Xerox Card Solutions and DocuMagnet

Hints & Tips for Xerox Card Solutions

Select a product for Hints & Tips on Using Xerox card solutions:


The following outlines tips for achieving optimum toner fusing on DocuCards with a 4135, 4635, 4635MX, 6135, DP96, DP180, 6180, 6100 or a Docutech 135.

Fuser Lubricant:
Use fuser AGENT, part #8R2955. Do not use fuser SHIELD, part #8R4077.

Variable Data Position:
Because of the difference in thickness between the carrier sheet and the card, quality imaging is not possible around the edges of the card or window. Do not image on the document or cards within " of the edge of the card.

Fuser Temperature:
Since we will be fusing on the card and the document, have the Xerox service representative set the fusing temperature at the high end of the nominal temperature range.

Fuser Contact Arc:
Set at specified width uniform across the roll length.

Duplex Imaging:
Always image the front side of the DocuCard first, then the back side. Note- When imaging WindoWell DocuCards, change the machine speed from pitch 7 to pitch 5. This will slow the machine down and allow more space between documents in the duplex inverter. If you run WindoWell DocuCards at pitch 7, the edge of the document catches on the edge of the window when two sheets pass each other in the duplex inverter.

Engineering Resource:
Please contact John Viavattine in Webster if you have more technical questions regarding fusing on DocuCards. John can be reached via phone at (585) 422-2705, via fax at (585) 455-5964 or via email

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Using a Tilt-a-tron

What is a Tiltatron:
Tiltatron: A separate mechanical feeding device, designed and built by Xerox engineers, that enables feeding of DocuCards. Its tilting action counteracts the "stack build up" in the thicker areas of the forms, allowing increased numbers of forms to be loaded into the paper supply drawer.

Why You Need a Tiltatron:
DocuCard throughput volume can be dramatically increased with the use of a drawer insert called a Tiltatron. By using the Tiltatron you can increase the quantity of forms placed in the drawer from 100 to 400. Different equipment and different DocuCard sheet sizes require slightly different Tiltatrons. The Tiltatrons for standard format DocuCards are available from CAS in approximately 2 weeks.

Ordering a Tiltatron:
When ordering a Tiltatron for standard format DocuCards, use the following part numbers:

PrinterPaper SizePart Number
DT1358.5 x 11DT135-77
DT1358.5 x 14DT135-78
41358.5 x 114135-03
41358.5 x 144135-16
46358.5 x 114635-04
46358.5 x 144635-03

Loading Forms with a Tiltatron:
  1. If you are running DocuCards verify that the sheet feed guide is in place toward the rear of the feed edge of the drawer. The feed edge is to the right on printers and to the left on publishers.
  2. Install the Tiltatron into the Paper Tray as shown below. Make sure it sits flat on the Paper Tray surface and that its "feet" nest into the indentations in the Paper Tray surface.
  3. Load 10-20 forms onto the Tiltatron and move the paper guides into loose contact with the forms.
  4. Finish loading the stack of forms onto the Tiltatron with the thick part of the stack (card or label portion of the form) over the tilting platform area. Note: the maximum capacity of forms has been loaded when the tilting platform has contacted the base of the Tiltatron. Attempting to overload the Tiltatron will affect sheet feeding performance.
  5. "Set" the stack prior to closing the paper supply drawer by pushing downward on the stack over the tilting platform and releasing. The top of the stack should return to a level condition.

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