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

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

• 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

Replacing Consumables

Replace Stitcher A Wire

NOTE: You will need wire cutters to perform this procedure. Wire cutters can be found next to Stitcher Spool B.

1. Open the Finisher Doors.

2. Raise the Stitcher Panel. The Stitcher Panel is a black plate about 228 mm (9 inches)

square. Lift the panel out from the bottom and then up. When flipped out and up, the panel has a series of pictures that provide instructions on how to change Stitcher A Wire.

3. Pull the green Stitcher Head Release Handle forward and up. The handle is above and to

the left of the Stitcher spools.

NOTE: If the spool is empty, skip to step 5; otherwise, continue with step 4.

4. If any wire remains on the spool, carefully rewind the wire out of the plastic tubing onto

the spool.

5. Locate the Stitcher wire plug. The plug is located behind the right Finisher Door and has

a white plastic tube leading up to it. The plug itself is a larger black tube about 38 mm (1.5 inches) in length.

6. Press down on the release clip. The release clip is a small semi-circle shaped silver clip.

NOTE: If you rewound the wire onto the spool in step 4, then step 7 is not necessary.

7. Pull the Stitcher wire plug out of the Stitcher Head.

CAUTION: Be careful when you pull the wire out of the plastic tubing. The wire can spring out and hit you if the wire is pulled rapidly.

DT6180 HandyBook 31

Replacing Consumables

8. Use the wire cutters to pull the remaining wire out of the plastic tubing.

9. Place the Stitcher plug in the measuring bracket. The measuring bracket is a black metal

plate about 25 mm (1 inch) in length, with a hole in it that the stitcher plug fits into. The bracket is located about 51 mm (2 inches) to the right of where the Stitcher plug was removed.

10. Locate the green Pin Release Handle under Stitcher Spool B. Pull the handle forward

and hold it in this position.

11. Pull the gold colored pin in the center of the Stitcher Wire Spool straight up.

12. Remove Stitcher Spool A.

13. Slide the new Stitcher Spool into position.

14. Reinstall the Stitcher Spool Pin. Push the pin down until it locks into place.

15. Grasp the end of the wire on the new spool.

WARNING: When the wire is cut, the cut piece may become airborne or cause the wire on the spool to de-spool, leaving it very tangled. Hold the piece that is being cut off to prevent projection or tangling.

16. Carefully clip the lead edge of the wire with the wire cutters. Make sure to remove any

bent or twisted wire.

17. Hold the end of the wire with the thumb and forefinger of each hand. Slowly feed the wire

into the plastic tubing until the wire extends from the Stitcher plug. Continue to feed the wire until the wire hits the backplate of the measuring bracket.

18. Remove the Stitcher plug from the measuring bracket.

19. Use the wire cutters to remove any bent wire in the plastic tubing, and slowly pull

approximately 610 mm (24 inches) of wire out of the Stitcher plug.

20. Use the wire cutters to carefully cut the wire and leave approximately 51 mm (2 inches) o

wire extending from the Stitcher plug.

DT6180 HandyBook 32

Replacing Consumables

21. Re-insert the plug into the Stitcher Head. The plug will snap itself into place if installed

correctly.

22. Push the green Stitcher Head Release Handle down and back.

23. Lower the Stitcher Panel.

24. Close the Finisher Doors.

DT6180 HandyBook 33

Replace the Binder Tape Reel

1. Open the Finisher Doors.

Replacing Consumables

2. Grasp the green handle on the Binder assembly and pull the drawer out until it stops. The

green handle is to the right of Paper Tray 3.

WARNING: All areas of the Binder assembly, including the Binder tape, are hot (approximately 425 °F / 218 °C). Be very careful when working in this area.

3. Raise the handle on the pressure roll and remove the Binder tape from the drive roll. The

handle is located on the upper right side of the Binder assembly.

4. Rewind the Binder tape onto the tape reel.

5. Move the reel retainer, located on the end of the tape reel spindle, to the horizontal or

unlocked position. The reel retainer is a flat metal piece that pivots on the end of the tape reel spindle.

DT6180 HandyBook 34

Replacing Consumables

6. Remove the tape reel.

7. Slide the new tape reel onto the tape reel drive. Make sure that the larger hole in the

center of the tape reel faces the tape reel drive.

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

9. Move the reel retainer to the vertical, or locked position.

NOTE: Tape feed problems can result if the reel retainer is not in the locked position.

10. Thread the tape around the spools following the instructions on the Binder tape loading

label which is located to the left of the Binder tape reel.

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

NOTE: Make sure the tape is threaded correctly. As it comes off the reel and over the first pulley, it must go through the sensor. If the tape is not threaded correctly, the message will not go away.

12. Turn the green knob to the right until the tape is at least 51 mm (2 inches) beyond the

tape guides.

DT6180 HandyBook 35

Replacing Consumables

NOTE: If a problem occurs when you are trying to turn the green knob, close the Finisher Doors. The Screen will display a 'Please wait - Finisher Reset in Progress' message. Wait until a 'Ready' message is displayed, then open the Finisher Doors and try feeding the Binder tape again.

13. Cut the tape by lifting up on the green tape cutter handle located on the left side of the

Binder assembly. Lift up the handle to manually cut the tape and then release the handle.

14. Remove the cut piece of tape.

15. Push the Binder drawer in until it stops.

16. Close the Finisher Doors.

For the highest quality performance, occasionally check the Binder tape length and adjust, if necessary.

DT6180 HandyBook 36

Replacing Consumables

Replace the Toner (Dry Ink) Bottle

CAUTION: Do not use warm water or cleaning solvents to remove Toner from your skin or clothing. This will set the Toner and make it difficult to remove. If Toner gets on your skin or clothing, use a brush to remove the Toner, blow it off, or wash it off with cold water and mild soap.

NOTE: There is an eight step diagram to the right of the Toner Bottle with instructions on how to

change the cartridge. To remove the Toner (Dry Ink) Bottle:

1. Open the Processor Doors.

2. Place a drop cloth or a few sheets of paper on the floor under the Toner Bottle area to

catch any Toner that may spill on the flooring.

3. Pull the empty Toner Bottle out of the machine until it stops.

4. Rotate the green handle up, to the unlatched position.

5. Remove the bottle from the receptacle.

NOTE: You may want to put the used Toner Bottle in the box that the new cartridge came in. Empty Toner Bottles are not returned to Xerox and can be disposed of according to your local recycling regulations.

To replace the Toner Bottle:

6. Remove the new Toner Bottle from the box. Make sure you do not remove the protective

DT6180 HandyBook 37

Replacing Consumables

seal that is attached to the bottle.

7. Shake the new bottle several times to loosen the Toner.

8. Insert the bottle into the receptacle.

9. Rotate the green handle down, to the latched position.

10. Push the new bottle all the way into the machine.

11. Hold the bottle in place with your hand and pull off the protective seal.

12. Close the Processor Doors.

Replace the Toner (Dry Ink) Waste Container

NOTE: When the message 'Replace the Waste Container' is displayed on your machine, replace the container as soon as possible. If the Toner (Dry Ink) Waste Container is not replaced, the machine will eventually stop and will not run until the container is replaced.

To replace the Toner Waste Container:

1. Open the Processor Doors.

2. Locate the Toner Waste Container which is located directly under Area 6, near the floor.

3. Place a drop cloth or a few sheets of paper on the floor under the Toner Waste Container

area to catch any Toner that may spill.

4. Grasp the tab on the Toner Waste Container and pull the container out of the machine,

slowly.

DT6180 HandyBook 38

Replacing Consumables

CAUTION: To prevent a Toner spill, do not tip or tilt the waste container.

5. Remove the cap from the top of the full Toner Waste Container.

6. Place the cap over the opening on the end of the full Toner Waste Container.

7. Remove the new Toner Waste Container from the box.

8. Slide the new Toner Waste Container all the way into the machine until the container

stops. NOTE: You do not need to remove the cap from the storage position at this time.

9. Close the Processor Doors.

CAUTION: Do not use warm water or cleaning solvents to remove Toner from your skin or clothing. This will set the Toner and make it difficult to remove. If any Toner gets on your skin or clothing, use a brush to remove the Toner, blow it off, or wash it off with cold water and mild soap.

NOTE: Old waste containers should not be emptied, cleaned and used again. There is a sensor

inside the container that remains dirty and the machine will not recognize the container. Save the full waste container and give it to the service technician on the next visit. The technician will dispose of it properly. This material is not a hazardous waste.

DT6180 HandyBook 39

Order Supplies, Consumables, and Parts

DT135/6100/6115/6135/6155/6180 Supplies/Consumables/Parts

EQUIPMENT SUPPLIES

Replacing Consumables

Dry Ink Waste Container - 502S67618

Toner - 6R206 Binder Tape/Reel - 8R1174 (32 K) Binder Tape/Reel - 8R4023 (25 K) Booklet Maker Staples - 8R566

ORDERING SUPPLIES

To order supplies (toner, fuser oil, staples, paper, transparencies, labels, etc), please call the Xerox Supplies Department or order online.

RECYCLING

You can return CRU's to Xerox by using the return shipping labels which are included in the packing materials. Or you can order replacement online.

Please call the Parts Desk

1-800-828-5881

1-800-822-2200

http://www.xerox.com

1-800-822-2200

http://www.xerox.com

http://www.xerox.com/gwa

METERED SUPPLIES (Auto-Replenish)

If you are a metered account, please call the Metered Account Hotline.

SOLD TIME AND MATERIALS (No Contract)

If you do not have a maintenance agreement and need to order CRU's, please call the T&M Parts Desk.

1-800-599-2198

1-800-828-5881

DT6180 HandyBook 40

Machine Maintenance

5. Machine Maintenance

Adjusting for Paper Curl

Measure 5 Sheets - 8½x 11, short edge

DT6180 HandyBook 41

MEASURE PAPER CURL

5 Sheets, Short Edge

Machine Maintenance

DT6180 HandyBook 42

Adjusting for Paper Curl - Adjusting the Decurler Lever

1. Open the right door of the processor.

2. Locate the decurler lever in area 7 of the paper path, as shown below.

Machine Maintenance

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.

DT6180 HandyBook 43

Machine Maintenance

Adjusting the Heavy Paper Levers

Adjust the heavy paper levers to prevent skewing from heavy weight or long paper.

1. Open the right door of the processor.

2. Open the left door of the processor.

3. Locate the black heavy paper levers behind area 4 and area 2.

4. Raise the heavy paper levers. a. Pull the silver latch release toward you.

b. Raise the left and right black levers to the vertical position, as shown below.

Raising the levers

DT6180 HandyBook 44

Machine Maintenance

5. Run the print job.

6. When the print job has been completed, lower the heavy paper lever. a. Pull the silver latch release toward you. b. Lower the left and right black levers to the horizontal position, as shown below.

Lowering the levers

8. Close the processor door

DT6180 HandyBook 45

Machine Maintenance

Adjust the Binder Tape Registration

NOTE: Adjusting the top edge of the Binder Tape changes the positioning of the tape. Adjusting the bottom of the Binder Tape changes the length of the tape.

To adjust the Binder Tape registration:

1. Make sure that the tape guides are clean and free of glue residue. The tape guides are on the top of the Binder.

2. Measure the adjustment amount for the top edge of a finished book. If the tape is overhanging on the top or bottom, and not covering the bottom or top, then the tape position needs to be adjusted.

3. Open the Finisher Doors.

4. Locate the black Binder tape knob on the front of the Binder Drawer; just to the right of Paper Tray 3. You should see the Binder tape coming out from the bottom and wrapping around the feeder back into the Finisher.

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

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

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

• Pull the knob and rotate it to the right to move the tape toward the top edge of the book, or

• Pull the knob and rotate it the left to move the tape toward the bottom edge of the

DT6180 HandyBook 46

Machine Maintenance

book.

7. Close the Finisher Doors.

8. Run a test job to inspect your adjustment.

9. If necessary, perform the procedure again as needed.

Enable a Paper Tray for Clean up

If you are using DocuSP software version 3.x and above:

1. From the DocuSP for DocuTech 2000 Series for 61xx window, select [Printer Manager]. The Printer Manager window will be displayed.

2. Right-click on the tray and select [Enable Cleanup] from the menu. A broom, in the fourth column from the left-hand side of the window, will mark the tray for clean up.

3. Repeat these steps until all trays you want enabled for clean up have a broom in column.

4. Select [Resume] in the Printer window.

If you are using DocuSP software version 2.x and below:

1. From the DocuSP Print Services window, select [Printer Manager]. The Printer Manager window will be displayed.

2. Select the tray you wish to enable for clean up. A menu will be displayed.

3. Select [Enable Clean Up] from the menu.

4. Repeat these steps until all trays you want enabled have a green check mark in the Clean Up column.

5. Select [Resume] in Printer window.

Enable or Disable the Binder

NOTE: You will need to logon as a System Administrator to perform this task.

To enable the Binder using DocuTech software version 3.x and above:

1. From the DocuSP for DocuTech 2000 Series for 61xx window, select [Printer Manager]. The Printer Manager window will be displayed.

2. Select the [Finishing] tab.

3. Under Internal Finishers, right-click on [Binder]. A menu will be displayed.

4. Select [Enable] or [Disable] from the menu. The status column will display the selection.

To enable the Binder using DocuTech software version 2.x and below:

1. From the DocuSP Print Services window, select [Printer Manager]. The Print Manager window will be displayed.

2. In Printer Manager, select [Options]. A menu will be displayed.

3. Select [Finishing] from the menu. The Finishing window will be displayed.

4. Select the [On-line Finishers] tab.

5. Select [Binder].

6. Select the Binder check box to disable or enable the Binder. A check mark in the box indicates the Binder is enabled.

7. Select [OK] to return to the Print Manager window.

DT6180 HandyBook 47

Machine Maintenance

Enable or Disable the Stacker

NOTE: Before you begin, you must be logged on as a System Administrator or Trusted User.

To enable or disable the Stacker using DocuSP software version 3.x:

1. Select [Printer Manager] on the DocuSP for DocuTech 2000 Series for 61xx window.

2. Select the [Stacking] tab.

3. Right-click on [Stacker] and select [Enable] or [Disable]. The Status column should now display the changed setting.

To enable or disable the Stacker using DocuSP software version 2.x or below:

1. Select [Printer Manager]. The Printer Manager window will be displayed.

2. Select [Options] on the toolbar. A menu will be displayed.

3. Select [Finishing] from the menu.

4. On the Finishing tab, select the [Stacker] box. A check mark will be displayed if the Stacker is enabled. Make sure there is no check mark inside the box if you want the Stacker disabled.

5. Select [Apply].

6. Select [Close].

Enable or Disable the Stitcher

NOTE: Before you begin you must be logged on as a System Administrator or Trusted User. To enable or disable the Stitcher using DocuSP software version 3.x:

1. From the DocuSP for DocuTech 2000 Series 61xx window, select [Printer Manager]. The Print Manager window will be displayed.

2. Select the [Finishing] tab.

3. Under Internal Finishers, right-click on [Stitcher]. A menu will be displayed.

4. Select [Enable] or [Disable] from the menu. The status column should now display the changed setting.

To enable or disable the Stitcher using DocuSP software version 2.x or below:

1. From the DocuSP Print Services window, select [Printer Manager]. The Print Manager window will be displayed.

2. Select [Options] on the toolbar. A menu will be displayed.

3. Select [Finishing] from the menu. The Finishing window will be displayed.

4. On the Finishing tab, select the [Stitcher]. A green check mark will be displayed in the box if the Stitcher is enabled. Make sure the green check mark is not displayed to disable the Stitcher.

5. Select [Apply].

6. Select [Close].

DT6180 HandyBook 48

Machine Maintenance

Modify the Bindexer Capacity Number

If you are using software version 3.x and above:

1. From the DocuSP for DocuTech 2000 Series 61xx window, select [Printer Manager]. The Printer Manager window will be displayed.

2. Select the [Stacking] tab.

3. Select the [Setting] button on the lower, right-hand side of the window. The Setting for All Stackers window will be displayed.

4. Under Bindexer Capacity use the [Up] and [Down] arrows to modify the capacity or enter a new bindexer capacity.

5. Select [OK] to save the selection.

If you are using software version 2.x and below:

1. From the DocuSP Print Services window, select the [Printer Manager] button. The Printer Manager window will be displayed.

2. Select [Options] from the toolbar. A menu will be displayed.

3. Select [Finishing] from the menu. The Finishing window will be displayed.

4. Select the [Finishing tab.

5. Under the Stacker Set Up section, use Slide to Select New Bindexer Number.

6. Select [OK] to save the selection.

Modify the Lighter / Darker Setting

NOTE: You must be logged on as Trusted User or System Administrator to perform this task. Only Trusted Users or System Administrators have access to changing the Image Quality settings.

To modify the Lighter / Darker Setting using DocuSP software version 3.x or above:

1. In the DocuSP for DocuTech 2000 Series for 61xx window, select [Printer Manager]. The Print Manager window will be displayed.

2. Select the [Image Quality] tab in the Printer Manager window. The Image Quality window will be displayed.

3. Select [Printer Darkness].

4. Make sure the Darkness Mode is set for Normal Darkness, and select a lighter or darker shade of gray depending on the desired effect.

5. Select [OK].

6. When an Information window is displayed stating 'The change to Darkness will take effect on the next set/subset to be printed,' select [OK].

To modify the Lighter / Darker Setting using DocuSP software version 2.x or below:

1. In the DocuSP Print Services window, select [Printer Manager]. The Print Manager window will be displayed.

2. Select [Options] from the toolbar. A menu will be displayed.

3. Select [Image Quality] from the menu. The Image Quality window will be displayed.

4. Select [Printer Darkness].

5. Make sure the Darkness Mode is set for Normal Darkness, and select a lighter or darker shade of gray depending on the desired effect.

6. Select [Apply].

DT6180 HandyBook 49

Machine Maintenance

Stop a Job From Printing at the Printer

NOTE: You must logon as a System Administrator or Trusted User to perform this task.

To stop a job at the printer using DocuSP software version 3.x or above:

1. In the DocuSP for DocuTech 2000 Series for 61xx window, select [Pause Printing] in the upper, right corner of the window. The button will be displayed as 'Resume Printing' and change to the color green.

2. Choose to do one of two options:

• Place a job on hold. From the Job Manager window, right-click on the job you want to hold. A menu will be displayed. Select [Hold]. The job status will change to 'Held by Operator.'

• Delete a job. From the Job Manager window, right-click on the job you want to delete. A menu will be displayed. Select [Delete] from the menu.

3. You may want to resume the printer after putting it on Pause. Select the large green [Resume Printing] button in the upper right-hand corner of the window. The button will be displayed as 'Pause Printing' and change to the color orange.

To stop a job at the printer using DocuSP software version 2.x or below:

1. In the DocuSP Print Services window, select [System] from the toolbar. A menu will be displayed.

2. Select [Pause Printer] from the menu to stop the printer.

3. Choose to do one of two options:

• Place the job on hold. From the Job Manager window, select the job you want to hold, then select [Job] from the toolbar. From the menu that will be displayed, select [Hold]. The job status will change to 'Held by Operator.'

• Delete the job from the queue. From the Job Manager window, select the job you want to delete, then select [Job] from the toolbar. From the menu that will be displayed, select [Delete].

4. You may want to resume the printer after putting it on Pause. To do this, select [System] from the toolbar, and then select [Resume Printer] from the menu.

DT6180 HandyBook 50

Problem Solving

6. Problem Solving

Potential solutions for common problems are available using the either of 2 methods:

1. If you know the fault code:

A. Look up Fault Code in the table, “COMMON FAULT CODES & CASE”, find Case

Number (page 50 - page 52).

B. Look up Case Number in the table, “PROBLEM LISTING AND SOLUTIONS,

LISTED by CASE NUMBER” to find Solution(s) (page 53 – page 63). C. Potential Solutions are listed by releva nce. D. Potential Solutions with detailed instructions are noted in last column. The

instructions are listed in alphabetical order starting on page 66.

2. If you have a problem without a fault code:

A. Refer to pages (page 53 – page 63) in Problem Listing Table, look for Problem

Description. B. Potential Solutions are listed by relevance. C. Potential Solutions with detailed instructions are noted in last column. The

instructions are listed in alphabetical order starting on page 66.

DT6180 HandyBook 51

COMMON FAULT CODES & CASE

Look-up Case Number in table “PROBLEM LISTING AND SOLUTIONS, LISTED by CASE NUMBER”, following Fault code table, for solutions.

Fault Code Case Descp Case

C16-351 Communication Failure Faults 10971 C16-352 Communication Failure Faults 10971 P01-220 Interlock System Failure Faults 3147 P01-221 Interlock System Failure Faults 3147 P03-201 Printer Run Faults 2823 P03-203 Printer Run Faults 2823 P03-204 Printer Run Faults 2823 P03-205 Printer Run Faults 2823 P03-208 Printer Run Faults 2823 P03-230 Printer Run Faults 2823 P03-230 Printer Run Faults 2823 P03-231 Printer Run Faults 2823 P03-232 Printer Run Faults 2823 P03-233 Printer Run Faults 2823 P03-234 Printer Run Faults 2823 P03-240 Printer Run Faults 2823 P03-241 Printer Run Faults 2823 P03-242 Printer Run Faults 2823 P03-243 Printer Run Faults 2823 P03-246 Printer Run Faults 2823 P03-247 Printer Run Faults 2823 P03-250 Printer Run Faults 2823 P03-251 Printer Run Faults 2823 P03-252 Printer Run Faults 2823 P03-252 Printer Run Faults 2823

Problem Solving

Fault Code Case Descp Case

P03-253 Printer Run Faults 2823 P03-254 Printer Run Faults 2823 P03-255 Printer Run Faults 2823 P03-258 Printer Run Faults 2823 P03-259 Printer Run Faults 2823 P03-261 Printer Run Faults 2823 P03-263 Printer Run Faults 2823 P03-300 Printer Run Faults 2823 P03-301 Printer Run Faults 2823 P03-302 Printer Run Faults 2823 P03-308 Printer Run Faults 2823 P03-309 Printer Run Faults 2823 P03-311 Printer Run Faults 2823 P03-313 Printer Run Faults 2823 P03-313 Printer Run Faults 2823 P03-314 Printer Run Faults 2823 P03-315 Printer Run Faults 2823 P03-325 Printer Run Faults 2823 P03-330 Printer Run Faults 2823 P03-331 Printer Run Faults 2823 P03-332 Printer Run Faults 2823 P03-333 Printer Run Faults 2823 P03-334 Printer Run Faults 2823 P03-336 Printer Run Faults 2823 P03-342 Printer Run Faults 2823 P03-343 Printer Run Faults 2823 P03-344 Printer Run Faults 2823 P03-361 Printer Run Faults 2823 P03-361 Printer Run Faults 2823 P03-363 Printer Run Faults 2823

DT6180 HandyBook 52

Problem Solving

Fault Code Case Descp Case

P03-364 Printer Run Faults 2823 P03-370 Printer Run Faults 2823 P03-371 Printer Run Faults 2823 P03-373 Printer Run Faults 2823 P03-374 Printer Run Faults 2823 P03-375 Printer Run Faults 2823 P03-378 Printer Run Faults 2823 P04-201 Timing Fault 3378 P06-203 Laser Faults 3385 P06-233 Laser Faults 3385 P06-237 Laser Faults 3385 P06-359 Laser Faults 3385 P06-365 Laser Faults 3385 P08-145 Area 8 and 9 Jam Faults 3706 P08-151 Area 3 and 4 Jam Faults 3726 P08-152 Area 4 Jam Fault 3732 P08-156 Area 3 and 4 Jam Faults 3726 P08-170 Area 8 and 9 Jam Faults 3706 P08-171 Area 8 and 9 Jam Faults 3706 P08-172 Area 8 and 9 Jam Faults 3706 P08-173 Area 8 and 9 Jam Faults 3706 P09-201 Arc Detection Faults 3792 P09-202 Arc Detection Faults 3792 P09-203 PR Belt End of Life Message 10987 P09-204 PR Belt End of Life Message 10987 P09-213 ESV Fault 3803 P09-215 Toner (Dry Ink) Dispense Fault 3806 P09-220 Belt Hole Sensor Faults 3811 P09-222 Belt Hole Sensor Faults 3811 P09-320 Processor Voltage Faults 3831

Fault Code Case Descp Case

P09-321 Processor Voltage Faults 3831 P09-322 Processor Voltage Faults 3831 P09-323 Processor Voltage Faults 3831 P09-324 Processor Voltage Faults 3831 P09-325 Processor Voltage Faults 3831 P09-325 Processor Voltage Faults 3831 P09-326 Processor Voltage Faults 3831 P09-327 Processor Voltage Faults 3831 P09-328 Processor Voltage Faults 3831 P09-329 Processor Voltage Faults 3831 P09-331 Processor Voltage Faults 3831 P09-504 ESV Fault 3803 P10-101 Pre-Fuser Sensor Fault 3847 P10-102 Fuser Jam Sensor Fault 2843 P10-104 Decurler Sensor Fault 3142 P10-105 Decurler Sensor Fault 3142 P10-201 Fuser Temperature Faults 3853 P10-202 Fuser Temperature Faults 3853 P10-203 Fuser Temperature Faults 3853 P10-204 Fuser Temperature Faults 3853 P10-206 Fuser Temperature Faults 3853 P10-210 Fuser Temperature Faults 3853 P10-215 Fuser Temperature Faults 3853 P10-215 Fuser Temperature Faults 3853 P10-216 Camming Fault 2549 P12-100 Finisher Entrance Faults 3265 P12-101 Finisher Entrance Sensor Blocked

3273

Faults

P12-104 Finisher Entrance Sensor Blocked

3273

Faults

P12-107 Finisher Entrance Faults 3265

DT6180 HandyBook 53

Problem Solving

Fault Code Case Descp Case

P12-108 Post Inverter Sensor Faults 3304 P12-111 Post Inverter Sensor Faults 3304 P12-112 Output Transport Sensor Faults 10984 P12-115 Output Transport Sensor Faults 10984 P12-116 Trail Edge Bindexer Entrance Fault 3336 P12-122 Bindexer Sensor Faults 3442 P12-123 Bindexer Sensor Faults 3442 P12-125 Bindexer Bin B Faults 3740 P12-126 Bindexer Bin B Faults 3740 P12-127 Bindexer Bin C Faults 10968 P12-128 Bindexer Bin C Faults 10968 P12-129 Bindexer Bin C Faults 10968 P12-140 Bins Exit Sensor Fault 1680 P12-143 Set Path Sensor Fault 4043 P12-144 Set Path Sensor Fault 4043 P12-151 Stacker Height Sensor Faults 4003 P12-218 Stitcher A Wire Sensor Fault 4077 P12-222 Stacker Height Sensor Faults 4003 P12-230 Set Path Sensor Fault 4043 P12-231 Set Path Sensor Fault 4043 P12-232 Set Path Sensor Fault 4043 P12-233 Set Path Sensor Fault 4043 P12-233 Set Path Sensor Fault 4043 P12-234 Set Path Sensor Fault 4043 P12-242 Finisher Interlock Faults 4088 P12-243 Finisher Interlock Faults 4088 P12-244 Finisher Interlock Faults 4088 P12-245 Finisher Interlock Faults 4088 P12-247 Finisher Interlock Faults 4088 P12-248 Finisher Interlock Faults 4088

Fault Code Case Descp Case

P12-248 Finisher Interlock Faults 4088 P12-251 Binder Under Temperature Faults 4095 P12-253 Binder Under Temperature Faults 4095 P12-254 Binder Under Temperature Faults 4095 P12-256 Binder Under Temperature Faults 4095 P12-271 Flapper and Tape Guide Faults 10978 P12-272 Flapper and Tape Guide Faults 10978 P12-273 Flapper and Tape Guide Faults 10978 P12-274 Flapper and Tape Guide Faults 10978 P12-275 Flapper and Tape Guide Faults 10978 P12-276 Flapper and Tape Guide Faults 10978 P12-276 Flapper and Tape Guide Faults 10978 P12-281 Flapper and Tape Guide Faults 10978 P12-282 Flapper and Tape Guide Faults 10978 P12-283 Flapper and Tape Guide Faults 10978 P12-285 Flapper and Tape Guide Faults 10978 P12-286 Flapper and Tape Guide Faults 10978 P12-287 Flapper and Tape Guide Faults 10978 P12-518 System Fault 4322 P14-102 Interposer Exit Sensor Faults 4207 P14-105 Interposer Exit Sensor Faults 4207

DT6180 HandyBook 54

Problem Solving

PROBLEM LISTING AND SOLUTIONS, LISTED by CASE NUMBER

First group of problems don’t have case number Look-up Solutions, listed in alphabetical order immediately following this table.

Area P=Processor I=Interposer F=Finisher

Area

Case #

Problem

Paper path jams, misfeeds, multifeeds (General – More specific later in table)

Related Fault

Codes

Potential Solutions

/Solutions Ranked by Relevance:

• Check the area where the jams are occurring to ensure that the paper path is clear of paper and other obstructions.

• If a jammed sheet of paper tears when being removed, ensure that you have removed all of the sheet pieces.

• Ensure that the paper path baffles are in the correct seated position.

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

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

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

• Ensure that the stock has no bent corners, or tears, and that the edges are straight.

• Remove any damaged sheets.

• Repeated jamming may be due to a

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

• Paper weight less than substance 20 (75 g/m2) will require careful setting

• of the decurler. Refer to the procedure, "Adjusting for paper curl," in this guide.

• If the misfeeds are occurring in the paper tray, ensure that the paper feeder is latched by pressing down on

following

Problem table?

Detail Solutions

DT6180 HandyBook 55

Problem Solving

Area

Case #

Problem

Paper tray elevator fails to rise or lower

Processor power is off unexpectedly

Related Fault

Codes

Potential Solutions

/Solutions Ranked by Relevance:

the green dot inside the tray.

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

• The stock should be kept in the original wrapper and stored correctly.

• Ensure that the stock is within the limitations described in the Satisfaction

• Guides in the "Paper Trays & Loading Media" chapter.

• Check paper capacities for trays & bindexer are within limits. See “Paper Trays & Loading Media” Chapter.

• Use proper paper storage techniques. Refer to Operator Guide.

• Ensure that the stock is loaded properly in the paper trays, with the rear

• and side guides against the stock stack.

• If the elevator fails to rise or lower in paper tray 1 or 2, latch the paper

• feeder by pressing down on the green dot inside the tray.

• Do not slam the trays closed. Push the trays in slowly but firmly.

• Ensure that all misfed stock has been removed from the immediate area of the paper trays.

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

1. Determine if the DocuSP controller

power and the processor power are off. If the controller’s screen is blank and the power-indicator light is not blinking, the controller power is off. Refer to the System Guide. If the paper tray lights are out, the power to the processor is off. Proceed with step 2.

2. Determine if the processor has a

ground fault protector. If there is not a ground fault protector installed, refer to the procedure "Calling for assistance," in

following

Problem table?

Detail Solutions

DT6180 HandyBook 56

Problem Solving

Area

Case #

Problem

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

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

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

Related Fault

Codes

Potential Solutions

/Solutions Ranked by Relevance:

this guide.

3. If the processor has a ground fault

protector, determine whether the protector has shut off the power. If the red light is visible on the protector, proceed with step

4. If the red light is not visible, something

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

4. Press the reset button on the processor

ground fault protector. If the red light switches off, proceed with step 5. If the red light does not switch off, or immediately switches on again, refer to the procedure, "Calling for assistance", in this guide.

5. Switch the white-handled circuit

breakers near the protector to the on (up) position. If the power comes on, proceed with step 6. If the circuit breakers immediately switch off again, call for assistance.

6. Select the Reset icon on the fault

frame. This should clear the fault.

7. Clear any other faults that may be

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

8. If the power repeatedly switches off

unexpectedly, call for assistance. Replace the tape reel with a new reel using the procedure, "Replace the Binder Tape Reel," in “Replacing Consumables”.

Refer to the binder tape reel storage information in the Operator Guide.. Adjust the binder tape registration using the procedure, "Adjust the Binder Tape Registration," in “Machine Maintenance” Chapter.

Adjust the binder tape length using the procedure entitled "Adjust the Binder Tape Registration," in “Machine Maintenance” Chapter.

following

Problem table?

Detail Solutions

DT6180 HandyBook 57

Problem Solving

Area

Case #

1680

Problem

Loose binder tape along the spine of the completed bound book

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

Poor stitch quality or short stitches

Bins Exit

Sensor Fault

Related Fault

Codes

P12-140

Potential Solutions

/Solutions Ranked by Relevance:

If an adjustment is made to the binder tape length during a job, it will not take effect until the next job is printed. If it is necessary to adjust the binder tape length during a job, adjust it using the procedures in the on-line help. This is a symptom of excessive moisture in the tape. Replace the tape reel with a new reel using the procedure, "Replace the Binder Tape Reel," in “Replacing Consumables”.

Refer to the binder tape storage guidelines in the Operator Guide. If the binder tape is sticking together, or if there are cosmetic defects in the bound book, replace the tape reel with a new reel using the procedure, "Replace the Binder Tape Reel," in “Replacing Consumables”.

Refer to the binder tape storage information in the Operator Guide.

Refer to the binder cleaning information in the Operator Guide. Reliable stitching can be expected with up to 65 sheets of substance 20 (75 g/m2) or

0.28 inch (7 mm) thick sets. Less reliable

stitching can be expected with over 70 sheets of substance 20 (75 g/m2).

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

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

Reduce the stock weight to enable the stitching of more sheets per set.

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

1. Clear the Paper Jams in Areas 16 and 17

2. Clean the Bins Exit Sensors (Q1222)

following

Problem table?

Detail Solutions

Y Y

DT6180 HandyBook 58

Problem Solving

Area

Case #

2549

2823

2843

3142

3147

3265

3273

Problem

Camming

Fault

Printer Run

Faults

Fuser Jam

Sensor Fault

Decurler

Sensor Fault

Interlock

System

Failure Faults

Finisher

Entrance

Faults

Finisher

Entrance

Sensor

Blocked

Faults

Related Fault

Codes

P10-216

P03-201 P03-203 P03-204 P03-205 P03-208 P03-230 P03-231 P03-232 P03-233 P03-234 P03-240 P03-241 P03-242 P03-243 P03-246 P03-247 P03-250 P03-251 P03-252 P03-253 P03-254 P03-255 P03-258 P03-259 P03-263 P03-300 P03-301 P03-302 P03-308 P03-309 P03-311 P03-313 P10-102

P10-104 P10-105

P01-220 P01-221

P12-100 P12-107

P12-101 P12-104

Potential Solutions

/Solutions Ranked by Relevance:

Detail Solutions

3. Power OFF, Then Power ON the

Printer

1. Release the Camming Motor Brake Y

2. Clear the Entire Paper Path From

the Paper Trays to the Finisher

3. Power OFF, Then Power ON the

Printer

1. Power OFF, Then Power ON the

Printer

1. Clear the Paper Jam in Areas 5 and

2. If Card Stock or Heavyweight Paper

Y is Being Used, Adjust the Heavy Paper Levers (See Machine maintenance, Adjusting the Heavy Paper Levers)

3. Clean the Fuser (Q1010) and

Y Prefuser Sensors (Q1009)

4. Use A New Ream of Paper Y

5. Fan the Paper, Turn the Paper

Y Over, and Reload

6. If Printing to the Edges of the Paper

Y Stock, set Lead Edge Screening to Stress

1. Clear the Paper Jam in Areas 7, 6,

Y and 5

2. Lower the Decurler Baffle Above

Y Area 7

3. Clean the Fuser (Q1010) and

Y Prefuser Sensors (Q1009)

1. Power OFF, Then Power ON the

Y Printer

1. Clean Finisher Entrance Sensor

Y (Q1201)

2. Power OFF, Then Power ON the

Y Printer

1. Clear the Fault in the Printer Fault

Y Clearance Window

2. Clean Finisher Entrance Sensor

Y (Q1201)

3. Power OFF, Then Power ON the Y

following

Problem table?

DT6180 HandyBook 59

Problem Solving

Area

Case #

3304

3336

3378

3385

3442

3706

3726

3732

3740

Problem

Post Inverter

Sensor Faults

Trail Edge

Bindexer

Entrance Fault

Timing Fault

Laser Faults

Bindexer

Sensor Faults

Area 8 and 9

Jam Faults

Area 3 and 4

Jam Faults

Area 4 Jam

Fault

Bindexer Bin

Related Fault

Codes

P12-108 P12-111

P12-116

P04-201

P06-203 P06-233 P06-237 P06-359 P06-365

P12-122 P12-123

P08-145 P08-170 P08-171 P08-172 P08-173

P08-151 P08-156

P08-152

P12-125 P12-126

Potential Solutions

/Solutions Ranked by Relevance:

Detail Solutions

Printer

1. Clear the Paper Jam in Areas 8, 11,

Y 12, and 13

2. Clean the Post Inverter (Q1202)

Y and Output Transport (Q1203) Sensors

1. Clear Paper Jams in Areas 11, 12,

Y 13, and 14

2. Clean the Post Inverter (Q1202)

Y and Output Transport (Q1203) Sensors

1. Select Reset / Restart From the

Y Fault Frame

2. Power OFF, Reset the Printer

Y Circuit Breakers, Then Power ON

1. Power OFF, Then Power ON the

Y Printer

1. Clear the Paper Jam in Areas 12,

Y 13, 14, and 15

2. Clean the Bin A Bindexer Sensor

Y (Q1205)

1. Clear the Paper Jam in Areas 8 and

Y 9

2. Open and Close the Area 9 Baffle

Y Securely

3. Power OFF, Then Power ON the

Y Printer

1. Clear the Paper Jam in Areas 3 and

Y 4

2. Open and Close the Area 3 and 4

Y Baffles Securely

3. Clean the Registration Transport

Y Sensor (Q861)

4. Clear the Fault in the Printer Fault

Y Clearance Window

5. Power OFF, Then Power ON the

Y Printer

1. Clear the Paper Jam in Area 4 Y

2. Open and Close the Area 4 Baffle

Y Securely

3. Clean the Registration Transport

Y Sensor (Q861)

4. Clear the Fault in the Printer Fault

Y Clearance Window

5. Power OFF, Then Power ON the

Y Printer

1. Clear the Paper Jam in Areas 12, Y

following

Problem table?

DT6180 HandyBook 60

Problem Solving

Area

P P

Case #

3792

3800

3803 3806

3811

3831

Problem

B Faults

Arc Detection

Faults

Uneven

Density Fault

ESV Fault

Toner (Dry

Ink) Dispense

Fault

Belt Hole

Sensor Faults

Processor

Voltage Faults

Related Fault

Codes

P09-201 P09-202

P09-212

P09-213, P09-504

P09-215

P09-220 P09-222

P09-320 P09-321 P09-322 P09-323 P09-324 P09-325 P09-326 P09-327 P09-328 P09-329 P09-331

Potential Solutions

/Solutions Ranked by Relevance:

13, 14, and 15

2. Clean the Bin B Bindexer Sensor (Q1206)

1. Power OFF, Then Power ON the Printer

2. If you Have Advanced Training, Follow the Instructions to Clean all of the Dicorotron Shields

1. Power OFF, Then Power ON the Printer

2. If you Have Advanced Training, Follow the Instructions to Clean the Density Sample Sensor (DSS)

3. If you Have Advanced Training, Follow the Instructions to Replace the Photoreceptor Belt

4. If you Have Advanced Training Follow the Directions to Perform a dc951 Xerographic Setup

1. Power OFF, Then Power ON the Printer

1. Tap on the Toner (Dry Ink) Cartridge to Loosen the Toner

2. Replace the Toner (Dry Ink) Bottle (See Replacing Consumables)

3. Power OFF, Then Power ON the Printer

1. Clear the Paper Jams in Areas 7, 6, 5, 4, and 2

2. Clear the Fault in the Printer Fault Clearance Window

3. Power OFF, Then Power ON the Printer

4. If you Have Advanced Training, Make Sure the Photoreceptor Belt is Securely Seated in the Xerographic Drawer

5. If you Have Advanced Training, Follow the Instructions to Clean the Belt Hole Sensor on the Photoreceptor Belt Drawer

1. Power OFF, Then Power ON the Printer

following

Problem table?

Detail Solutions

Y Y N

Y N

Y Y Y Y Y Y Y N

3847

Pre-Fuser

Sensor Fault

P10-101

1. Clear the Paper Jams in Areas 7, 6, 5, 4, and 2

DT6180 HandyBook 61

Problem Solving

Area

Case #

3853

4003

4043

4077

4088

4095

4207

4322

Problem

Fuser

Temperature

Faults

Stacker Height

Sensor Faults

Set Path

Sensor Fault

Stitcher A

Wire Sensor

Fault

Finisher

Interlock

Faults

Binder Under

Temperature

Faults

Interposer Exit

Sensor Faults

System Fault

Related Fault

Codes

P10-201 P10-202 P10-203 P10-204 P10-206 P10-215 P10-210

P12-151 P12-222

P12-143 P12-144 P12-230 P12-231 P12-232 P12-233 P12-234

P12-218

P12-242 P12-243 P12-244 P12-245 P12-247 P12-248

P12-251 P12-253 P12-254 P12-256

P14-102 P14-105

P12-518

Potential Solutions

/Solutions Ranked by Relevance:

Detail Solutions

2. Load Paper in the Selected Paper

Y Tray Correctly (See Paper Trays & Loading Media)

3. Clean the Registration Transport

Y Sensor (Q861)

4. Clean the Pre-Fuser Sensor

Y (Q1009)

5. Use A New Ream of Paper Y

6. Clear the Fault in the Printer Fault

Y Clearance Window

7. Power OFF, Then Power ON the

Y Printer

1. Power OFF, Then Power ON the

Y Printer

1. Clear the Paper Jams in Areas 17

Y and 19

2. Clean the Front Stack (Q1227),

Y Rear Stack Height (Q1218), and Set Path (Q1221) Sensors

3. Power OFF, Then Power ON the

Y Printer

1. Clear the Paper Jams in Areas 17

Y and 19

2. Clean the Set Path Sensor (Q1221) Y

3. Power OFF, Then Power ON the

Y Printer

1. Clear the Stitcher A Fault Y

2. Replace Stitcher A Wire (See

Y Replacing Consumables)

3. Power OFF, Then Power ON the

Y Printer

1. Clear the Paper Jam in Areas 11,

Y 14, 17, and 18

2. Open and Close the Finisher Top

Y Cover and the Finisher Front Doors

1. Power OFF, Then Power ON the

Y Printer

1. Remove Paper From Interposer

Y Areas B1 and B2

2. Open, Then Close the Left and

N Right Interposer Doors

3. Power OFF, Then Power ON the

Y Printer

1. Remove all Prints From the Top

N Tray

following

Problem table?

DT6180 HandyBook 62

Problem Solving

Area

Case #

4427

4487

4503

4523

Problem

Dark

Background

on Copies

Deletions on

Every Copy

Black Lines

and Streaks

on Every Copy

Residual or

Double Image

on Every Page

Related Fault

Codes

Potential Solutions

/Solutions Ranked by Relevance:

Detail Solutions

1. Modify the Lighter / Darker Setting

Y (see Machine Maintenance)

2. Power OFF, Then Power ON the

Y Printer

3. If you Have Advanced Training,

N Make Sure the Photoreceptor Belt is Securely Seated in the Xerographic Drawer

4. If you Have Advanced Training,

N Follow the Instructions to Replace the Photoreceptor Belt

5. If you Have Advanced Training

N Follow the Directions to Perform a dc951 Xerographic Setup

6. Replace the Toner (Dry Ink) Waste

Y Container (see Replacing Consumables)

1. Use A New Ream of Paper Y

2. Make Sure That all Covers are

N Closed and Back Covers are Attached Correctly

3. If you Have Advanced Training,

N Replace the Transfer Assist Blade

4. If you Have Advanced Training,

N Follow the Instructions to Clean the Charge Dicorotron Shield

1. If you Have Advanced Training,

N Follow the Instructions to Replace the Photoreceptor Belt

2. If you Have Advanced Training

N Follow the Directions to Perform a dc951 Xerographic Setup

3. If you Have Advanced Training,

N Follow the Instructions to Clean all of the Dicorotron Shields

4. If you Have Advanced Training,

N Replace the Transfer Assist Blade

5. If you Have Advanced Training,

N Follow the Instructions to Replace the Developer

6. If You Have Advanced Training,

N Rotate the Wick Blade

7. This Problem Requires Additional

N Assistance. Contact Support

1. Use A New Ream of Paper Y

2. Add Fuser Agent (See Replacing Consumables)

following

Problem table?

DT6180 HandyBook 63

Problem Solving

Area

Case #

4535

4841

4854

4876

Problem

on One Job

Black Spots

and Marks on

Every Copy

Paper Jam in

Areas 17, 19

and the Stacker

Paper Jam in

Areas 11 to

14, 17, and 18

Paper Jam in

Areas 7, 6,

and 5

Related Fault

Codes

Potential Solutions

/Solutions Ranked by Relevance:

Detail Solutions

1. Modify the Lighter / Darker Setting

(See Machine Maintenance)

2. If the Job is Sent From a DigiPath,

Y Clean the Document Glass on the DigiPath

3. Use A New Ream of Paper Y

4. If you Have Advanced Training,

N Follow the Instructions to Vacuum Area 8 (Top Transport) and Areas 2 and 4 (Registration)

5. If you Have Advanced Training,

N Follow the Instructions to Replace the Photoreceptor Belt

6. If you Have Advanced Training,

N Follow the Instructions to Clean the Spot on the Photoreceptor Belt

1. If There is a Fault Code Displayed

N Then Begin a New Search Using the Fault Code

2. Clear the Paper Jams in Areas 17

Y and 19

3. Clear the Fault in the Printer Fault

Y Clearance Window

4. Clean the Front Stack (Q1227),

Y Rear Stack Height (Q1218), and Set Path (Q1221) Sensors

5. Push Down on the Stacker Safety

Y Door

1. If There is a Fault Code Displayed

N Then Begin a New Search Using the Fault Code

2. Clear the Paper Jam in Areas 11,

Y 14, 17, and 18

3. Clear the Fault in the Printer Fault

Y Clearance Window

4. Clean Finisher Entrance Sensor

Y (Q1201)

5. Clean the Post Inverter (Q1202)

Y and Output Transport (Q1203) Sensors

1. If There is a Fault Code Displayed

N Then Begin a New Search Using the Fault Code

2. Clear the Paper Jam in Areas 7, 6,

Y and 5

3. Clear the Fault in the Printer Fault

Y Clearance Window

following

Problem table?

DT6180 HandyBook 64

Problem Solving

Area

Case #

9466

10971

10978

10984

10987

11000

10968

Problem

Black Spots

and Marks on

Every Other Copy on All

Jobs

Communicatio

n Failure

Faults

Flapper and

Tape Guide

Faults

Output

Transport

Sensor Faults

PR Belt End of

Life Message

Fatal / Critical

System Error

Message

Bindexer Bin

C Faults

Related Fault

Codes

C16-351 C16-352

P12-271 P12-272 P12-273 P12-274 P12-275 P12-276 P12-281 P12-282 P12-283 P12-285 P12-286 P12-287

P12-112 P12-115

P09-203, P09-204

P12-127 P12-128 P12-129

Potential Solutions

/Solutions Ranked by Relevance:

Detail Solutions

4. Clean the Fuser (Q1010) and

Y Prefuser Sensors (Q1009)

5. If Paper is Jammed in the Fuser,

Y Release the Camming Motor Brake

1. If you Have Advanced Training,

N Follow the Instructions to Replace the Photoreceptor Belt

2. This Problem Requires Additional

N Assistance. Contact Support

1. Power OFF, Reset the Printer

Y Circuit Breakers, Then Power ON

2. Reset the White Power Switch Y

3. Perform an Immediate Shutdown at

Y the DocuSP

1. Clear Paper Jams in Areas 17 and

Y 18

2. Clean the Tape Binder Area Y

3. Replace the Binder Tape (See

Y Replacing Consumables)

1. Clear Paper Jams in Areas 11, 12,

Y and 13

2. Clean the Post Inverter (Q1202)

Y and Output Transport (Q1203) Sensors

1. This Problem Requires Additional

N Assistance. Contact Support

2. If you Have Advanced Training,

N Follow the Instructions to Replace the Photoreceptor Belt

1. Select Reset / Restart From the

Y Fault Frame

2. Perform an Immediate Shutdown at

Y the DocuSP

1. Clear Paper Jams in Areas 13, 14,

Y and 15

2. Clean the Bindexer Sensors

Y (Q1205, Q1206, Q1207)

following

Problem table?

DT6180 HandyBook 65

Solutions in Alphabetical Order

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

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