Page 1 Version 51.xx, October 2006 701P25101 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 2 Printed in the United States of America. XEROX® and all Xerox product names mentioned in this publication are trademarks of XEROX CORPORATION. Other company trademarks are also acknowledged.
Page 3 Product Recycling and Disposal If you are managing the disposal of your Xerox product, please note that the product contains lead, mercury and other materials whose disposal may be regulated due to environmental considerations in certain countries or states. The presence of lead and mercury is fully consistent with global regulations applicable at the time that the product was placed on the market.
Page 4 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 5: Table Of Contents
Adding fuser shield ........... 3-23 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 6 Printer satisfaction guides ........... . . 5-4 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 7 Xerox support services ........
Page 8 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 9: About This Guide
About this guide Contents DocuTech 128/155/180 HighLight Color Operator Guide Introduction The DocuTech 128/155/180 HLC Operator Guide is one of a number of publications that make up the Xerox Document Services Platform Series. The guide is intended for Xerox DocuTech 128/155/180 HLC...
Page 10 Conventions v i ii • “Technical information” contains the hardware and software capacity guidelines for the DocuTech 128/155/180 HLC systems. • “Supplies” lists the supplies that you might want to keep in stock, and the information you need to order them.
Page 11: Safety Notices
System safety Laser safety DocuTech 128/155/180 HighLight Color Operator Guide It is your responsibility to ensure your Xerox equipment is safe at all times. This section includes equipment safety notices related to laser safety, ozone safety, and operation safety. WARNING: Use of controls or adjustments, or performances other than specified herein, may result in hazardous radiation exposure.
Page 12: Ozone Safety
Providing the proper environmental parameters as specified in the Xerox installation instructions ensures that concentration levels meet safe limits. Your Xerox equipment and supplies have been designed and tested to meet strict safety requirements. These include safety agency examination and approval, and compliance to established environmental standards.
Page 13: European Union Declaration Of Conformity
Never use supplies or cleaning materials for other than their intended purposes. Keep all materials out of the reach of children. The CE marking applied to this product symbolizes Xerox Europe Declaration of Conformity with the following applicable Directives of the European Union as of the dates indicated below.
Page 14: Certification To 1999/5/Ec Radio Equipment And Telecommunications Terminal Equipment Directive
ISM equipment may have to be limited or special mitigation measures taken. This Xerox product has been self-certified by Xerox for pan- European single terminal connection to the analogue public switched telephone network (PSTN) in accordance with Directive 1999/5/EC.
Page 15: Electricity At Work Regulation - Uk
Safety notices In the event of problems, you should contact your local Xerox representative in the first instance. The product has been tested to and is complaint with TBR21, a specification for terminal equipment for use on analogue switched telephone networks in the European Economic Area.
Page 16: Check Your Understanding
Xerox Europe Customer Service Engineers ensure Xerox equipment is serviced and maintained to exacting Xerox safety standards. If you would like your Xerox equipment to be serviced and maintained to such high standards, please contact your local Xerox Europe Customer Service Organization. They will be pleased to assist you.
Page 17: Additional Queries
TEST EQUIPMENT MAY PROVIDE MISLEADING RESULTS AND MAY CAUSE DEATH, PERSONAL INJURY AND/OR DAMAGE TO PROPERTY. I would like to carry out my own safety tests on the Xerox equipment in my premises. You may, of course, request such tests as you deem necessary to satisfy yourself that your Xerox equipment is safe.
Page 18 Safety notices DocuTech 128/155/180 HighLight Color Operator Guide 1- 8...
Page 19: System Components
The DocuTech 155 prints up to 155 prints per minute using 8.5 x 11 inch/A4 (216 x 279 mm) stock. The DocuTech 128 prints up to 128 prints per minute using 8.5 x 11 inch/A4 (216 x 279 mm) stock.
Page 20: Optional Components
Finisher) configuration is 180 PPM only and does not support LCDS & IPDS. The Xerox DocuTech HLC prints high quality, high resolution documents in simplex or duplex mode at high production speeds, from LCDS, PostScript, PCL, and other data streams. The system can switch between printing different types of data streams without a need for rebooting or reconfiguring software.
Page 21 Print resolution: DP128/155/180 HLC 600 x 2400 dpi (High volume printer only) 600 x 2400 dpi (High volume printer) 600 x 600 dpi (Production publisher) Data formats supported The Xerox DocuTech 128/155/180 HLC can print the following data formats: • ASCII •...
Page 22: Paper Weights
75 gsm. However, there is no standard 75 gsm paper. The available stock that is closest in weight to 20 pound paper is 80 gsm. The following special stocks can be used with the DocuTech 128/ 155/180 HLC: •...
Page 23: General Paper Characteristics
General paper characteristics Graphical user interface overview DocuTech 128/155/180 HighLight Color Operator Guide • Predrilled paper: Has holes for use in binders or binder rings. Before loading predrilled paper, fan it to remove any loose plugs that could cause paper jams.
Page 24: System Software And Job Flow
Decomposer The Job Chooser reconciles the job attributes with the virtual printer attributes. Once the job is ready for print, the Job Chooser gives the job to the appropriate decomposer, PostScript or PCL. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 25: Printer Overview
The printer system is available in two configurations: 1. High volume printer with inverter feeder/stacker and up to three feeder/stackers 2. Production publisher with a 2-tray interposer and finisher DocuTech 128/155/180 HighLight Color Operator Guide 2- 7...
Page 26: High Volume Printer
System components High volume printer 2- 8 The components, special features, and configurations of the Xerox DocuTech 128/155/180 HLC printer are shown in the following figures. Figure 2-2. Printer with inverter feeder/stacker + feeder/ stacker (standard base configuration) 1. Feeder tray 2.
Page 27 Please Wait indicator Tray Unlock button DocuTech 128/155/180 HighLight Color Operator Guide Two processor feeder/paper trays (trays 1 and 2) are located in the main part of the printer. Trays 1 and 2 can handle paper sized from 8 by 10 inches / 203 by 254 mm to 9.02 by 14.02 inches / 230 by 356 mm.
Page 28 The purge tray should be emptied when it has received 100 sheets of paper. The system does not notify you when the tray is full. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 29 Bin control panels on stackers DocuTech 128/155/180 HighLight Color Operator Guide Inverter feeder/stacker NOTE: High volume printer configuration only Each output feeder/stacker has offsetting capability and a capacity of 2500 sheets of 20 pound or 80 gsm paper. This capacity does not apply to 11 by 17 inch and A3 papers.
Page 30 10 inches / 203 by 254 mm to 17 by 14.02 inches / 432 by 356 Unlike the processor feeder trays, the HCF trays have Paper Level switches, which detect the position of the elevator to determine the fullness of the tray. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 31 High-capacity stackers More High volume printer configurations DocuTech 128/155/180 HighLight Color Operator Guide The high-capacity stacker (HCS) bins are located in the top half of the feeder/stacker modules, accessed through double doors. Two high-capacity stacker bins are standard, with up to two additional bins available as options (providing up to four bins total).
Page 32: Production Publisher
Production publisher Convenience tray 2- 1 4 The standard base components, special features, and configurations of the Xerox DocuTech 180 HLC production publisher printer are shown in the following figures. Figure 2-8. Production publisher: Printer + 2-tray interposer + stitcher/binder 1.
Page 33 Finisher. The Interposer inserts blank or preprinted sheets as required. Figure 2-9. Interposer (production publisher only) The following lists the interposer components 1. Paper transport (lower) 2. Paper transport (upper) 3. Inserter tray 4. Feeder/inserter tray DocuTech 128/155/180 HighLight Color Operator Guide 2- 15...
Page 34 Dual stitching is available for landscape and portrait prints. Stitch placement can be changed through the DocuSP software. NOTE: For more information about setting stitch placement, refer to the on-line help system. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 35 Paper stocks supported on bypass transport DocuTech 128/155/180 HighLight Color Operator Guide The stacker NOTE: Production publisher configuration only The stacker collects unfinished or finished stitched or bound jobs. When the stacker is full, or the job is completed, the stacker door opens and the stacker drawer that holds the prints comes out.
Page 36 For information on marketing partners that provide solutions for support and interface with finishers, contact your local Xerox sales representative. Bypass transport on the production publisher...
Page 37 DocuTech 128/155/180 HighLight Color Operator Guide High volume printer paper path The following figure shows the path the paper takes through the high volume printer. Figure 2-11. Route of paper through the high volume printer 1. Processor feeder tray 1 2.
Page 38 Drilled holes (on left edge) c. Origin 0,0: portrait orientation 10. Purge tray 11. Bypass transport a. Side 2 of sheet passing through bypass transport b. Drilled holes (on left edge) c. Origin 0,0: portrait orientation DocuTech 128/155/180 HighLight Color Operator Guide...
Page 39 9. Bindexer area 10. Bind area 11. Stitch area 12. Stacker area Bypass transport paper path The following figures show the paper path through the bypass transport, viewed from the front of the printer. DocuTech 128/155/180 HighLight Color Operator Guide 2- 21...
Page 40 System components 2- 2 2 High volume printer bypass transport paper path Figure 2-13. Bypass transport paper path (high volume printer configuration shown) 1. Sheet path 2. Exit rollers 3. Floor DocuTech 128/155/180 HighLight Color Operator Guide...
Page 41: The System
The DocuSP controller Controller overview DocuTech 128/155/180 HighLight Color Operator Guide The basic hardware components of the DocuTech 128/155/180 HLC systems are the DocuSP controller and the printer. The DocuSP controller is the connection between you and the system. You communicate through the DocuSP software by selecting and managing the jobs displayed on the screen and sending them to the printer for production.
Page 42 Do not place the processor or monitor on top of the printer. The DocuTech 128/155/180 HLC supports several types of tape drives that may be used to load resources (forms, fonts, etc.) or to submit offline LCDS print jobs.
Page 43 LCDS print jobs. Peripheral cabinet (9-track and 18/36-track tape drives) Some Xerox customers may already have a peripheral cabinet that houses a 9-track magnetic and an 18/36-track cartridge tape drive. If a peripheral cabinet has either of the following 18-track...
Page 44: Paper Sizing And Print Speed
Stop printing the job and print an error sheet. – Print the data on an oversized sheet. If you encounter any problems related to paper sizing, contact your lead operator or Xerox service representative. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 45 Long and short edge feeding DocuTech 128/155/180 HighLight Color Operator Guide To feed through the printer, the leading edge of the paper must be at least 10 inches long. Therefore, the following standard sizes of paper must be loaded so that sheets feed long edge first: •...
Page 46 System components DocuTech 128/155/180 HighLight Color Operator Guide 2- 2 8...
Page 47: Routine Maintenance
3 Routine maintenance Cleaning and maintenance overview Necessary Precautions DocuTech 128/155/180 HighLight Color Operator Guide This section describes the routine activities you perform to maintain the reliability and productivity of your printer. Some printer components need to be cleaned periodically to help keep the system operating reliably, and to ensure that the print quality is consistent.
Page 48: Finisher Precaution
Routine maintenance Finisher precaution 3- 2 approved or recommended by Xerox. If you use other supplies, you may damage the system. • Keep supplies in stock as listed in the Service and supplies chapter. • Whenever you use or remove a part from the system, handle the part carefully.
Page 49: Paper
Paper Storing paper DocuTech 128/155/180 HighLight Color Operator Guide You can add the same kind of paper to a tray when the supply is low without stopping the printer. You must have the same paper or stock loaded in two trays for the system to continue printing while you are loading the other tray.
Page 50: Conditioning Paper
Use the following chart to determine the number of hours needed to condition stacked cartons of paper. NOTE: The numbers in the top two rows indicate the temperature difference between the storage area and the operating environment, not actual room temperatures. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 51: Paper Curl
Paper curl DocuTech 128/155/180 HighLight Color Operator Guide Table 3-1. Paper conditioning Temperature difference between storage and operating areas Fahrenheit Centigrade Cartons Hours needed to condition the paper Example: If you want to move ten cartons of paper from a storage...
Page 52: Adding Paper To Tray 1 Or 2
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.
Page 53: Using The Custom Transfer Assist Blade
Using the custom transfer assist blade DocuTech 128/155/180 HighLight Color Operator Guide For stock outside the recommended limits, refer to the "Technical information" chapter in this guide. Figure 3-4 Positioning the stack 8. Move the rear guide forward until it touches the edge of the stack.
Page 54 Paper Size 10 to 10.9 inches/254 to 277 mm 11.5 to 11.6 inches/292 to 294 mm 12.1 to 12.9 inches/307 to 328 mm DocuTech 128/155/180 HighLight Color Operator Guide Set Paper Size 11.7 inches/297 mm 13 inches/330 mm 14 inches/356 mm...
Page 55: Adjusting For Paper Curl
Adjusting for paper curl Measuring the paper curl DocuTech 128/155/180 HighLight Color Operator Guide Each sheet of paper has a natural curve called the curl. Storing or using the paper under humid conditions may increase the curl. When too much curl causes paper handling problems, adjust the decurler in the processor.
Page 56 Routine maintenance 3- 1 0 Note: Corners of the sheets of paper should not exceed curl shown in this chart. Move green decurler lever Figure 3-6 Measuring the paper curl DocuTech 128/155/180 HighLight Color Operator Guide Image Move green decurler lever...
Page 57: Adjusting The Decurler Lever
Adjusting the decurler lever DocuTech 128/155/180 HighLight Color Operator Guide Perform the following steps to adjust the decurler lever. CAUTION: Do not use any paper that is not suitable for system use. 1. Open the right door of the processor.
Page 58: Maintaining The Printer
Pull the empty dry ink bottle out until it stops. b. Move the green handle to the unlatched position. c. Remove the empty bottle and discard it. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 59 DocuTech 128/155/180 HighLight Color Operator Guide Figure 3-8 Removing the empty bottle 4. To insert a new bottle, place the bottle on the edge of the bottle guide. a. With a slow, firm motion push the bottle into the dispense position over the hopper.
Page 60: Replacing The Highlight Color Container
1. Open the front processor access door and locate the highlight color container at the right side of the processor. 2. Place a drop cloth on the floor under the highlight color container area. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 61 DocuTech 128/155/180 HighLight Color Operator Guide 3. Remove the empty container by grasping its handle. With a slow, firm motion, remove the container. Figure 3-11 Highlight color container 4. Pull the container out until it stops. 5. Remove the container and discard it.
Page 62: Changing The Highlight Color Customer Changeable Units
6. Make sure the cart is level. a. If the cart is not level, loosen the locknut holding the height adjustment knob in place. b. Use the height adjustment knob to regulate the level. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 63 DocuTech 128/155/180 HighLight Color Operator Guide c. When the HLC unit is level, tighten the lock nut. Figure 3-12 Leveling the cart 7. Push down firmly on the cart pedal until you hear or feel the pedal catch. The pedal should stay locked down. The pallet within the cart is raised.
Page 64 Figure 3-14 Removing the CCU from the printer 10. Push down firmly on the cart pedal until you hear or feel a click. The pallet, which now contains the CCU, is lowered into DocuTech 128/155/180 HighLight Color Operator Guide...
Page 65 DocuTech 128/155/180 HighLight Color Operator Guide the cart. If the pallet does not move, check that the CCU is all the way out of the printer and push down on the pedal again. Figure 3-15 Closing the top cover 11. Close the top cover and store it.
Page 66 10. Remove the cart from the printer and close the cart top cover. 11. Close the printer doors. 12. Store the cart. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 67 Removing the CCU using the service stand DocuTech 128/155/180 HighLight Color Operator Guide Storing the cart and CCU NOTE: If any dry ink gets on your hands, wash them with soap and cold water. Heat sets the ink permanently. If any dry ink gets on your clothes, brush them with a dry paper towel or a stiff bristled brush.
Page 68 9. Tighten the lock nuts on the jack screws to lock the jack screws in position. 10. Unlatch the CCU by turning the photoreceptor backup roller handle clockwise for a quarter turn to an upright position. Figure 3-19 Unlatching the CCU DocuTech 128/155/180 HighLight Color Operator Guide...
Page 69: Adding Fuser Shield
Adding fuser shield DocuTech 128/155/180 HighLight Color Operator Guide 6. Then, turn the yellow CCU handle a quarter turn clockwise. Figure 3-20 Removing the CCU from the printer 11. Using the metal flange of the color CCU, pull the CCU out of the printer until it is completely in the stand.
Page 70 4. Wipe the fuser lubricant filler area to remove any residual lubricant. 5. Fill the fuser lubricant reservoir. a. Pull the fuser lubricant reservoir out until it stops. b. Remove the reservoir cap by turning it counterclockwise. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 71 DocuTech 128/155/180 HighLight Color Operator Guide Figure 3-22 Preparing to add fuser blend WARNING: Fuser lubricant spills cause the floor to be slippery. If any fuser lubricant is spilled onto the floor, it must be removed immediately. c. Open a new box of fuser lubricant and remove a bottle.
Page 72 Inspect the area around the fuser to ensure no fuser blend was spilled. Clean as required. g. Push the fuser blend reservoir in until it stops. 6. Push the fuser drawer in until it latches into place. Figure 3-24 Closing the fuser drawer DocuTech 128/155/180 HighLight Color Operator Guide...
Page 73: Waste Containers
The fuser blend message disappears after the system makes approximately 20 prints. The waste containers in the DT 128/155/180 HLC collect dry ink and developer after it has been used by the printer. When a container becomes full, it must be replaced or the printer eventually stops printing.
Page 74 Routine maintenance Replacing the 128/155/180 toner waste bottle 3- 2 8 4. Insert the new waste HLC developer waste container into the transport assembly. Push the retainer out of the way with your thumb. Continue seating the new waste container onto the tray and release the container latch.
Page 75 DocuTech 128/155/180 HighLight Color Operator Guide Figure 3-27 Flat cap on waste bottle 4. Place the flat cap on the round bottle opening and snap it down. This prevents spillage when discarding the bottle. 5. Discard the waste material and container by placing the container in the trash.
Page 76: Wire Module Removal And Replacement
CAUTION: Handle the wire module with care since the wires can be damaged or broken easily. Do not touch the donor rolls. Touching the roll surface with your fingers can contaminate the surface, causing image quality problems. To replace the wire module: DocuTech 128/155/180 HighLight Color Operator Guide...
Page 77 2. Snap the wire module retainer springs behind the tabs. 3. Slide the HLC developer module into the machine. 4. Latch the CCU into place. 5. Remove the cart or service stand. 6. Close the doors. DocuTech 128/155/180 HighLight Color Operator Guide 3- 31...
Page 78: Cleaning The System And Its Components
3. Remove the cleaning cartridge when it is unloaded. 4. Mark the usage on the tape label. Do not use a grease pencil. You must clean the 18/36-track cartridge tape drive regularly to keep it functioning properly. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 79: Cleaning The 26-Track Cartridge Tape Drive
Cleaning the 26-track cartridge tape drive Cleaning the DVD drive Cleaning the diskette drive DocuTech 128/155/180 HighLight Color Operator Guide The 26-track, or quarter inch cartridge (QIC) tape drive heads should be cleaned at least once a week. If you use the drive for eight hours or more per day, then you should clean the drive daily.
Page 80: Cleaning The Sensors And The Reflecting Surfaces
Q1221, Q1218, and Q1227 sensors • Q1222 and Q1210 sensors 1. Open the right and left doors of the printer and locate Area 4. 2. Raise the Area 4 green handle until it locks into place. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 81 Routine maintenance Figure 3-30 Area 4 and green handle 3. Locate the Q850 and Q861 sensor. Figure 3-31 Q850 and Q861 sensor DocuTech 128/155/180 HighLight Color Operator Guide 3- 35...
Page 82: Cleaning The Q1011/1009 Sensor And Mirror
To access sensors Q1106 and Q1166, open the top cover of the high capacity stacker. To clean the sensors: 1. Brush or wipe the sensor windows lightly. 2. Remove any dust present in the area. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 83: Cleaning The Q1107 Sensor
To access sensor Q1107, open the top cover of the high capacity stacker. To clean the sensor: 1. Brush or wipe the sensor windows lightly. 2. Remove any dust present in the area. DocuTech 128/155/180 HighLight Color Operator Guide 3- 37...
Page 84: Cleaning The Q1164 Sensor
To access sensor Q1164, open the top cover of the last feeder/ stacker module, the one containing the purge tray. To clean the sensor: 1. Brush or wipe the sensor windows lightly. 2. Remove any paper dust present in the area. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 85: Cleaning The Display
Cleaning the display Cleaning the exterior surfaces of the system DocuTech 128/155/180 HighLight Color Operator Guide Figure 3-35 Q1164 sensor The display should be cleaned as required. Clean the display with a soft, lint-free cloth dampened with a glass or lens and mirror cleaner. Do not spray the liquid directly onto the display because it may cause damage.
Page 86: Clearing Or Cleaning The Finisher Sensors
Customer Support Center Representative. 1. Open the processor top cover. NOTE: The Q1201 sensor is located under the processor top cover on the right side. 2. Locate the Q1201 sensor, as shown in figure 3-37 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 87: Clearing The Q1202 And Q1203 Sensors
Clearing the Q1202 and Q1203 sensors DocuTech 128/155/180 HighLight Color Operator Guide Figure 3-37 Locating the Q1201 sensor 3. Brush a folded sheet of paper under the sensor to clear any obstructions. 4. Close the processor cover. NOTE: Production publisher configuration only Clearing the Q1202 and Q1203 sensors should be performed only when directed by a Customer Support Center Representative.
Page 88 Figure 3-38 Locating the Q1202 and Q1203 sensors 3. Brush a folded sheet of paper under each sensor to clear any obstructions, as shown in figure 3-39. Figure 3-39 Clearing the Q1202 and Q1203 sensors 4. Close the finisher top cover. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 89: Cleaning The Q1222 And Q1210 Sensors
Cleaning the Q1222 and Q1210 sensors DocuTech 128/155/180 HighLight Color Operator Guide NOTE: Production publisher configuration only Cleaning the Q1222 and the Q1210 sensors should be performed only when directed by a Customer Support Center Representative. 1. Open the finisher top cover.
Page 90: Clearing The Q1205, Q1206, And Q1207 Sensors
Customer Support Center Representative. 1. Open the finisher front doors. 2. Open the bindexer door. 3. Locate the Q1205, Q1206, and Q1207 sensors, as shown in figure 3-42. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 91: Clearing The Q1213 Sensor
Clearing the Q1213 sensor DocuTech 128/155/180 HighLight Color Operator Guide Figure 3-42 Locating the Q1205, Q1206, and Q1207 sensors 4. Brush a folded sheet of paper across each sensor to clear any obstruction. 5. Close the bindexer and finisher doors.
Page 92: Clearing The Q1221, Q1218, And Q1227 Sensors
Clearing the Q1221, Q1218, and Q1227 sensors should be performed only when directed by a Customer Support Center Representative. 1. Open the finisher front doors. 2. Locate the Q1221, Q1218, and Q1227 sensors, as shown in figure 3-44. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 93: Cleaning The Binder
Use the plastic binder platen cleaner on the tape reel or use a clean, lint-free cloth. 2. Grasp the green handle on the binder drawer. Pull the drawer out until it stops. DocuTech 128/155/180 HighLight Color Operator Guide 3- 47...
Page 94 Lift up on the cleaner and push down against the single end tab. Move the cleaner back and forth until the end tab breaks. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 95: Cleaning The Binder Tape Guides
NOTE: Cleaning the binder tape guides Cleaning the binder platen DocuTech 128/155/180 HighLight Color Operator Guide d. Continue to move the cleaner in the same manner until the 2-sided tabs break. NOTE: Ensure that the following cleaning procedures are performed in the order listed.
Page 96: Cleaning The Flappers
Figure 3-48 Cleaning the binder platen NOTE: Production publisher configuration only Using the binder platen cleaner, clean the top and side surfaces of the binder flappers until all the glue is removed. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 97: Cleaning The Calipers
Routine maintenance Figure 3-49 Cleaning the flappers Cleaning the calipers NOTE: Production publisher configuration only Using the binder platen cleaner, clean the binder caliper surfaces until all the glue is removed. DocuTech 128/155/180 HighLight Color Operator Guide 3- 51...
Page 98: Closing The Binder
There is a label behind the stitcher panel that gives instructions for replacing the stitcher spool A. Refer to this label if needed. The following steps must be performed to replace the stitcher spool A. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 99 DocuTech 128/155/180 HighLight Color Operator Guide 1. Open the finisher doors. 2. Lift the stitcher panel, which is located directly above the stitcher spools. 3. Pull the green stitcher head release handle forward and up until it latches into place, as shown in figure 3-51.
Page 100 If there is no wire on the spool, use the wire cutters to pull the remaining wire carefully out of the tubing, as shown in figure 3-53. NOTE: The wire cutter tool needed to perform this procedure is located next to stitcher spool B. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 101 DocuTech 128/155/180 HighLight Color Operator Guide Figure 3-53 Removing the wire from the tubing • If there is wire on the spool, hold it on the spool and carefully rewind the remaining wire out of the tubing and onto the stitcher spool, as shown in figure 3-54.
Page 102 Locate the green pin release handle under spool B, as shown in figure 3-56. Figure 3-56 Removing the stitcher spool pin b. Pull and hold the handle forward and remove the pin. c. Release the handle and remove stitcher spool A. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 103 DocuTech 128/155/180 HighLight Color Operator Guide 8. Install the new stitcher spool. a. Slide the new stitcher spool into position with the paper wrapper still in place. b. Replace the stitcher spool pin. Push it down until it locks into place, as shown in figure 3-57.
Page 104 10. Feed the wire slowly into the tubing until the wire extends from the stitcher plug, as shown in figure 3-59. Figure 3-59 Feeding the wire 11. Remove the stitcher plug from the measuring bracket. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 105: Storing The Binder Tape Reels
Storing the binder tape reels DocuTech 128/155/180 HighLight Color Operator Guide 12. Slowly and carefully pull about 3 feet (1 meter) of wire from the spool. 13. Cut the wire, leaving about 2 inches (51mm) of wire extending from the end of the stitcher plug.
Page 106 4. Place partially used rolls of binder tape in their original resealable foil containers. Ensure that the edge is sealed tightly. Figure 3-61 Storing the binder tape 5. Store the partially used rolls of binder tape in a dry place cooler than 90°F (32°C). DocuTech 128/155/180 HighLight Color Operator Guide...
Page 107: Replacing The Binder Tape Reel
Replacing the binder tape reel DocuTech 128/155/180 HighLight Color Operator Guide NOTE: Production publisher configuration only Use this procedure to replace the binder tape in the system. To ensure proper binding and to reduce binder tape jams, do not leave binder tape in the system when the binder is not in use.
Page 108 NOTE: Ensure that the larger center hole in the reel faces the drive. 5. Slide the new tape reel onto the tape reel drive. a. If necessary, rotate the tape reel slightly until it clicks into position. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 109 NOTE: NOTE: DocuTech 128/155/180 HighLight Color Operator Guide NOTE: The tape will not feed properly if the retainer is not locked. b. Move the reel retainer to the locked position. Figure 3-65 Locking the reel NOTE: Ensure that the tape passes through the binder tape sensor.
Page 110 8. Turn the green knob clockwise until the tape extends at least 2 inches (51mm) beyond the tape guides. Figure 3-68 Feeding the tape manually 9. Cut the tape. a. Lift up on the green tape cutter handle, as shown in figure 3-69. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 111: Adjusting The Binder Tape Registration
Adjusting the binder tape registration DocuTech 128/155/180 HighLight Color Operator Guide b. Remove the cut piece of tape. Figure 3-69 Cutting the tape 10. Close the binder drawer. 11. Close the finisher doors. NOTE: Production publisher configuration only The binder tape knob is used to align the registration of the binder tape to the top edge of a bound book.
Page 112 7. Adjust the tape position by performing one of the following steps: • Pull the knob and rotate it clockwise to move the tape toward the top edge of the book, as shown in figure 3-71. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 113 DocuTech 128/155/180 HighLight Color Operator Guide Figure 3-71 Adjusting the tape position up • Pull the knob and rotate it counterclockwise to move the tape toward the bottom edge of the book. Figure 3-72 Adjusting the tape position down 8. Close the finisher doors.
Page 114 Routine maintenance DocuTech 128/155/180 HighLight Color Operator Guide 3- 6 8...
Page 115: Problem Solving
4 Problem Solving How problems are displayed Printer faults and fault windows DocuTech 128/155/180 HighLight Color Operator Guide The system is designed to help you find and solve problems as they happen. The system detects hardware and software problems, displays error or fault messages and screens, and sounds an alert tone (if it is enabled) when a problem needs to be corrected.
Page 116: When A Fault Occurs
Follow the instructions in the Suggested solutions column of the problem solving charts in this guide. WARNING: Remember that the fuser and binder area surfaces are hot. Proceed with caution when clearing all jams. Table 4-1. Resolving a processor problem DocuTech 128/155/180 HighLight Color Operator Guide...
Page 117 The stock should be kept in the original wrapper and stored correctly. Refer to the "Technical information" chapter. • Ensure that the stock is within the limits described in the "Technical information" chapter. DocuTech 128/155/180 HighLight Color Operator Guide Problem Solving 4- 3...
Page 118 30 seconds between switching the printer off and switching the printer back Fault Code P09-418 If this fault is persistent, replace the wire module. If the fault continues, call for service. Refer to the wire module removal and replacement procedure in this guide. 4- 4 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 119 3. Do not clear the paper path unless directed to do so. The system will maintain job integrity. DocuTech 128/155/180 HighLight Color Operator Guide 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.
Page 120: Solving Print Quality Problems
NOTE: A message may appear on the controller screen telling you that there is a suspected page delivery error and advising you to check the output. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 121 Clearing paper jams in printer areas 2 through 10 for both configurations DocuTech 128/155/180 HighLight Color Operator Guide In the following figures, the printer jam clearance areas have arrows pointing to them or circles drawn around them. Figure 4-1 Area 2...
Page 122 Problem Solving 4- 8 Figure 4-3 Area 4 Figure 4-4 Area 5 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 123 Problem Solving Figure 4-5 Area 6 Figure 4-6 Area 7 DocuTech 128/155/180 HighLight Color Operator Guide 4- 9...
Page 124 NOTE: If a jammed sheet rips as you are removing it from area 8, you may have to use the pinch lever in area 9 to remove the paper. Refer to the Note following the area 14 figure for additional instructions. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 125 Using the pinch lever to access area DocuTech 128/155/180 HighLight Color Operator Guide Figure 4-8 Area 9 To clear jams from area 9: 1. Lower and pull out tray 1 to give you better access to area 9. 2. Pull the area 9 green lever toward you to unlatch it. Be sure to relatch the lever after you have cleared any paper in this area.
Page 126 Problem Solving Figure 4-9 Area 10 Figure 4-10 Area 11 (all feeder/stackers) NOTE: High volume printer configuration only DocuTech 128/155/180 HighLight Color Operator Guide 4- 1 2...
Page 127 Problem Solving Figure 4-11 Area 12 (all feeder/stackers) NOTE: High volume printer configuration only DocuTech 128/155/180 HighLight Color Operator Guide 4- 13...
Page 128 Problem Solving Clearing paper jams in the Feeder/Stackers 4- 1 4 Figure 4-12 Area 13 NOTE: Figures 4-12 and 4-13 applicable on the high volume printer configuration only. Figure 4-13 Area 14 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 129 NOTE: You may sometimes find paper lying on top of area 14, even though there is no message indicating a jam in this area. Discard the paper. Figure 4-14 Area 15 NOTE: High volume printer configuration only DocuTech 128/155/180 HighLight Color Operator Guide 4- 15...
Page 130 Problem Solving Figure 4-15 Area 16 NOTE: High volume printer configuration only DocuTech 128/155/180 HighLight Color Operator Guide 4- 1 6...
Page 131 Problem Solving Figure 4-16 Area 17 NOTE: If your printer has frequent jams in this area, you may need to clean the Q1106 sensor. NOTE: High volume printer configuration only DocuTech 128/155/180 HighLight Color Operator Guide 4- 17...
Page 132 19 and 20 after clearing an area 18 paper jam. NOTE: High volume printer configuration only 1. Open the bypass transport module door. 2. Press the area 19 green lever in the direction of the arrow printed on it. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 133 3. Remove any paper from the exposed area. 4. Press the green lever to the left until the latch catches. 5. Press the area 20 green lever in the direction of the arrow printed on it. DocuTech 128/155/180 HighLight Color Operator Guide 4- 19...
Page 134 1. If the Ready to Open indicator is not lit, press the Tray Unlock button located on the feeder tray control panel. Figure 4-20 2. When the Ready to Open indicator lights, open the feeder tray. Pull the tray all the way out for best results. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 135 DocuTech 128/155/180 HighLight Color Operator Guide 3. For the processor feeder trays, press the green lever to unlatch the paper feeder assembly. Figure 4-21 4. Remove and discard any partially fed paper. Ensure that: • The paper supply is neatly stacked.
Page 136: Incorrect Paper Size Message
NOTE: In order to assure good print quality for your jobs, the printer purges any dog-eared or skewed sheets. In addition, the printer may stop and issue an incorrect paper size message. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 137: Interposer Problems
Refer to the binder tape reel storage information in this guide. together, or cosmetic defects in the bound book DocuTech 128/155/180 HighLight Color Operator Guide NOTE: Production publisher configuration only Table 4-2. Resolving an interposer problem NOTE: Production publisher configuration only...
Page 138 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. 4- 2 4 DocuTech 128/155/180 HighLight Color Operator Guide...
Page 139: Binder Tape Fault
Refer to the satisfaction guides in the "Technical information" chapter. Binder tape fault DocuTech 128/155/180 HighLight Color Operator Guide NOTE: Production publisher configuration only To clear a binder tape fault: 1. Open the finisher doors.
Page 140: Stitcher Spool A Fault
3. Ensure that there is wire on the spool. 4. Pull the green stitcher head release handle forward and up until it latches into place, as shown in figure 4-23. Figure 4-23 Stitcher head release handle DocuTech 128/155/180 HighLight Color Operator Guide...
Page 141 DocuTech 128/155/180 HighLight Color Operator Guide Figure 4-24 Removing the stitcher wire plug 5. Remove the stitcher wire plug. • The stitcher wire plug is located above the binder area, as shown in figure 4-24. • Press and hold down the release clip.
Page 142 7. Insert the plug into the measuring bracket, as shown in figure 4-26. Figure 4-26 The measuring bracket 8. Feed the wire until the wire touches the back of the measuring bracket. 9. Remove any stitcher wire fragments. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 143 DocuTech 128/155/180 HighLight Color Operator Guide • Fold a piece of copy paper in half lengthwise. Place the folded sheet of copy paper under the stitcher head, as shown in figure 4-27. • Pull out the stitcher knob and allow it to snap back into place to free any stitcher wire fragments.
Page 144: Checking Paper Curl
If the problem persists, gather the necessary information (details follow) and call the appropriate Customer Service Support Center phone number. Your site DocuTech 128/155/180 HighLight Color Operator Guide...
Page 145 DocuTech 128/155/180 HighLight Color Operator Guide representative can supply you with the telephone number for the Customer Service Support Center in your area. The correct phone number is attached to your printer at installation time. Before calling for service, make note of: •...
Page 146 Problem Solving DocuTech 128/155/180 HighLight Color Operator Guide 4- 3 2...
Page 147: Technical Information
17 x 11 inch (432 x 279 mm) or A3 stock DT HLC 128: 128 prints per minute - 8.5 x 11 inch (216 x 279 mm), 8.5 x 14 inch (216 x 254 mm), and A4 stock; fewer prints -...
Page 148 NOTE: This tray information is applicable to trays 3-6 on the High volume printer configuration and tray 3 on the Production publisher configuration. US Letter (8 1/2 x 11 inches) US Legal (8 1/2 x 14 inches) DocuTech 128/155/180 HighLight Color Operator Guide...
Page 149: Additional Paper Capacities
Inverter Stock sizes Top tray Stock sizes Capacity Stacker Stock sizes DocuTech 128/155/180 HighLight Color Operator Guide US Ledger (17 x 11 inches) 9 x 11 inches 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))
Page 150: Printer Satisfaction Guides
48 hours before loading the paper into the system. • To make adjustments to the DocuTech 128/155/180 HLC for DocuTech 128/155/180 HighLight Color Operator Guide...
Page 151: Stock Satisfaction Guides
8 x 10 inches to 17 x 11 inches (203 x 254 mm to 432 x 279 mm) DocuTech 128/155/180 HighLight Color Operator Guide the curl in the paper, refer to the “Routine maintenance” and “Problem solving” sections of this guide.
Page 152 Table 5-3. Satisfaction guide for paper trays 3, 4, 5, and 6 NOTE: High volume printer configuration only Less reliable feeds may be expected DocuTech 128/155/180 HighLight Color Operator Guide Suggested alternatives Weights outside the limits shown are not recommended.
Page 153 Type or Xerographic bond condition paper in good condition Drilled stock, fanned thoroughly Using various stocks DocuTech 128/155/180 HighLight Color Operator Guide Less reliable feeds may be expected Slightly curled paper Intermixed weights Xerox vellum Full cut tabs Label stock...
Page 154 3, 4, and 5 with holes to the left. Do not bind or run 2-sided prints. Never-tear Do not bind or run 2-sided prints. DocuTech 128/155/180 HighLight Color Operator Guide Instructions for use...
Page 155 DocuTech 128/155/180 HighLight Color Operator Guide Stock Type 3 hole drilled, edge Do not stitch or bind. Do not run with tabs. reinforced, 4024 DP Tabs can be inserted off-line. paper For optimum satisfaction, use the paper trays 1 and 2 plate assembly. The plate assembly can be ordered by a Customer Service Representative.
Page 156: Using Non-Standard Stock
Running stock wider than 9 inches (229 mm) 4, and 5. (other than 17 x 11 inches or A3) may increase the risk of misregistration, skew, and tray 3 elevator problems. DocuTech 128/155/180 HighLight Color Operator Guide Instructions for use Impact on performance...
Page 157: Paper Stock Rotation
DocuTech 128/155/180 HLC Bypass Transport when using a third-party finishing device. Due to the physical limitations of the DocuTech 128/155/180 HLC Bypass Transport, some paper stocks will be damaged or will jam while being rotated. Currently, when using an external finishing...
Page 158 Operator that the paper stock to be rotated will not fit in the Bypass Transport. The Signature Booklet Maker attached to a DocuTech 128/155/ 180 HLC printer is only capable of handling paper stock up to 9 inches (229 mm) in length in a portrait orientation.
Page 159 Largest 12.73 x 12.73 square Largest 10.89 x 14.33 rectangle DocuTech 128/155/180 HighLight Color Operator Guide Millimeter Diagonal in inches equivalent 267 x 368 17.90 279 x 432 20.25 *Although the diagonal meets the 18-inch (457 mm) rotation limit, the paper stock long dimension exceeds the processor path width.
Page 160: Finisher Satisfaction Guides
The following guides summarize the stacker, stitcher, binder, and top tray capabilities. Table 5-10. Stacker capacity Less reliable stacking may be expected DocuTech 128/155/180 HighLight Color Operator Guide Suggested alternatives Use the top tray for larger sizes Weights outside the limits...
Page 161 (7 mm) thick sets Stacker Stacker capacity adjusts capacity automatically to suit various set sizes DocuTech 128/155/180 HighLight Color Operator Guide Less reliable stacking may be expected Suggested alternatives Over substance 20 (75 g/ When using copy paper m2) stock as sets or stacks...
Page 162 Lighter than substance 20 m2) to 10% of the sheet count (75 g/m2) in a set. Avoid adjacent inserts for substance greater than 24 (90 g/m2). Transparencies or never-tear paper cannot be used as inserts when binding. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 163 415 sheets, substance 24 (90 g/m2) 310 sheets, substance 32 (120 g/m2) 225 sheets, substance 110 (200 g/m2) DocuTech 128/155/180 HighLight Color Operator Guide Less reliable stacking may Suggested alternatives be expected 125 sheets of substance 16 Consider stitching for set sizes...
Page 164 Do not use excessively curled registration problems: paper. Slightly curled paper Stock not defined here is Precut tabs cannot be sent included in the “Using various to the top tray. stocks” section in this guide. DocuTech 128/155/180 HighLight Color Operator Guide...
Page 165: Service And Supplies
6 Service and supplies Xerox support services Customer support DocuTech 128/155/180 HighLight Color Operator Guide After the installation of your printer, there are a few ongoing tasks that must be performed. These tasks may include all or some of the following: •...
Page 166: Operator Training
To contact the U.S. Xerox Customer Support Center, call 1-800-821-2797. The Xerox Customer Support Center provides 24 hour support. Operator training is conducted either at your location or at a Xerox Customer Education Center shortly after the printer is installed. The training includes hands-on practice running basic jobs, performing routine maintenance, and solving problems.
Page 167 These items include paper, dry ink, fuser blend, and developer. Once your printer volume is established, planning ahead and buying Xerox supplies in quantity can save you money. Your supply specialists can help you. NOTE: The supplies resources listed below are for the United States only.
Page 168: Routine Maintenance
During the last five working days of each month, you need to review and transmit the data to Xerox for billing purposes. Refer to the section on Billing in the Help on the DocuSP controller for complete information on how to view and print the billing meter readings.
Page 169 8.5 x 11 inch 8.5 x 11 inch 8.5 x 14 inch 8.5 x 11 inch 8.5 x 11 inch DocuTech 128/155/180 HighLight Color Operator Guide Table 6-1. Consumable supplies Item Description Xerox paper quantities are 10 reams (5,000 sheets) to a carton...
Page 170 Clear, with a white strip on the edge Xerox labels are packaged 100 sheets to a box 33 labels per sheet 6 labels per sheet Custom form (uncut) DocuTech 128/155/180 HighLight Color Operator Guide U.S. part number 3R3096 3R3066 3R3802 3R3098 3R3107...
Page 171 Developer Blue Developer Packaged 2 bottles per carton. Red Developer Green Developer Cardinal Red Developer DocuTech 128/155/180 HighLight Color Operator Guide Item Description Packaged 3 cartridges per carton. 220K/carton with 6% black only area coverage 300K/Carton with 1.5% area coverage as highlight color 300K/Carton with 1.5% area...
Page 172 CAUTION: *Fuser blend and Fuser shield are NOT interchangeable. Contact your Xerox representative before switching from one to the other. NOTE: Developer is ordered and stocked by the Xerox Service Representative for your site. The part numbers are provided here for informational purposes only.
Page 173 DocuTech 128/155/180 HighLight Color Operator Guide Use the following table to help record the supplies and accessories you require, the date on which the order should be placed, and the actual date of the order. Table 6-2. Supplies checklist Item...
Page 174 Service and supplies Date of Date Description Quantity Item order ordered DocuTech 128/155/180 HighLight Color Operator Guide 6- 1 0...

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