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Xerox Document Binder 120, Operator'S Manual

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PROBLEM SOLVING

7-6

XEROX DOCUMENT BINDER 120 OPERATOR MANUAL

Areas 3A, 3B, 3C

To clear a jam in areas 3A, 3B or 3C, do the following:

1.

Read the instructions in the Message Display.

2.

Use the Mimic Display to locate the jam.

3.

Open the Right Front Door.

CAUTION:

  Be careful not to pull on the Book String Guides when

removing jammed books.

4.

Follow the instructions on the jam clearance label(s) to remove
the book and any obstruction.

NOTE:

  Any books removed during this jam clearance operation

have completed the binding process. If they are undamaged,
store them with your other completed books.

CAUTION:

  Close the Right Front door as soon as you clear the

jam.  If you leave the door open too long, any books waiting in the
Binder Module area will overheat.  This will result in defective binding
and warped books.

5.

Close the Right Front Door.

6.

Do one of the following:

a.

If the Binder is in the on-line mode, proceed to step 7.

b.

If the Binder is in the manual mode, insert the next copy
set or copy set with cover into the Manual Feeder and
press the 

Manual Start

 button.  Ignore the remaining steps

in this procedure.

7.

Read the instructions in the Message Display.

a.

Xerox 5100 or 5680/5892

?

 

If a copy set was delivered to the Output Tray of the
host machine, the indicator light for the selected Cover
Tray will flash and the Message Display will instruct
you to press 

Reset

.  After you do so, a second

message will instruct you to press 

Manual Start

.

NOTE:

  Once you press Manual Start, the Binder 120

will accept the copy set and bind it into a book.  The
Binder 120 is now ready for normal binding operation.

?

 

If no copy set was delivered to the Output Tray of the
host machine, the Message Display will advise you
that the Binder 120 is ready to bind.

b.

Xerox 5800, 5890 or 5895

The Message Display will advise you that the Binder 120 is
ready to bind.

0312058B-SBR

Summary of Contents for Document Binder 120

Page 1: ...XEROX Xerox Document Binder 120 Operator Manual January 1999 701P99911 ...

Page 2: ...rights reserved XEROX The Document Company the stylized X and all Xerox products mentioned in this publication are trademarks of XEROX CORPORATION XEROX The Document Company the stylized X and all Xerox products mentioned in this publication are trademarks of Xerox Corporation and Xerox Canada Ltd is the licensee of the trademarks ...

Page 3: ... the Xerox Corporation may void the user s authority to operate this equipment Xerox Limited The CE marking applied to this product symbolizes Xerox Limited Declaration of conformity with the following applicable Directives of the European Union as of the dates indicated January 1 1995 Council Directive 73 23 EEC amended by Council Directive 93 68 EEC approximation of the laws of the member states...

Page 4: ...h through the Binder 120 2 11 3 Preparing the Binder 120 for on line and off line operation 3 1 Modes of operation 3 2 On line 3 2 Stand by 3 2 Off line 3 2 Connecting to a Xerox 5100 3 3 Checklist for connecting to a Xerox 5100 3 10 Connecting to a Xerox 5800 or 5895 3 11 Checklist for connecting to a Xerox 5800 or 5895 3 18 Connecting to a Xerox 5680 5892 3 19 Checklist for connecting to a Xerox...

Page 5: ...owing information when you call for assistance Customer number ___________________________________ Machine type Xerox Document Binder 120 Serial number ___________________________________ Software version ___________________________________ Host machine type ___________________________________ Customer Support Representative ___________________________________ The Binder 120 requires the use of sp...

Page 6: ...NT BINDER 120 OPERATOR MANUAL 2 1 2 Getting to know the Binder 120 This chapter introduces the Xerox Binder 120 illustrates its major components and provides you with information you will need to begin making books ...

Page 7: ...120 will be in the stand alone mode for manual binding of books Switching to a different host machine Use this procedure to disconnect the Binder 120 from one host machine and connect it to a different one After doing so the Binder 120 will remain in the on line mode for automatic binding of books Switching from on line to stand by mode Use this procedure to disconnect the Interface Module of the ...

Page 8: ...is procedure to connect the Binder 120 from the stand alone mode to a Xerox 5388 host machine 1 Press the Binder 120 Power Switch to the Off O position 2 Unplug the Binder 120 Power Cord from the electrical wall outlet and the Binder 120 Set the Power Cord on top of the Binder 120 ...

Page 9: ... table in chapter 8 Technical data If the Binder 120 detects the use of a non Xerox cover a Please Feed Set Using a Xerox Cover Press Reset to Continue message will appear in the Message Display of the Control Panel of the Binder 120 The Binder 120 will stop processing You must perform a jam clearance to remove the copy set and cover from the Binder 120 See chapter 7 Problem solving for further in...

Page 10: ...ustomer Tools features that you can customize or program to meet your specific needs These features are as follows Energy Saver Spine Width Units Display Attention Lamp Sound Tone Electronic Counter Security Code Software Version This chapter describes these Customer Tools features and explains how to change them ...

Page 11: ...er 120 surface Do not apply cleaning liquids or sprays directly to the Binder 120 apply them to a cloth first Store the cover cassettes according to the directions provided in this chapter Ordering supplies The Binder 120 requires the use of specially designed Xerox covers The covers are contained in cassettes that have a capacity of 150 covers The cassettes are ordered in cases of three A variety...

Page 12: ... resolving the various problems that can occur during the operation of the Binder 120 It includes detailed procedures for resolving specific problems as well as a general problem solving table If you are unable to correct the problem follow the procedure for calling for service at the end of the chapter ...

Page 13: ...1 8 Technical data This chapter provides the product specifications and paper cover specifications for your Binder 120 It also includes the sheet capacities for the various spine widths a copy paper satisfaction guide and the book cool down times ...

Page 14: ... the Binder 120 until the book is available in the Output Tray Book capacity On line 5 to 100 sheets Manual 1 to 120 sheets Output Tray capacity 20 to 80 books depending on the spine width Cover Tray capacity Cover Tray 1 1 cover cassette 150 covers Cover Tray 2 1 cover cassette 150 covers Warm up time From the Off position Approximately 2 minutes From the Energy Saver mode Approximately 2 minutes...

Page 15: ...lbs 216 kg with cassettes Noise level Stand by 43 4 decibels Run 62 3 decibels Power consumption Warm up 800 watts Standby 237 watts Operation 324 watts Energy Saver 31 watts Heat output Warm up 2730 BTU per hour Standby 809 BTU per hour Operation 1106 BTU per hour Energy Saver 108 BTU per hour ...

Page 16: ...r size Either 8 5 x 11 inch US XCL or A4 XL Paper weight 20 lb 80 gsm to 110 lb 200 gsm for tabs inserts and title sheets the tabs inserts and title sheets must be the same size as the sheets in the copy set 20 lb 80 gsm to 32 lb 120 gsm for all other types Cover type Specially designed Xerox covers Cover cassette capacity 150 covers per cassette 3 cassettes per case ...

Page 17: ...24 lb 80 gsm 1 162 1 5 min 15 min 12 min 13 1 8 3 16 30 13 25 14 28 1 4 6 31 60 26 50 29 55 3 8 9 61 90 51 75 56 84 1 2 13 91 120 76 100 85 120 1 The binding capacity and reliability will decrease with extremes of paper characteristics such as curl static temperature humidity and paper brand The capacities listed are minimums maximums for Xerox paper 2 Minimum sheets allowed in manual mode is 1 Mi...

Page 18: ...y Paper Excellent Good Not Recommended Size 8 5 x 11 A4 Any other sizes Weight 20 24 lb 75 90 gsm 25 110 lb 91 200 gsm 20 lb 80 gsm 110 lb 200 gsm Copy Paper Type and Condition Xerographic copy paper Preprinted forms Recycled paper Less than 0 25 inch 6 mm curl Less than 0 5 inch 13 mm curl Tabs Plastic reinforced paper Synthetic paper Labels coated and carbonless stock Window stock Transparencies...

Page 19: ...ould not however allow them to lie open until the recommended cool down time Spine width inches millimeters Cool down time in minutes 1 1 16 1 5 10 1 8 3 15 1 4 6 25 3 8 9 35 1 2 13 45 1 The times indicated are for stacks of books consisting of copy sets fed into the Binder 120 from the host machine Individual books will cool down in approximately half the time shown Books consisting of cooled dow...

Page 20: ...TECHNICAL DATA 8 8 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL Notes ...

Page 21: ...r 120 experiences a jam the following events will occur The Attention Lamp if enabled will flash every 15 seconds The Sound Tone if enabled will beep every 15 seconds A red light will light on the Mimic Display at the location of the jam The Message Display will provide information about the jam Jam locator illustration Labels appear throughout the Binder 120 at the points where jams can occur The...

Page 22: ...rped books 5 Close the Interface Module Door 6 Read the instructions in the Message Display a Xerox 5100 or 5680 5892 If a copy set was delivered to the Output Tray of the host machine the indicator light for the selected Cover Tray will flash and the Message Display will instruct you to press Reset After you do so a second message will instruct you to press Manual Start NOTE Once you press Manual...

Page 23: ...ult in defective binding and warped books 7 Close the Left Front Door 8 Do one of the following a If the Binder is in the on line mode proceed to step 9 b If the Binder is in the manual mode insert the next copy set or copy set with cover into the Manual Feeder and press the Manual Start button Ignore the remaining steps in this procedure 9 Read the instructions in the Message Display a Xerox 5100...

Page 24: ...eck any copy sets removed from the host machine for damage and integrity If the copy sets are undamaged save them for manual processing into bound books through the Manual Feeder For further information refer to the Manual processing of copy sets and covers removed during jam clearance section of this chapter 11 Restart the host machine ...

Page 25: ...Front Door 6 Do one of the following a If the Binder is in the on line mode proceed to step 7 b If the Binder is in the manual mode insert the next copy set or copy set with cover into the Manual Feeder and press the Manual Start button Ignore the remaining steps in this procedure 7 Read the instructions in the Message Display a Xerox 5100 or 5680 5892 If a copy set was delivered to the Output Tra...

Page 26: ...eck any copy sets removed from the host machine for damage and integrity If the copy sets are undamaged save them for manual processing into bound books through the Manual Feeder For further information refer to the Manual processing of copy sets and covers removed during jam clearance section of this chapter 9 Restart the host machine ...

Page 27: ...Door 6 Do one of the following a If the Binder is in the on line mode proceed to step 7 b If the Binder is in the manual mode insert the next copy set or copy set with cover into the Manual Feeder and press the Manual Start button Ignore the remaining steps in this procedure 7 Read the instructions in the Message Display a Xerox 5100 or 5680 5892 If a copy set was delivered to the Output Tray of t...

Page 28: ...eck any copy sets removed from the host machine for damage and integrity If the copy sets are undamaged save them for manual processing into bound books through the Manual Feeder For further information refer to the Manual processing of copy sets and covers removed during jam clearance section of this chapter 9 Restart the host machine ...

Page 29: ...ust reset the Ground Fault Interrupter GFI WARNING Do not use the Binder 120 or perform any additional testing if the following procedure fails Call for service See the Calling for service section of this chapter for further information NOTE When testing the GFI the Binder 120 Power Cord must be connected to both the Binder 120 and the electrical wall outlet To reset the GFI do the following 1 Pre...

Page 30: ...ver was present in the Binder 120 insert just the copy set into the Manual Feeder Follow the directions on the labels adjacent to the Manual Feeder area of the Binder 120 for the correct positioning of the copy set without cover Select the desired Cover Tray for automatic insertion of the cover 6 Press the Manual Start button on the Control Panel of the Binder 120 7 Retrieve the book from the Outp...

Page 31: ...the bound book the book may not bind properly 1 Manually insert the sheet s into the bound book at the appropriate spot s Tamp the sheet s into place as neatly as you can 2 Open the Manual Feeder door 3 Insert the bound book into the Manual Feeder NOTE Follow the directions on the labels adjacent to the Manual Feeder area of the Binder 120 for the correct positioning of the book 4 Select None as t...

Page 32: ...lit The Energy Saver button has been pressed to activate this mode or the Binder 120 has been idle for the period of time specified for this mode Press the Energy Saver button to exit Energy Saver mode Wait for the Binder 120 to warm up See chapter 5 Customizing your Binder 120 for more information about Energy Saver mode Lights are lit on the Mimic Display of the Binder 120 Control Panel A jam ha...

Page 33: ...the Binder 120 This prevents further sets from being delivered to the Output Tray of the host machine Clear the host machine jam messages as directed by the host machine User Interface screen Host machine shuts down while making copy sets The selected Cover Tray is out of covers Load a cassette containing covers into the Cover Tray Host machine shuts down and Binder 120 displays a message to empty...

Page 34: ...n Frequent misfeeds in the 4a area The covers may be stuck together because the cover cassette is damaged and or the covers have become deformed due to improper storage Clear the jam as directed in the Locating and clearing a jam section of this chapter Check the cover cassette for damage that may be causing the covers to feed improperly Ensure that the cover cassettes are being stored as directed...

Page 35: ... width for the selected Cover Tray Load a cover cassette containing the correct cover spine width into the selected Cover Tray Binder displays a message instructing you to feed a set using a Xerox cover A non Xerox cover type is being used The cover sensor cannot detect the Xerox cover because the cover is deformed Clear the jam as directed in the Locating and clearing a jam section of this chapte...

Page 36: ...This could happen if you manually load covers into the cassette Load the correct cover size into the cover cassette or load a different cover cassette Books are warped or have spine damage The force of the ejection of the books into the Output Tray causes damage to the spine The doors of the Binder 120 were left open too long during jam clearance Any books left waiting in the Binder Module were da...

Page 37: ...vice Support Representative CSSR will ask you questions about the problem with the Binder 120 Please be prepared to provide the following information as requested Description of the problem Status code if any displayed in the Message Display of the Control Panel of the Binder 120 NOTE To display the status code press the Stop button on the Control Panel of the Binder 120 Binder 120 Serial Number _...

Page 38: ...PROBLEM SOLVING XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 7 19 Notes ...

Page 39: ...PROBLEM SOLVING 7 20 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL Notes ...

Page 40: ...n the Cover Trays Doing so could cause the covers to become deformed This will affect both the appearance of the covers and Binder 120 performance If you experience frequent misfeeds from the Cover Trays refer to chapter 5 Problem solving for problem resolution CAUTION Be careful not to damage the bar codes when storing the individual cassettes If a bar code is unreadable due to damage the Binder ...

Page 41: ...OX DOCUMENT BINDER 120 OPERATOR MANUAL 6 3 Cleaning the Binder 120 Clean the surface of the Binder 120 with the same cleaning solution that you use on your host machine Use a non abrasive glass cleaner or water ...

Page 42: ...CARE 6 4 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL Notes ...

Page 43: ...he top of the Control Panel of the Binder 120 This lamp illuminates to alert you to certain conditions that require your attention The default for this feature is enabled Sound Tone This feature allows you to enable or disable the Sound Tone for the Binder 120 This tone sounds to alert you to certain conditions that require your attention The default for this feature is enabled Electronic Counter ...

Page 44: ...ress and release the Energy Saver and Stop buttons The Message Display and Cover Supply Contents Display will now contain instructions for accessing the Customer Tools 2 Do one of the following a If the security code has not been changed enter the default security code by pressing the Language button five times b If the security code has been changed enter the current five button security code NOT...

Page 45: ... you press the Manual Start button the minutes increment by 15 until you reach 45 The cycle then begins again at 0 5 Press the Stop button to save the settings and exit the Energy Saver feature 6 Do one of the following Press the New Job button until the next feature you want to change appears on the second line of the Cover Supply Contents Display Press the Reset button to exit the Customer Tools...

Page 46: ...ss the Stop button to save the settings and exit the Lamp and Tone feature 7 Do one of the following Press the New Job button until the next feature you want to change appears on the second line of the Cover Supply Contents Display Press the Reset button to exit the Customer Tools features Electronic Counter 1 Enter the Customer Tools mode as instructed in the previous section of this chapter 2 Pr...

Page 47: ...sage will advise you that the Security Code is not the same Press the Manual Start button to begin the feature again 6 Do one of the following Press the New Job button until the next feature you want to change appears on the second line of the Cover Supply Contents Display Press the Reset button to exit the Customer Tools features Software Version 1 Enter the Customer Tools mode as instructed in t...

Page 48: ...CUSTOMIZING YOUR BINDER 120 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 5 7 Notes ...

Page 49: ...CUSTOMIZING YOUR BINDER 120 5 8 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL Notes ...

Page 50: ... width you must select the cover supply If you are in the on line mode you must use the Cover Trays as the cover source If you are in stand by or off line mode you either can use the Cover Trays or add the covers manually 3 Loading cassettes into the Cover Trays if necessary This step is applicable only if you have selected one or both Cover Trays as the cover source When a selected Cover Tray is ...

Page 51: ...er into the Manual Feeder along with the copy set This will result in an inaccurate spine width measurement 3 Remove the copy set from the Manual Feeder Using the Spine Width Sheet Capacity Table to determine spine width If you are using 20 lb 24 lb or 80 gsm Xerox paper you can use the Spine Width Sheet Capacity Table located in chapter 8 Technical data as an alternative to the Manual Feeder for ...

Page 52: ... from Cover Tray 1 first When Cover Tray 1 empties the Binder 120 will automatically begin feeding from Cover Tray 2 It will repeat the process of switching from the full to the empty tray until the job completes This ensures that you will not lose any valuable production time while you replace an empty cassette NOTE When using Cover Tray 1 and Cover Tray 2 together you must have the identical cov...

Page 53: ...mpty you cannot select it from the Control Panel of the Binder 120 You must insert a cassette containing covers into the Cover Tray before being able to select a Cover Tray The Binder 120 alerts you in several ways when a Cover Tray is empty These ways shown below can vary for the Cover Tray in use or a Cover Tray not in use that is empty 1 Ready to Open indicator light 2 Cover Supply Contents Dis...

Page 54: ...stop processing after completing the current set and delivering it to the Output Tray b For the Xerox 5800 5890 or 5895 the host machine may stop before completing the set in progress NOTE Before resuming production you must replace the empty cassette You then must follow the procedure applicable to the host machine For the Xerox 5100 5680 or 5892 press the Manual Start button to process the set l...

Page 55: ...k button for the Cover Tray The amber Please Wait indicator light will go on to advise you that the Cover Tray is unlocking When the Cover Tray is unlocked the green Ready to Open indicator light will go on NOTE You must press the Unlock button only if the Cover Tray you are loading currently contains covers When a Cover Tray is empty the Binder 120 automatically unlocks the Cover Tray for you 2 P...

Page 56: ...assette into the Cover Tray backwards you may damage the cassette 4 Place the new cassette into the Cover Tray Ensure that the bar code is facing the front of the Cover Tray 5 Close the Cover Tray The amber Please Wait indicator light will go on to advise you that the Cover Tray is locking When the Cover Tray is locked the red In Use indicator light will go on NOTE The Cover Tray will not close un...

Page 57: ...ired 4 Place the set of originals in the Document Handler of the host machine 5 Press the Start button on the host machine The copies will be delivered from the Output Tray of the host machine into the Binder 120 via the Interface Module 6 Retrieve the bound books from the Output Tray of the Binder 120 NOTE The entire binding process for each copy set takes about two minutes from the time the copy...

Page 58: ... Trays Use this procedure when the Binder 120 is in either stand by or off line mode and you wish to use the Cover Trays as the cover source 1 Select the correct cover supply from the Control Panel of the Binder 120 2 Open the Manual Feeder Door 0312039B SBR 0312031A SBR Xerox Document Binder 120 ...

Page 59: ...ual Feeder area of the Binder 120 b For landscape horizontal page orientation insert the copy set so that top page of your copy set faces the right side of the Binder 120 and the top of the pages face downward into the Manual Feeder as the word Xerox is shown in the figure NOTE Follow the orientation labels on the Manual Feeder area of the Binder 120 4 Press the Manual Start button on the Control ...

Page 60: ...he Binder 120 until it is available as a bound book in the Output Tray of the Binder 120 NOTE When the books exit the Binder 120 you can handle them and browse through them You should not however allow them to lie open until the glue in the cover spine has cooled and reached full strength The recommended cool down time depends on the width of the spine and the number of books Refer to the book coo...

Page 61: ... the correct covers It eliminates the effort of loading the correct cassettes into a Cover Tray 1 Select None from the Cover Supply section on the Control Panel of the Binder 120 2 Insert the copy set into the book cover according to the page orientation step a or step b a For portrait vertical page orientation insert the copy set so that the top page of your copy set faces the front of the cover ...

Page 62: ...igure 3 Open the Manual Feeder Door 4 Insert the copy set with the cover into the Manual Feeder according to the page orientation step a or step b a For portrait vertical page orientation insert the copy set with the cover so that the top page of your copy set faces the right side of the Binder 120 as the word Xerox is shown in the figure and the cover spine faces downward into the Manual Feeder N...

Page 63: ...iminates the need to press the Manual Start button for each book 6 Retrieve the bound books from the Output Tray of the Binder 120 NOTE The entire binding process for each copy set takes about two minutes from the time the copy set enters the Binder 120 until it is available as a bound book in the Output Tray of the Binder 120 NOTE When the books exit the Binder 120 you can handle them and browse ...

Page 64: ...MAKING THE BOOKS 4 16 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL Notes ...

Page 65: ...he Interface Module lock into place 4 Squeeze the Alignment Bracket Lever and move the Alignment Bracket out of its storage position to the diamond u symbol on the Alignment Bracket Label The solid line next to the symbol should be even with the arrow on the side of the Interface Module NOTE The Alignment Bracket has three positions The Alignment Bracket Label denotes each position by a symbol The...

Page 66: ... pressing the Caster Releases 7 Unlock all of the Binder 120 Casters by pressing with your foot on the green Caster Release of each locked Caster 8 Move the Binder 120 toward the host machine so that the left front corner of the Binder 120 is in line with the right front corner of the host machine NOTE Allow up to three feet one meter of workspace between the Binder 120 and the host machine 031208...

Page 67: ... the next step CAUTION The ends of the Interface Cable insert into the Interface Connectors in only one direction 11 Insert one end of the Interface Cable into the Interface Connector of the Binder 120 and the other end into the Interface Connector of the host machine Align the notched portion of each end of the Interface Cable with the notched portion of each Interface Connector NOTE The Output T...

Page 68: ...cket is flush with the right front corner of the host machine Use the arrows and edging around the cutout corner as an aid in positioning the Binder 120 NOTE When the Binder 120 is in the proper position the Alignment Bracket will fit snugly against the host machine However the machines will not be at a 90 degree angle with each other The actual angle of alignment will be slightly greater than 90 ...

Page 69: ...O position 2 Unplug the Binder 120 3 Raise the Interface Module to the diamond u position 4 Move the Alignment Bracket out of storage to the diamond u position 5 Extend the Receiving Plate outward 6 Rotate the Receiving Plate up as far as it will go 7 Unlock the Binder 120 Casters 8 Move the Binder 120 toward the host machine 9 Plug in the Binder 120 10 Press the Binder 120 Power Switch to the On ...

Page 70: ... that it has no contact with the host machine Additionally the Retainer or Spacer on the Output Tray of the host machine is detached from the Damper Arm so that the Damper Arm is at its normal operating position The Binder 120 and the host machine can now operate independently of each other The operator must use the Manual Feeder of the Binder 120 to insert the copy sets into the Binder 120 While ...

Page 71: ...necting to a Xerox 5100 Use this procedure to connect the Binder 120 from the stand alone mode to a Xerox 5100 host machine 1 Press the Binder 120 Power Switch to the Off O position 2 Unplug the Binder 120 Power Cord from the electrical wall outlet and the Binder 120 Set the Power Cord on top of the Binder 120 ...

Page 72: ...Bracket Lever and move the Alignment Bracket out of its storage position to the triangle s symbol on the Alignment Bracket Label The solid line next to the symbol should be even with the arrow on the side of the Interface Module NOTE The Alignment Bracket has three positions The Alignment Bracket Label denotes each position by a symbol The triangle s symbol represents the position used for the Xer...

Page 73: ...pressing the Caster Releases 7 Unlock all of the Binder 120 Casters by pressing with your foot on the green Caster Release of each locked Caster 8 Move the Binder 120 toward the host machine so that the left front corner of the Binder 120 is in line with the right front corner of the host machine NOTE Allow up to three feet one meter of workspace between the Binder 120 and the host machine 0312074...

Page 74: ...only one direction 10 Insert one end of the Interface Cable into the Interface Connector of the Binder 120 and the other end into the Interface Connector of the host machine Align the notched portion of each end of the Interface Cable with the notched portion of each Interface Connector NOTE The Output Tray of the host machine will adjust automatically to its correct position if it is not already ...

Page 75: ...ment strips that hold the Retainer away from the Output Tray 13 Connect the Damper Arm on the host machine Output Tray to the Retainer Align the top edge of the Damper Arm attachment strip with the top edge of the Retainer attachment strip and squeeze to attach NOTE Connecting the Damper Arm to the Retainer allows the copy sets to enter the Binder 120 without interference from the Damper Arm 03120...

Page 76: ... toward the Output Tray of the host machine so that the cutout corner of the Alignment Bracket is flush with the right front corner of the host machine Use the arrows and raised green edging around the cutout corner as an aid in positioning the Binder 120 NOTE When the Binder 120 is in the proper position the Alignment Bracket will fit snugly against the host machine However the machines will not ...

Page 77: ... OPERATION XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 3 9 WARNING If you are wearing open toe shoes be careful when pressing the Lock Levers 16 Lock at least two of the Binder 120 Casters by pressing with your foot on the gray Lock Lever of the Casters ...

Page 78: ... the Interface Module to the triangle s position 4 Move the Alignment Bracket out of storage to the triangle s position 5 Extend the Receiving Plate outward 6 Rotate the Receiving Plate up as far as it will go 7 Unlock the Binder 120 Casters 8 Move the Binder 120 toward the host machine 9 Plug in the Binder 120 10 Connect the Interface Cable 11 Press the Binder 120 Power Switch to the On I positio...

Page 79: ...to a Xerox 5800 or 5895 Use this procedure to connect the Binder 120 from the stand alone mode to a Xerox 5800 or 5895 host machine 1 Press the Binder 120 Power Switch to the Off O position 2 Unplug the Binder 120 Power Cord from the electrical wall outlet and the Binder 120 Set the Power Cord on top of the Binder 120 ...

Page 80: ...lignment Bracket Lever and move the Alignment Bracket out of its storage position to the triangle s symbol on the Alignment Bracket Label The solid line next to the symbol should be even with the arrow on the side of the Interface Module NOTE The Alignment Bracket has three positions The Alignment Bracket Label denotes each position by a symbol The triangle s symbol represents the position used fo...

Page 81: ... pressing the Caster Releases 7 Unlock all of the Binder 120 Casters by pressing with your foot on the green Caster Release of each locked Caster 8 Move the Binder 120 toward the host machine so that the left front corner of the Binder 120 is in line with the right front corner of the host machine NOTE Allow up to three feet one meter of workspace between the Binder 120 and the host machine 031207...

Page 82: ...r 120 and into the electrical wall outlet NOTE Do not plug the Binder 120 Power Cord into the utility outlet on the host machine The utility outlet is for service use only CAUTION The ends of the Interface Cable insert into the Interface Connectors in only one direction 11 Insert one end of the Interface Cable into the Interface Connector of the Binder 120 and the other end into the Interface Conn...

Page 83: ...arefully disconnect the attachment strips that hold the Retainer away from the Output Tray 14 Connect the Damper Arm on the host machine Output Tray to the Retainer Align the top edge of the Damper Arm attachment strip with the top edge of the Retainer attachment strip and squeeze to attach NOTE Connecting the Damper Arm to the Retainer allows the copy sets to enter the Binder 120 without interfer...

Page 84: ...0 toward the Output Tray of the host machine so that the cutout corner of the Alignment Bracket is flush with the right front corner of the host machine Use the arrows and raised green edging around the cutout corner as an aid in positioning the Binder 120 NOTE When the Binder 120 is in the proper position the Alignment Bracket will fit snugly against the host machine However the machines will not...

Page 85: ...OPERATION XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 3 17 WARNING If you are wearing open toe shoes be careful when pressing the Lock Levers 17 Lock at least two of the Binder 120 Casters by pressing with your foot on the gray Lock Lever of the Casters ...

Page 86: ...to the triangle s position 4 Move the Alignment Bracket out of storage to the triangle s position 5 Extend the Receiving Plate outward 6 Rotate the Receiving Plate up as far as it will go 7 Unlock the Binder 120 Casters 8 Move the Binder 120 toward the host machine 9 Run two two sheet collated sets through the host machine 10 Plug in the Binder 120 11 Connect the Interface Cable 12 Press the Binde...

Page 87: ...ng to a Xerox 5680 5892 Use this procedure to connect the Binder 120 from the stand alone mode to a Xerox 5680 5892 host machine 1 Press the Binder 120 Power Switch to the Off O position 2 Unplug the Binder 120 Power Cord from the electrical wall outlet and the Binder 120 Set the Power Cord on top of the Binder 120 ...

Page 88: ...o place 4 Squeeze the Alignment Bracket Lever and move the Alignment Bracket out of its storage position to the diamond u symbol on the Alignment Bracket Label The solid line next to the symbol should be even with the arrow on the side of the Interface Module NOTE The Alignment Bracket has three positions The Alignment Bracket Label denotes each position by a symbol The triangle s symbol represent...

Page 89: ... pressing the Caster Releases 7 Unlock all of the Binder 120 Casters by pressing with your foot on the green Caster Release of each locked Caster 8 Move the Binder 120 toward the host machine so that the left front corner of the Binder 120 is in line with the right front corner of the host machine NOTE Allow up to three feet one meter of workspace between the Binder 120 and the host machine 031208...

Page 90: ...e top surface of the Output Tray denotes the location of the metal clip on the underside 11 While squeezing the metal clip slowly move the Output Tray to the outer position NOTE The Output Tray has two positions inner and outer The inner position is used for normal operation of the host machine The outer position is used when the host machine is connected to the Binder 120 The distance between eac...

Page 91: ...one direction 13 Insert one end of the Interface Cable into the Interface Connector of the Binder 120 and the other end into the Interface Connector of the host machine Align the notched portion of each end of the Interface Cable with the notched portion of each Interface Connector NOTE The Output Tray of the host machine will adjust automatically to its correct position if it is not already there...

Page 92: ...0 toward the Output Tray of the host machine so that the cutout corner of the Alignment Bracket is flush with the right front corner of the host machine Use the arrows and raised green edging around the cutout corner as an aid in positioning the Binder 120 NOTE When the Binder 120 is in the proper position the Alignment Bracket will fit snugly against the host machine However the machines will not...

Page 93: ...OPERATION XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 3 25 WARNING If you are wearing open toe shoes be careful when pressing the Lock Levers 17 Lock at least two of the Binder 120 Casters by pressing with your foot on the gray Lock Lever of the Casters ...

Page 94: ...Move the Alignment Bracket out of storage to the diamond u position 5 Extend the Receiving Plate outward 6 Rotate the Receiving Plate up as far as it will go 7 Unlock the Binder 120 Casters 8 Move the Binder 120 toward the host machine 9 Connect the two parts of the Spacer on the host machine Output Tray 10 Squeeze the metal pin located underneath the inside edge of the host machine Output Tray 11...

Page 95: ...necting to a Xerox 5890 Use this procedure to connect the Binder 120 from the stand alone mode to a Xerox 5890 host machine 1 Press the Binder 120 Power Switch to the Off O position 2 Unplug the Binder 120 Power Cord from the electrical wall outlet and the Binder 120 Set the Power Cord on top of the Binder 120 ...

Page 96: ...o place 4 Squeeze the Alignment Bracket Lever and move the Alignment Bracket out of its storage position to the diamond u symbol on the Alignment Bracket Label The solid line next to the symbol should be even with the arrow on the side of the Interface Module NOTE The Alignment Bracket has three positions The Alignment Bracket Label denotes each position by a symbol The triangle s symbol represent...

Page 97: ... pressing the Caster Releases 7 Unlock all of the Binder 120 Casters by pressing with your foot on the green Caster Release of each locked Caster 8 Move the Binder 120 toward the host machine so that the left front corner of the Binder 120 is in line with the right front corner of the host machine NOTE Allow up to three feet one meter of workspace between the Binder 120 and the host machine 031211...

Page 98: ...r 120 and into the electrical wall outlet NOTE Do not plug the Binder 120 Power Cord into the utility outlet on the host machine The utility outlet is for service use only CAUTION The ends of the Interface Cable insert into the Interface Connectors in only one direction 11 Insert one end of the Interface Cable into the Interface Connector of the Binder 120 and the other end into the Interface Conn...

Page 99: ...mes If you do not maintain the proper alignment the Binder 120 either may not receive the copy sets at all or may receive them improperly Improperly received copy sets could result in input jams in the Interface Module 14 Move the Binder 120 toward the Output Tray of the host machine so that the cutout corner of the Alignment Bracket is flush with the right front corner of the host machine Use the...

Page 100: ...ANUAL 15 Rotate the Receiving Plate down until it rests on the Output Tray of the host machine WARNING If you are wearing open toe shoes be careful when pressing the Lock Levers 16 Lock at least two of the Binder 120 Casters by pressing with your foot on the gray Lock Lever of the Casters 0312087A SBR ...

Page 101: ...ace Module to the diamond u position 4 Move the Alignment Bracket out of storage to the triangle u position 5 Extend the Receiving Plate outward 6 Rotate the Receiving Plate up as far as it will go 7 Unlock the Binder 120 Casters 8 Move the Binder 120 toward the host machine 9 Run two two sheet collated sets through the host machine 10 Plug in the Binder 120 11 Connect the Interface Cable 12 Press...

Page 102: ...and 5895 do the following From the Current Job Programming screen touch the Full Feature Copying tab Touch the Copy Output feature Touch the Finishing Accessories Disabled option Touch the Save button NOTE You must perform the above procedure or the host machine will display a finisher fault 2 Press the Binder 120 Power Switch to the Off O position 3 Unplug the Binder 120 Power Cord from the elect...

Page 103: ...Binder 120 a Xerox 5100 To disconnect from a Xerox 5100 remove the Interface Cable from the Interface Connector of the host machine and the Binder 120 b Xerox 5800 or 5895 To disconnect from a Xerox 5800 or 5895 loosen the screws at the ends of each Interface Connector and remove the Interface Cable from the Interface Connector of the host machine and the Binder 120 c Xerox 5680 5892 To disconnect...

Page 104: ...face Connector and remove the Interface Cable from the Interface Connector of the host machine and the Binder 120 5 Rotate the Receiving Plate up as far as it will go WARNING If you are wearing open toe shoes be careful when pressing the Caster Releases 6 Unlock all of the Binder 120 Casters by pressing with your foot on the green Caster Release of each locked Caster 0312092A SBR 0 312091B SBR ...

Page 105: ...structions and illustration s for your host machine step a or b a Xerox 5100 5800 5890 or 5895 Disconnect the Damper Arm by carefully pulling the Retainer attachment strip away from the Damper Arm attachment strip Return the Retainer to its storage position by curving the Retainer backwards aligning the attachment strips and squeezing to attach NOTE For the Xerox 5890 this step is not required The...

Page 106: ...ge of the host machine Output Tray NOTE A green label on the top surface of the Output Tray denotes the location of the metal clip on the underside While squeezing the metal clip move the Output Tray back to the inner position NOTE The Output Tray has two positions inner and outer The inner position is used for normal operation of the host machine The outer position is used when the host machine i...

Page 107: ...ket Label denotes each position by a symbol The triangle s symbol represents the position used for the Xerox 5100 5800 and 5895 It corresponds to the triangle symbol on the Angle Registration Label The diamond u symbol represents the position used for the Xerox 5890 and 5680 5892 It corresponds to the diamond symbol on the Angle Registration Label The curved arrow symbol represents the position us...

Page 108: ...ace Module is somewhat heavy Be careful when lowering the Interface Module 14 Squeeze the Interface Module Release Grip and lower the Interface Module all the way down to the left side of the Binder 120 15 Move the Binder 120 to the desired location WARNING If you are wearing open toe shoes be careful when pressing the Lock Levers 16 Lock at least two of the Binder 120 Casters by pressing with you...

Page 109: ...INE AND OFF LINE OPERATION XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 3 41 17 Plug the Binder 120 Power Cord into the Binder 120 and into the electrical wall outlet 18 Press the Binder 120 Power Switch to the On I position 0312017B SBR ...

Page 110: ...k the Binder 120 Casters 7 Move the Binder 120 away from the host machine 8 Do one of the following For the Xerox 5100 5800 or 5895 detach the Retainer from the Damper Arm on the host machine Output Tray and return the Retainer to its storage position For the Xerox 5680 5892 disconnect the two parts of the Spacer For the Xerox 5890 detach the Retainer from the Damper Arm on the host machine Output...

Page 111: ...tive by calling the number that you recorded in chapter 1 Introduction To disconnect the Binder 120 from one host machine and connect it to a different one do the following 1 Perform steps 1 to 14 from the procedure entitled Disconnecting from a host machine discussed earlier in this chapter NOTE Once you lower the Interface Module all the way down to the left side of the Binder 120 you will not n...

Page 112: ...sed earlier in this chapter 1 Retract the Receiving Plate 2 Lower the Interface Module all the way down to the left side of the Binder 120 3 Store the Alignment Bracket 4 Do one of the following For the Xerox 5100 5800 or 5895 detach the Retainer from the Damper Arm on the host machine Output Tray and return the Retainer to its storage position For the Xerox 5680 5892 disconnect the two parts of t...

Page 113: ...e correct position and height when aligning the Binder 120 to it 1 For the Xerox 5800 5895 and 5890 program the host machine to run two two sheet collated sets single or duplex 2 For the Xerox 5680 5892 do the following Connect the two parts of the Spacer Move the Output Tray to the outer position 3 Move the Alignment Bracket out of storage to the appropriate position for your host machine 4 Raise...

Page 114: ...PREPARING THE BINDER 120 FOR ON LINE AND OFF LINE OPERATION 3 46 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL Notes ...

Page 115: ...nal components of the Binder 120 Take a few minutes to become familiar with these components 1 Left Front Door 2 Interface Module 3 Manual Feeder Door 4 Power On Off Switch 5 Control Panel 6 Attention Lamp 7 Output Tray 8 Book Guide 9 Right Front Door 10 Cover Tray 2 11 Cover Tray 1 12 Caster 1 1 2 2 3 4 5 6 7 8 9 10 11 12 0312002C SBR ...

Page 116: ...ER 120 OPERATOR MANUAL 2 3 Below is an illustration of the location of the Xerox Document Binder 120 Operator Manual holder located on the Rear Cover of the Binder 120 1 Operator Manual 2 Operator Manual Holder View from rear of Binder 120 0312060B SBR ...

Page 117: ...ables you to program the Binder 120 and provides operational information The appearance of the Control Panel varies for the United States and for Xerox Limited and Xerox Canada Limited Below are illustrations of both versions of the Control Panel The table following the illustrations contains descriptions of each of the components United States Xerox Limited Xerox Canada Limited 10 ...

Page 118: ...ou to switch between the default and second languages All messages in the Message Display and Cover Supply Contents Display will display in the selected language 6 Energy Saver Button Energy Saver reduces power consumption Press this button to enter and exit Energy Saver mode When Energy Saver is on the green light to the right of this button will light NOTE You can enable Energy Saver only when n...

Page 119: ...0 To process the set first clear the jam in the Binder 120 Then press the Manual Start button To complete the rest of the job follow the directions on the User Interface screen of the host machine 9 Stop Button Press this button to stop the operation of the Binder 120 When you do so the binding process will halt and the Attention Lamp if enabled will light If the Binder 120 is connected to a host ...

Page 120: ...It enables copy sets to feed from the host machine to the Binder 120 for automatic binding into books Below is an illustration of the major components of the Interface Module 1 Interface Cable Connectors 2 Interface Module Release Grip 3 Pivot Area 4 Angle Registration Label 5 Interface Module Door 6 Alignment Bracket 7 Receiving Plate 8 Receiving Plate Control Grip View from left side of Binder 1...

Page 121: ... 120 It enables you to feed the copy sets manually or if applicable copy sets with covers manually Refer to chapter 4 Making the Books for detailed instructions on using the Manual Feeder The illustration below shows the Manual Feeder Door open to the position for receiving copy sets manually 1 Manual Feeder Door shown open 2 Manual Feeder 1 2 1 2 0312006C SBR ...

Page 122: ...pties the Binder 120 will unlock the Cover Tray automatically for you 2 In Use indicator Red This indicator lights when the Cover Tray contains covers the tray is currently selected and the tray is locked and ready for operation 3 Please Wait indicator Amber This indicator lights after you press the Unlock button and the Cover Tray is in the process of unlocking It also lights after you close the ...

Page 123: ... Tray will appear in the Message Display of the Binder 120 Control Panel If enabled the Attention Lamp will light and the Sound Tone will beep twice The Binder 120 will finish binding the copy sets in process but will not accept any new sets To continue feeding sets to the Binder 120 you must empty the Output Tray of both the Binder 120 and the host machine You then must restart the host machine W...

Page 124: ... or Auto Input Station delivers the copy set to the Set Drive Station where the copy set sheets are aligned 4 Book Drive Station If a Cover Tray has been selected the cover is delivered to the Book Drive Station where the cover is held open The Set Drive Station feeds the copy set into the open cover in the Book Drive Station 5 Binder Module The Book Drive Station delivers the book to the Binder M...

Page 125: ...GETTING TO KNOW THE BINDER 120 2 12 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL Notes ...

Page 126: ... switching between on line and stand by modes Chapter 4 Making the books This chapter provides an overview of books and book making It contains instructions for determining the correct spine width selecting the desired cover source and loading cassettes Additionally it describes the procedures for making books in both automatic and manual modes Chapter 5 Customizing your Binder 120 This chapter de...

Page 127: ...e characters in the middle of a text string refer to selections on the Control Panel for example press the Manual Start button Initial capitals Specific part names of the machine are identified by initial capitals for example Interface Module Manual Feeder Cover Tray 1 etc WARNING A WARNING indicates an operation maintenance procedure practice condition or statement that if not strictly followed c...

Page 128: ... the Binder 120 does not operate normally refer to chapter 7 Problem Solving Electrical safety Do not use an extension cord Always connect the Binder 120 power cable directly into a properly grounded power source receptacle If in doubt have the receptacle checked by a qualified electrician Do not use an adapter plug to connect the Binder 120 to an electrical outlet that lacks a ground connection t...

Page 129: ...e procedure that is not described in this Operator Manual or you have not been trained to do by a Xerox Service Representative or Customer Support Engineer Do not remove any covers or guards that are attached with screws There are no parts that you can maintain or service behind these covers Use the materials and supplies specifically designated for the Binder 120 The use of supplies that are not ...

Page 130: ...nsure that the room temperature and relative humidity are within the following ranges Temperature 50 F 10 C to 90 F 32 C Relative humidity 15 to 85 Place the Binder 120 on a flat level surface Ensure that the Binder 120 is level for optimum performance Avoid locations that subject the Binder 120 to the following conditions Direct sunlight which may make the screen difficult to see Extreme changes ...

Page 131: ...or service if required The diagrams below illustrate the service space requirements for on line and off line modes Service space requirements for the on line mode 30 762 mm 30 762 mm Host Machine Output Tray Interface Module Up Binder 120 30 762 mm front Service space requirements for the off line mode 10 254 mm Interface Module Down 36 914 mm 10 254 mm 10 254 mm Binder 120 front ...

Page 132: ... sources provide additional information 5100 For operation of the Xerox 5100 see your Xerox 5100 Copier Operator Manual 5800 family For operation of the Xerox 5800 family of products see the copier user guide for the specific product 5680 5892 For operation of the Xerox 5680 5892 see your Xerox 5680 5892 Copier Operator Manual 2 3 4 1 1 2 0312001C SBR ...

Page 133: ...INTRODUCTION XEROX DOCUMENT BINDER 120 OPERATOR MANUAL 1 9 Notes ...

Page 134: ...INTRODUCTION 1 10 XEROX DOCUMENT BINDER 120 OPERATOR MANUAL Notes ...

Page 135: ...g the Cover Trays 4 10 Manual operation without using the Cover Trays 4 13 5 Customizing your Binder 120 5 1 Descriptions of the Customer Tools features 5 2 How to change the Customer Tools features 5 3 Entering the Customer Tools mode 5 3 Changing the Customer Tools features 5 4 6 Care 6 1 Helpful hints 6 1 Care of your Binder 120 6 1 Ordering supplies 6 1 Storing the cover cassettes 6 2 Cleaning...

Page 136: ... 120 OPERATOR MANUAL vii Calling for service 7 18 8 Technical data 8 1 Product specifications 8 2 Paper cover specifications 8 4 Spine width sheet capacity 8 5 Copy paper guide for reliable Binder 120 operation 8 6 Booklet cool down time 8 7 ...

Page 137: ...TABLE OF CONTENTS viii XEROX DOCUMENT BINDER 120 OPERATOR MANUAL ...

Page 138: ...NOTICES iv XEROX DOCUMENT BINDER 120 OPERATOR MANUAL ...

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