear
• 3 hole drilled, edge reinforced, 4024 DP
paper
• Transparencies with a 0.5 inch (13 mm)
white stripe
• Removable stripe
• Transparencies
• Tabs
• Preprinted stock
• High speed
• transparencies with white
• stripe
• Label stock
• Letterhead (preprinted)
DT6180 HandyBook 25
Do not bind or run 2-sided prints.
Do not stitch or bind. Do not run with tabs. Tabs
can be inserted off-line.
For optimum satisfaction, use the paper trays 1
and 2 plate assembly. The plate assembly can be
ordered by a Customer Service Representative.
Up to 500 sheets can be placed in the tray.
Load the paper into all trays with holes to the left,
reinforced side down.
Select Properties... on the Trays pull-down
menu. On the Stock window, under Type, select
Drilled.
Image quality problems may occur near the
reinforcement with side 2 printing.
Remove the paper immediately before use to
ensure that prints stay flat.
Print with no more than 200 sheets in a tray.
Select a quantity of 50 or fewer at a time.
Load the stock with the white stripe to the right
into trays 1 and 2.
Load the shiny side up for optimum performance.
Do not load more than 50 removable-stripe
transparencies into trays 1 and 2.
With the white stripe to the right, place the
transparencies on top of approximately 50 sheets
of paper in the tray.
Do not run as inserts to a bound job. Printing is
not allowed on inserts.
Mylar tabs should be run out of tray 4.
Preprinted forms must be made up of ink that has
the following characteristics:
• Can withstand temperatures up to 400°F
(204°C)
• Can withstand pressure of 140 psi at the
above temperature
• Can withstand the above conditions for 25
Milliseconds
Load the stock with the stripe to the right in trays
1 and 2.
Load the stock face up into trays 1 and 2; face
down into trays 3, 4, and 5.
Do not select 2-sided prints.
Load the paper into trays 3, 4, and 5; side 1 with
the printed side down, top edge to the front of the
tray.
Paper Trays & Loading Media
Stock type Instructions for use
Load the paper into trays 1 and 2; side 1 up with
the top edge to the front of the tray.
Do not use freshly preprinted paper in trays 1 and
2.
• Textured paper
• Window stock
• Xerox Carbonless
Do not use the following stocks:
• Multipart forms
• Stocks outside of the recommended size and weight ranges
Heavily textured paper may produce prints with a
ragged character appearance or deletions. To
test, run a proof print.
Run if the window is 2.2 to 4 inches (57 to 102
mm) from the top edge of the paper and at least 1
inch (25.4 mm) from each side of the paper.
Run only as the first page or a front cover to
avoid finisher bin jams.
Load the window stock face-up into a tray (tray 1
or 2 is recommended) with the top edge toward
the front of the tray.
If running plastic-covered window stock, there
may be some distortion. To test, run a proof copy.
Xerox Carbonless Paper is recommended.
Satisfaction Guide for Stitcher
The specifications for stock fed to the Stitcher for reliable stapling are as follows:
Size:
Weight:
NOTE: For larger sizes, send to Top Tray as Unstapled.
Set size limit due to copy paper weight:
203 mm x 254 mm to 229 mm x 356 mm 8 x 10 inches to 9 x 14.33 inches
- Weights outside the above limits are not
Metric Imperial
60 g/m² to 200 g/m²
recommended.
16 to 110 index / 53 bond or xerographic
- Weights outside the above limits are not
recommended.
• Collated: Up to 65 sheets of 80 g/m² (20 lb), or 7 mm (0.28 inch) thick sets. Less reliable stapling
may be expected from 66 to 70 sheets.
• Uncollated: 50 sheets maximum per stitch, 7 mm (0.28 inch) thick sets. Minimum: 2 sheets.
Type or condition: Xerographic bond paper in good condition, and drilled or hole-punched paper. The
Stacker capacity adjusts automatically to suit various set sizes.
DT6180 HandyBook 26
Recommended Shift Preventative Maintenance Plan
3. Recommended Shift Preventa tive Maintenance Plan
Regular operator maintenance of your equipment is likely to improve overall
performance. The maintenance could be done at the beginning or end of the
shift, which ever is decided upon by your team. The following are suggested
maintenance activities.
1. Clean All Sensors.
2. Full Shutdown and Restart.
3. Check and Fill Fuser Agent.
4. Shift handoff communication between operators regarding system issues
encountered on previous shift.
5. Clean Dicorotron Shields (NOTE: Only perform this task if you have been
eXcellerate Trained. Refer to your eXcellerate training materials for
details.)
Shift preventative Maintenance Plan Details
1. Clean All Sensors.
Clean Finisher Entrance Sensor (Q1201)
Clean the Bin A Bindexer Sensor (Q1205)
Clean the Bin B Bindexer Sensor (Q1206)
Clean the Binder Tape Guide Sensor (Q1213)
Clean the Bindexer Sensors (Q1205, Q1206, Q1207)
Clean the Bins Exit Sensors (Q1222)Error! Bookmark not defined.
Clean the Front Stack (Q1227), Rear Stack Height (Q1218), and Set Path (Q1221)
Sensors
Clean the Fuser (Q1010) and Prefuser Sensors (Q1009)
Clean the Post Inverter (Q1202) and Output Transport (Q1203) Sensors
Clean the Pre-Fuser Sensor (Q1009)
Clean the Registration Transport Sensor (Q861)
Clean the Set Path Sensor (Q1221)
Clean the Tape Binder Area
DT6180 HandyBook 27
Recommended Shift Preventative Maintenance Plan
2. Shut Down, Then Start Up the System, Then Power On the Printer
WARNING: Powering OFF the System, and thus the printer will result in the loss of all jobs in the
print queue. Under normal operating conditions, use the DocuSP Controller software to power OFF
the machine.
NOTE: If jobs are currently printing or waiting to print, they should be placed on hold before you power OFF
the System and the printer. You must be logged on as a System Administrator or Trusted User to place a job
on hold.
To Shut Down and Start Up the System:
1. Make sure that the “System Administrator” is logged in on the machine.
2. In the DocuSP [System Menu], on the walk up dialog frame, select [Shutdown].
3. Select the [Yes] confirmation button.
4. Allow the system to shut down.
5. In the Solaris command line type [boot] and hit the [return] key.
6. Ignore the various messages displayed on the monitor as the machine boots up.
To power ON the printer:
1. Make sure that the “System Administrator” is logged in on the machine.
2. In the Print Manager window, select [Printer] from the toolbar. A menu will be displayed.
3. Select [Printer On] from the menu.
The printer that your Controller is attached to will be powered ON. This process will happen without a
confirmation window.
3. Check and Fill Fuser Agent. See
4. Replacing Consumables: Add Fuser Agent page 27.
4. Shift handoff communication between operators regarding system
issues encountered on previous shift.
5. Clean Dicorotron Shields (NOTE: Only perform this task if you
have been eXcellerate Trained. Refer to your eXcellerate training
materials for details.)
DT6180 HandyBook 28
Replacing Consumables
4. Replacing Consumables
Add Fuser Agent
NOTE: You should add Fuser Agent as soon as possible after the message is displayed. If Fuser
Agent is not added the machine will stop running after approximately 5,000 prints and will not run
until Fuser Agent is added.
To add Fuser Agent:
1. Open the Processor Doors.
2. Place a drop cloth on the floor under the Fuser area to catch any Fuser Agent that may
spill.
WARNING: The Fuser area can reach temperatures of approximately 425 ° F / 218 °
C. Use extreme care to prevent burns when working in this area.
3. Grasp the green handle and lift up to open the Fuser Drawer.
4. Pull the Fuser Drawer all the way out of the machine until it stops.
WARNING: Fuser Agent contains silicone which can cause irritation upon contact
with the eye. Use latex gloves if you have them or make sure that you wash your
hands with soap and water after you finish this procedure.
5. Pull the Fuser Agent reservoir out until it stops.
6. Remove the reservoir cap.
DT6180 HandyBook 29
Replacing Consumables
7. Open a new box of Fuser Agent and remove the bottle.
CAUTION: Make sure you use the Fuser Agent specific to the machine model y ou
are using. Fuser Agent for the machine model DocuTech 90 is not compatible with
the DocuTech 135.
8. Remove the cap from the bottle of the Fuser Agent.
9. Carefully pour the Fuser Agent into the reservoir until the level reaches the Max line.
CAUTION: There is an anti-splash seal in the reservoir. To avoid damage to this
seal, do not push the Fuser Agent bottle into the reservoir with excessive force.
WARNING: If any Fuser Agent is spilled onto the floor, it must be removed
immediately as the floor can become slippery.
10. Replace the reservoir cap.
11. Push the Fuser Agent reservoir in to the machine until it stops.
12. Push the Fuser Drawer all the way into the machine until the drawer latches into place.
13. Close the Processor Doors. The Fuser Agent message will disappear after approximately
20 prints are made.
DT6180 HandyBook 30
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