X4500 Scanner
4036-304
• Problem Solving
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.
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4036-304
Table of Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Service Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Ease of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Digital Copier and Full-function Fax Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Network Scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Duplex Scanning through the Auto Document Feeder (ADF) . . . . . . . . . . . . . . 1-2
Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Scanner Mechanism Overview and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Problem Solving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MFD Controller Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Scanner Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Cover and Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ADF Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Document Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
ADF Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
ADF Optical CCD Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
User Interface Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Upper Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Flatbed CCD Optical Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Carriage Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Carriage Belt Pulley Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
MFD Controller Cage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
iii
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4036-304
Distribution Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Main Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Scanner Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
MFD Controller Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1
iv
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4036-304
Safety Information
Safety Information
•
This product is designed, tested and approved to meet strict global safety standards
with the use of specific Lexmark components. The safety features of some parts may
not always be obvious. Lexmark is not responsible for the use of other replacement
parts.
•
•
The maintenance information for this product has been prepared for use by a
professional service person and is not intended to be used by others.
There may be an increased risk of electric shock and personal injury during
disassembly and servicing of this product. Professional service personnel should
understand this and take necessary precautions.
Consignes de Sécurité
•
Ce produit a été conçu, testé et approuvé pour respecter les normes strictes de
sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les
caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange.
•
•
Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à
un personnel de maintenance qualifié.
Le démontage et l'entretien de ce produit pouvant présenter certains risques
électriques, le personnel d'entretien qualifié devra prendre toutes les précautions
nécessaires.
Norme di sicurezza
•
Il prodotto è stato progettato, testato e approvato in conformità a severi standard di
sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di
sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark
non è responsabile per l’utilizzo di parti di ricambio di altri produttori.
•
•
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate
soltanto al personale di assistenza autorizzato.
Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire
scosse elettriche e danni alla persona è più elevato. Il personale di assistenza
autorizzato, deve, quindi, adottare le precauzioni necessarie.
Safety Information v
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4036-304
Sicherheitshinweise
•
Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet,
um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die
sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von
Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen.
•
•
Die Wartungsinformationen für dieses Produkt sind ausschließlich für die
Verwendung durch einen Wartungsfachmann bestimmt.
Während des Auseinandernehmens und der Wartung des Geräts besteht ein
zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das
zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.
Pautas de Seguridad
•
Este producto se ha diseñado, verificado y aprobado para cumplir los más estrictos
estándares de seguridad global usando los componentes específicos de Lexmark.
Puede que las características de seguridad de algunas piezas no sean siempre
evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio.
•
•
La información sobre el mantenimiento de este producto está dirigida
exclusivamente al personal cualificado de mantenimiento.
Existe mayor riesgo de descarga eléctrica y de daños personales durante el
desmontaje y la reparación de la máquina. El personal cualificado debe ser
consciente de este peligro y tomar las precauciones necesarias.
Informações de Segurança
•
Este produto foi concebido, testado e aprovado para satisfazer os padrões globais
de segurança na utilização de componentes específicos da Lexmark. As funções de
segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de substituição.
•
•
As informações de segurança relativas a este produto destinam-se a profissionais
destes serviços e não devem ser utilizadas por outras pessoas.
Risco de choques eléctricos e ferimentos graves durante a desmontagem e
manutenção deste produto. Os profissionais destes serviços devem estar avisados
deste facto e tomar os cuidados necessários.
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4036-304
Informació de Seguretat
•
Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes
normes de seguretat globals amb la utililització de components específics de
Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre
siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.
•
•
La informació pel manteniment d’aquest producte està orientada exclusivament a
professionals i no està destinada a ningú que no ho sigui.
El risc de xoc elèctric i de danys personals pot augmentar durant el procés de
desmuntatge i de servei d’aquest producte. El personal professional ha d’estar-ne
assabentat i prendre les mesures convenients.
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viii Service Manual
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4036-304
1. Overview
This manual is for maintenance engineers. It describes the maintenance areas,
installation, disassembly, and the main troubleshooting guides.
Take your time to read this manual thoroughly to obtain comprehensive knowledge about
the scanner before servicing the unit.
Service Guidelines
1. Before disassembling the scanner, make sure the power supply cord is disconnected
from the power outlet. Do not remove or install the connectors on the scanner with
the power supply turned ON.
2. Use caution not to drop small parts or screws inside the unit when disassembling
and reassembling.
3. Do not pull the connector cable when disconnecting it. Hold the connector.
4. When carrying the scanning head unit, put it in an anti-static bag.
5. Keep the document glass platen surface clean with a dry clean lint free cloth.
Product Description
The 4036-304 Scanner is a multifunction solution that offers integrated print, copy, fax
and color network-scanning capabilities for increased small workgroup productivity. The
scanner is easy to use and provides low-cost access to key office functions, including fax
from workstation, network color copying, scanning, and electronic document routing.
Give your document to the scanner, and in a few steps, it scans to the network and
delivers it wherever, to whomever you want. With this scanner, inefficient trips to the
mailroom, copier, fax machine and to your workstation are a thing of the past.
Product Features
Ease of Use
The user interface on the front of the scanner looks like a panel on a copier with standard
phone keys added. The operating steps follow the same procedure as that of a copier or
fax machine.
Overview 1-1
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4036-304
Digital Copier and Full-function Fax Machine
When the scanner is connected to a Lexmark printer, it performs convenient digital
copying. When connected to telephone line, the scanner performs a full fax function - to
send and to receive faxes.
Network Scanning
The scanner uses two Color Charge-Coupled Devices (CCD) when scanning. Through a
network port at the rear of the scanner, the product is able to do network scanning.
Duplex Scanning through the Auto Document Feeder (ADF)
To increase workgroup productivity, the scanner uses the advance duplex scanning
capability. The scan speed limit is 20 ppm at 300 dpi resolution. The auto document
feeder can hold up to 50 pages at one time.
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4036-304
Product Specifications
The scanner is designed to meet the following product specifications:
Scanner
Scanner Type
Flatbed Scanner with ADF built in
Optical Resolution
Flatbed: 300x600 dpi
ADF: 300x300 dpi
Enhanced Resolution
Scan Speed
9600x9600 dpi
10 ppm at 300 dpi color for single page scanning
20 ppm at 300 dpi line-art, duplex for ADF
Scan Method
Light Source
CPU
Color Charge-Coupled Device (CCD)
Cold Cathode Fluorescent Lamp (CCFL)
Arm 7 KS32C41000
Scan Area
Display
Max. 8.5 x 14.0 inch (legal size) for ADF
640x480 color VGA touch screen
Image Types
42-bit color (internal)
14-bit gray (internal)
1-bit line-art, Dither, Error Diffusion
Scan Accuracy
1. Leading Edge
2. Side Edge
3. Skew
Flatbed
ADF
<-1 ~ +2 mm
<-1 ~ +2 mm
<1 mm
<2.5 ~ +2.5 mm
<2.5 ~ +2.5 mm
<2 mm
4. Magnification Rate
Tolerance (Horizontal
and Vertical)
-1.5% ~ +1.5%
-1.5% ~ +1.5%
Physical Dimension
Weight
Width: 570 mm Depth: 430 mm Height: 315 mm
14 kg
Overview 1-3
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4036-304
Environment:
-Operating
10°C to 35°C (50°F to 95°F)
20% to 80% RH (Relative Humidity)
-40°C to 65°C (-40°F to 149°F)
10% to 90% RH (Relative Humidity)
-Storage
Random Vibration:
-Unpacked non-op
-Package
10-200Hz, 0.005 p.s.d. (G^2/Hz)
5-200Hz, 0.015 p.s.d. -6 dB/oct
One hour in 3 major axes
-Bump
-Drop
Severity: 25g/6ms, 1000 times in each direction
Must meet NSTA specification
Drop Point: 1 corner, 3 edges and 6 surfaces
Total 10 times
Acoustic Noise
Operating: 58 dB or less
EC 1000-4-2 ESD Standard
UL, CSA, TUV/GS, SEMKO
Electrostatic Discharge
Safety Regulation
EMC regulation
FCC Part 15 Subchapter J Class A
CE Marking, C-Tick
ADF
General Specifications:
-Optical Resolution
-Document Capacity
300x300 dpi
50 sheets
Document:
-Document Size
Max. 8.5 x 14 inch (W x L)
Min. 4.5 x 5.5 inch (W x L)
0.05~0.15 mm
-Thickness
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4036-304
Theory of Operation
System Description
The Lexmark X4500 is a duplexing scanner option which can synchronously scan both
the top and bottom sides of a document in color. The major system components include a
main scanner control board, an automatic document feeder, flatbed, two optical CCD
modules (one in ADF, one in flatbed), a user interface with a touch screen panel and a
multifunction device controller cage located within the base of the scanner. The MFD
controller cage includes a 1394 communications card to communicate with the main
scanner board (for generation 1 controller cards only; for generation 2 controller cards,
the 1394 communications circuitry is built into the controller card), a MFD controller board
to process all jobs performed on the X4500, a hard disk drive containing the operational
code for the system and providing memory for processing jobs, and a power distribution
board. An external power supply provides 5, 12, and 24 V dc to the entire scanner
system.
The following figure shows the system block diagram.
Mechanical Operation
Flatbed Operation
When scanning, place the document on the flatbed glass platen, the flatbed optical unit/
carrier moves across the underside of the glass, and scans the document. A charge-
coupled device (CCD) mounts to the carrier and optically reads the image from the page.
The carrier is driven by a 2-phase stepping motor which moves the carriage at 1/300 inch
each step.
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Auto Document Feeder Operation
When using the Auto Document Feeder (ADF) mechanism, a page is fed into the ADF by
a pick roller and through the ADF by a feed roller. A separation pad located opposite to
the pick roller is used to properly feed the pages one at a time when placed on the input
tray. The flatbed optical unit/carrier is positioned to the far left so when the paper passes
through the ADF, the bottom side of the page is scanned by the flatbed CCD. The home
position sensor detects when the carrier is in the proper position for ADF scanning. In
addition, an ADF cover open sensor detects when the upper ADF assembly is open or
closed into proper operating position. The scanner cannot operate when this sensor is
open.
While the page is fed through and scanned from the bottom via the flatbed CCD, the top
side of the page is simultaneously scanned via a CCD unit positioned within the ADF unit.
As the page feeds between the two CCD units, the page discharges to the exit tray on the
left side of the ADF.
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4036-304
Abbreviations
ADF
CCD
CCFL
CDB
DMM
LED
MFD
PCBA
UI
Auto Document Feeder
Charge-Couple Device
Cold Cathode Fluorescent Lamp
Command Descriptor Blocks
Digital Multimeter
Light Emitting Diode
Multi Function Device
Printed Circuit Board Assembly
User Interface
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2. Problem Solving
This chapter describes two methods to solve the operational problems. The first relies on
the scanner internal diagnostics to report error codes. The second uses troubleshooting
techniques to isolate the problem. In many cases, the internal error codes will help you to
locate the source of the problem quickly. If no error codes are reported, or if the error
codes do not locate the source of the problem, refer to the troubleshooting section.
Error Codes
MFD Controller Errors
MFD Controller Errors are errors detected by the MFD controller card within the MFD
cage pertaining to electronic cards. All MFD controller cage errors are posted to the user
interface touch screen along with audible beep codes and LED codes. During the Power-
On Self Test procedure, errors detected cause a number of audible beeps to be produced
three times. The corresponding LED pattern continuously displays on the controller card
until the system is powered down. Use the following tables to read the beep/LED codes
and follow the recommended repair action.
Note: For generation 1 MFD controller cards, there are two rows of four LEDs. The LEDs
are difficult to view as the controller cage must be removed from the scanner. The LED
pattern shown depicts which LEDs are illuminated in the two rows.
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4036-304
Note: For generation 2 MFD controller cards, there are four pairs of LEDs. The LEDs are
viewable after the controller cage is removed from the scanner. The LED pattern shown
depicts which LEDs are illuminated in the two rows.
MFD
Error number and
description
Number
of beeps
controller
card
LED pattern
(on= , off=
Action
)
generation
Error: 21 - Modem not found
2
1st
Modem on the MFD
controller card is not
found. Replace the
MFD controller card.
2nd
1st
Error: 22 - PCI Bus failure
2
Replace the MFD
controller card.
2nd
2
Error: 23 - Internal scanner
card failure
The 1394
communication protocol
on the MFD controller
card has failed. Replace
the MFD controller card.
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4036-304
MFD
Error number and
description
Number
of beeps
controller
card
LED pattern
(on= , off=
Action
)
generation
Error: 24 - Serial port failure
2
2
3
1st
Problem with TTY/Serial
Port. Replace the MFD
controller card.
2nd
1st
Error: 28 - Problem with the
CPU
Replace the MFD
controller card.
2nd
1st
Check connections to
the hard disk drive and
associated cables for
continuity. Check power
going to the hard disk
drive. Replace the
power distribution card
if no power is present. If
power is present,
Error: 31 - No hard drive
found.
Note: Error message not
displayed. Only beep code
and LED patterns are
generated for error 31.
2nd
1st
replace the hard disk
drive.
3
Replace or reformat the
hard disk drive. See
“Hard disk drive
Error: 32 - Corrupt hard
disk drive
Note: Error message not
displayed. Only beep code
and LED patterns are
generated for error 32.
2nd
1st
Error: 34 - Hard Drive failure
3
There was an error
writing to the hard disk
drive. Replace or
reformat the hard disk
drive refresh” on
2nd
Problem Solving 2-3
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MFD
Error number and
description
Number
of beeps
controller
card
LED pattern
(on= , off=
Action
)
generation
Error: 41 - Scanner interface
not found
4
1st
The scanner image
processor board was
not found. Check
connections to the
interface board. If
connections are good,
replace the image
processor board.
2nd
1st
N/A
5
The memory DIMM was
not detected or not
functioning. Replace the
memory DIMM.
Error: 51 - Not enough
memory
Note: Error message not
displayed. Only beep code
and LED patterns are
generated for error 51.
2nd
1st
Error: 52 - Not enough
memory
5
The memory DIMM was
found, but not enough
memory is present.
Replace the memory
DIMM.
2nd
1st
Error: 71 - User Interface
failure
7
A problem was detected
with the user interface.
Check the connection of
all cables connecting
the UI to the MFD
controller card. If cables
are okay, replace the
user interface. If
2nd
problem persists,
replace the MFD
controller card.
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Scanner Errors
Scanner Errors are errors detected within the scanner mechanism and auto document
feeder assembly. These errors appear on the user interface touch screen along with a
number of flashes of the flatbed CCD lamp (the flash sequence is repeated 10 times).
See the following table for an explanation of each error code and the corrective action to
resolve the problem.
Number of CCD
Lamp Flashes
Error Message Displayed
to UI
Action
1
Oasis 1 SDRAM failure
Oasis 2 SDRAM failure
CPU SDRAM failure
Replace the main scanner
board.
2
3
4
Replace the main scanner
board.
Replace the main scanner
board.
Flatbed A/D Dark Calibration
Error
Replace the flatbed optical
unit assembly. If problem
persists, replace the main
scanner board.
5
6
ADF A/D Dark Calibration
Error
Replace the ADF optical unit.
If problem persists, replace the
main scanner board.
Home Sensor failure
Check the flatbed motor, belt
and home position sensor for
proper operation. Replace any
defective parts. If no defective
parts are found, replace the
main scanner board.
7
8
Flatbed Lamp failure
ADF Lamp failure
Check the flatbed optical unit
for proper connection.
Replace the flatbed optical
unit if necessary.
Check the ADF optical unit for
proper connection. Replace
the ADF optical unit if
necessary.
None
None
SCSI Command Not
Supported
Replace the main scanner
board.
Invalid field in CDB
Replace the main scanner
board.
Problem Solving 2-5
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Number of CCD
Lamp Flashes
Error Message Displayed
to UI
Action
None
Could not match scanner,
aborting
The MFD controller cage
could not find the rest of the
scanner. Make sure the USB-
style cable is properly
connected between the 1394
communications board and
main scanner control board.
If problem persists, replace the
main scanner board. If
problem persists, replace
1394 communications board.
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Troubleshooting
The tables in this section provide detailed troubleshooting information.
The Power does not come on
Relevant
Unit
Cause
Check *
Action
Unplugged
from outlet
None
Visual check
Insert the ac
plug into the
outlet.
AC power
unplugged at
LVPS
Visual check
Insert the ac
cable into
power supply
power supply.
Power switch
is OFF
None
None
Visual check
Visual check
Turn the power
switch on.
Power supply
power
Connect the
connector.
distribution
board
connection
failure
Power supply
output voltage
failure
LVPS
Tester check
the LVPS
(+5V +12V,
Replace the
power supply.
+24V, GND)
Power
distribution
board
Power
distribution
board
Tester check
(+5V, GND)
Replace the
failed power
distribution
board.
MFD
controller
board
MFD
controller
board
None
If problem still
exists, replace
MFD controller
board.
* Check explains how to check the failed item.To do a visual check observe the part or
observe the offline test display on the front panel. To do a tester check, check the voltage
levels of the relevant units. (See Connector Locations.)
Problem Solving 2-7
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Scan module does not move to lock position
Relevant
Cause
Check
Action
Unit
Home
CCD board
Tester check
Replace the
CCD PCBA.
position
sensor board
failure
Motor-main
control PCBA
connection
failure
None
Visual check
Connect the
connector.
Motor failure
Carrier motor
None
Visual check
Visual check
Replace the
carrier motor.
Power supply-
main control
board
Connect the
connector.
connection
failure
Power supply
fails.
Power supply
Tester check
(+24V, GND)
Replace the
power supply.
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Scan module does not move to the home position
Relevant
Cause
Check
Action
Unit
Home
position
None
Visual check
Connect the
connector.
sensor board-
main control
PCBA
connection
failure
Home
Sensor in the
flatbed CCD
assembly
Tester check
Visual check
Replace the
flatbed CCD
optical unit.
position
sensor board
failure
Power supply-
main control
board
None
Connect the
connector.
connection
failure
Power supply
fails
Power supply
Lamp
Tester check
(+5V, +24V,
GND)
Replace the
power supply.
Lamp failure
Visual check
Visual check
Visual check
Replace the
flatbed CCD
optical unit.
Inverter
failure
Inverter
None
Replace the
flatbed CCD
optical unit.
CCD board-
main scanner
board
Connect the
connector.
connection
failure
CCD board
fails
CCD board
Tester check
Replace the
flatbed CCD
optical unit.
Problem Solving 2-9
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Scan module does not move to the flatbed position
Relevant
Cause
Check
Action
Unit
Power supply-
main scanner
board
None
Visual check
Connect the
connector.
connection
failure
Power supply
fails
Power supply
None
Tester check
(+5V, +24V,
GND)
Replace the
power supply.
Motor-main
scanner
board
Visual check
Connect the
connector.
connection
failure
Motor failure
Carrier motor
Carrier belt
Visual check
Visual check
Replace the
carrier motor.
Belt broken or
loose
Reposition belt
or replace if
defective.
Reading is not performed
Relevant
Cause
Unit
Check
Action
ADF cover
open
ADF cover
Visual check
Close the ADF
cover.
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Image does not appear
Relevant
Unit
Cause
Check
Action
ADF cover
open
ADF cover
Visual check
Close the ADF
cover.
1394
None
Visual check
Connect the
connector.
Communica-
tion board-
main control
board
connection
failure
Lamp Inverter
failure
Lamp inverter
None
Visual check
Visual check
Replace the
CCD optical
unit.
CCD board-
main scanner
board
Connect the
connector.
connection
failure
CCD board
fails
CCD board
Visual check
Replace the
optical unit.
Large jitter
Cause
Relevant
Unit
Check
Action
1394
None
Visual check
Connect the
connector.
Communica-
tion - main
control board
connection
failure
Motor-main
scanner
PCBA
connection
failure
None
Visual check
Visual check
Connect the
connector.
Motor failure
Carrier motor
Replace the
carrier motor.
Problem Solving 2-11
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Reading position deviation
Relevant
Unit
Cause
Check
Action
Motor-main
scanner
PCBA
None
Visual check
Connect the
connector.
connection
failure
Motor failure
Carrier motor
Visual check
Replace the
carrier motor.
Home
position
sensor board-
main scanner
PCBA cable
failure
Flatbed CCD
optical unit
cable
Tester or
visual check
Replace the
flatbed CCD
optical unit
cable.
Home
Flatbed CCD
optical unit
Tester check
Replace the
flatbed CCD
optical unit.
position
sensor board
failure
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Image unclear
Cause
Relevant
Unit
Check
Action
Lamp too
dark
Lamp
Visual check
Replace CCD
optical unit.
Dirt on
Calibration
reference
plate
Visual check
Visual check
Visual check
Clean the
calibration
reference
plate
flatbed glass
with isopropyl
alcohol.
Dirt on the
mirrors
Mirrors
Clean the
mirrors with
isopropyl
alcohol.
Dirt on the
lens
Lens
Clean the lens
with isopropyl
alcohol.
Problem Solving 2-13
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Strange Sound Generated (flatbed)
Relevant
Cause
Check
Action
Unit
Motor unit
failure
Motor unit
Visual check
Replace the
carrier motor.
Main scanner
card failure
Main scanner
card
Replace the
main scanner
card.
Replace the
main scanner
card.
Scanning
module
Scanning
module
Check if
scanning
module is
loose.
Replace the
flatbed CCD
optical unit.
Dirt on rail
None
Visual check
Clean the rail
with isopropyl
alcohol.
Frequent paper jam, double feed or skew
Relevant
Cause
Check
Action
Unit
Paper setting
failure
Operation
error
Is the paper
correctly set
in the paper
chute?
Teach users to
properly
position the
paper.
Paper failure
Operation
error
Is the
specified
None
paper used?
ADF
connector
ADF unit
Visual check
of motor
Connect the
connector.
slip-off
rotation
Pad assembly
failure
Pad assembly
Check the
pad assembly
for wear and
tear.
Clean/replace
the pad
assembly/touch
spring unit
ADF unit
failure
ADF unit
Replace the
ADF unit.
Replace the
ADF unit.
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Strange sound generated (ADF)
Relevant
Cause
Check
Action
Unit
Paper setting
failure
Operation
error
Is the paper
correctly set
in the paper
chute?
Teach users to
properly
position the
paper.
Paper failure
Operation
error
Is the
specified
paper used?
None
ADF
connector
slip-off
ADF unit
ADF unit
Visual check
of motor
rotation
Connect the
connector.
ADF unit
failure
Replace the
ADF unit.
Replace the
ADF unit.
Problem Solving 2-15
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2-16 Service Manual
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3. Maintenance
This chapter describes cleaning methods maintenance parts replacement, and
adjustment and lubrication necessary for normal scanner operation.
Perform preventative maintenance in the shorter term either every six months or every
60,000 sheets scanning.
Cleaning
Cover and Glass
With soft cloth, wipe the cover and glass. If the dirt is heavy, use a neutral cleanser or
alcohol. Wipe the glass carefully so no cleanser remains on the surface.
Touch Screen
Wipe the touch screen with a clean, lint-free cotton cloth dampened with water.
ADF Unit
Push the ADF unit backward to open the unit. Clean the pad assembly and feed roller in
the ADF with a lint-free cloth and isopropyl alcohol. Clean the pad assembly by wiping it
in the direction of the arrow as shown.
Maintenance 3-1
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Maintenance Tools
The following table describes the tools necessary for the maintenance of this scanner.
Name
Description
Flathead screwdriver
Phillips screwdriver (magnetic)
Nut driver
Idler pulley module screw
Nominal No.2 M3, M4
6 mm
Digital voltmeter
Chip Puller
With 0.01 V range
Puller for main scanner board chip
Removals
Parts Replacement
1. Clean the disassembly and assembly location.
2. Turn off the power switch and remove the AC plug from the outlet before
disassembly and assembly.
3. Follow the disassembly and assembly procedures. Never loosen the screws of parts
that must not be disassembled. These screws have a red coating.
4. Store the disassembled parts in a clean place to avoid loss.
5. After replacement, check the contacts and spare part mounting.
6. Assemble in the reverse order of disassembly.
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CCD Board Screws
Screws for the CCD board in the optical unit are as shown. These screws have a red
coating indicating they should never be loosened.
Flatbed CCD Optical Unit
ADF CCD Optical Unit
Maintenance 3-3
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ADF Snap-in Pad Module Removal and Mounting
After scanning approximately 100,000 pages through the ADF, the ADF pad module may
be worn and you may experience problems with document feeding. In this case, replace
the ADF pad module.
To remove the ADF snap-in pad module:
1. Push the ADF unit backward.
2. Gently pull out the snap-in pad module.
To mount the ADF snap-in module,
1. Hold both arms of the snap-in pad module.
2. Gently place the module into the pad holder.
Note: Inspect the feed roller and clean as necessary.
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Document Cover Removal
Lift the document cover to remove the studs from the hinge holes. The studs are loosely
attached to the hinge holes to accommodate the depth of the original.
ADF Cover Removal
Remove the two ADF cover screws and lift the ADF cover.
Maintenance 3-5
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ADF Optical CCD Unit Removal
Warning: Do not loosen any screws with red coating.
two screws from the ADF optical CCD unit as shown, and pull out the unit.
2. Use a flat screwdriver to raise the latch and remove the inverter board.
3. Disconnect the lamp connector from the inverter board.
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3. Disconnect 15PIN ADF motor/sensor cable from ADF motor/sensor card.
4. Lift the ADF unit and remove it.
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Note: The upper and lower units of the ADF unit can now be separated.
User Interface Removal
1. Remove the document output tray and document cover.
2. Place the scanner on its back.
3. Remove the three screws to loosen the user interface from the scanner.
Maintenance 3-9
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4. Place the scanner right side up and slide the user interface forward.
5. Disconnect the cables.
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6. Remove the right side touch screen support bracket to disconnect the ground wire.
7. Remove the user interface gently.
Maintenance 3-11
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5. Remove the four screws on the left side of the housing.
6. Remove the five screws form the front of the housing.
7. Remove the upper housing.
Maintenance 3-13
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Flatbed CCD Optical Unit Removal
Warning: Do not loosen any screws with red coating.
2. Press the pulley on the carriage belt pulley assembly toward the center of the unit
and remove the carriage belt from the pulley.
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3. Remove the sliding rod and the flat cable. (See following figures.) Warning: Be very
careful when handling the flatbed optical CCD. The lamp is exposed and can be
easily broken. Do not touch.
4. Take out the flatbed optical CCD.
5. Disconnect the belt from the side of the flatbed optical CCD.
Maintenance 3-15
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Carriage Motor Assembly Removal
2. Press the pulley on the carriage belt pulley assembly toward the center of the unit
and remove the carriage belt from the pulley.
3. Disconnect connector from carriage motor assembly.
4. Remove the three screws from carriage motor assembly.
5. Remove the carriage motor.
Carriage Belt Pulley Assembly Removal
1. Remove the upper housing unit.
2. Press the pulley on the carriage belt pulley assembly toward the center of the unit
and remove the carriage belt from the pulley.
3. Remove the two screws.
4. Remove the carriage belt pulley assembly.
MFD Controller Cage Removal
1. Remove the document output tray and document cover.
2. Place the scanner on its back.
3. Remove eight screws from the bottom housing.
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4. Lower MFD controller cage and disconnect the three connectors and ground wire.
Maintenance 3-17
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5. Swing the MFD controller cage assembly to the right and disconnect the two cables.
Use a screwdriver on the lower cable connector to unlatch the connector.
6. Remove the MFD controller cage.
Note: When reinstalling the USB-style cable to the main control board, connect the cable
to the upper connector.
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Hard Disk Drive, MFD Controller Card, 1394
Communications Card and Power Distribution Board
Removal
2. With the MFD controller cage positioned upside down near an edge of a table,
remove the two screws from the back side and three screws from the bottom.
3. Turn the MFD controller cage right side up and lift the upper shield from the cage.
Maintenance 3-19
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4. Remove the component you want from within the MFD cage.
3-20 Service Manual
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Note: When replacing the main scanner control board with a new one, remove the
EPROM from the old board (with a chip puller) and install it in the new board. This
EPROM contains settings unique to the scanner.
3-22 Service Manual
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4. Connector Locations
The pin assignments shown are voltages and grounds which can be tested in the field.
Use a multimeter grounded to the scanner MFD controller cage when measuring the
voltage for the main scanner board.
Main Scanner Board
ADF Video Circuit J7:
Pin No.
Assignment
1
3
5
Ground
Ground
Ground
ADF Video Circuit J8:
Pin No.
Assignment
1
2
Ground
+24V dc
Ground
Ground
Ground
+5V dc
Ground
Ground
+24V dc
3
4
5
9
12
13
14
Flatbed Video Circuit J9:
Pin No.
Assignment
14
15
+24V dc
Analog Ground
Connector Locations 4-1
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MFD Controller Cage
All components within the MFD controller cage are self diagnosed. Any errors are
reported as MFD controller cage errors.
Low Voltage Power Supply
The following diagram and chart represents the power supply output connector.
Pin No.
Wire Color
Assignment
1
2
Black
Black
Black
Black
Black
Black
White
Red
Ground
Ground
Ground
Ground
Ground
Ground
+24V dc
+5V dc
+12V dc
+5V dc
+5V dc
+5V dc
3
4
5
6
7
8
9
Yellow
Red
10
11
12
Red
Red
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Assembly 1: Upper Scanner
13
1
12
11
10
8
2
9
7
6
3
5
4
5-2 Service Manual
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Assembly 1: Upper Scanner
Asm-
Index
Part
Number
Units Description
1
2
56P2717
56P0024
56P0032
56P0020
56P0030
56P0023
56P0025
56P0029
56P0079
56P0028
56P0027
56P0026
56P2401
1
1
1
1
1
1
1
1
1
1
1
1
1
Tray, Document Input
Cover, Scanner Document
Cover, Upper with Glass
User Interface, Complete
Assembly, Lower ADF
Tray, Document Output
Assembly, ADF Optical Unit
Assembly, Upper ADF
Pad, Pick Roller
3
4
5
6
7
8
9
10
11
12
13
Sensor, Paper Feed
Sensor, Paper Present
Board, ADF Motor/Sensor
Cover, ADF Upper
Parts Catalog 5-3
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Assembly 2: Lower Scanner
5
4
3
2
8
1
6
7
9
11
10
17
19
12
18
16
20
15
13
21
14
22
23
24
5-4 Service Manual
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4036-304
Assembly 2: Lower Scanner
Asm-
Index
Part
Number
Units Description
1
56P0036
56P0035
56P0033
56P0031
56P1466
56P0308
56P0037
56P0042
56P0034
56P0021
12G6918
56P1473
11D0328
11D0329
11D0330
11D0331
11D0332
11D0333
11D0334
11D0335
11D0336
11D0337
11D0338
11D0339
99A0471
56P0192
56P0022
56P2467
56P1472
56P2554
56P2555
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Cable, ADF CCD (6PIN + 14PIN)
Cable, ADF Motor/Sensor (15PIN)
Pulley Assembly, Carriage Belt
Assembly, Flatbed CCD Optical Unit
Lamp, Flatbed CCD
2
3
4
5
6
Card Assembly, Flatbed CCD Lamp Invertor
Belt, Carriage
7
8
Cable, Flatbed Optical Unit
9
Motor Assembly, Carriage
10
11
12
13
13
13
13
13
13
13
13
13
13
13
13
13
14
15
16
17
18
18
Board, Main Scanner Control
Power Supply, Universal, External
Cable, 1394 Communications (generation 2)
Line Cord, US, Canada, APG (LV), LAD (LV)
Line Cord, Peru
Line Cord, Argentina
Line Cord, Brazil
Line Cord, Chile
Line Cord, Denmark
Line Cord, France, Germany, Spain, Belgium, England, Europe
Line Cord, Italy
Switzerland
Line Cord, UK, Ireland, Egypt
Line Cord, Israel
Line Cord, South Africa
Line Cord, PRC
Board, Power Distribution
Board, 1394 Communications (used only with generation 1 controller board)
Drive Assembly, Hard Disk
Cable, HDD to Controller - 80 Conductor
Board, Controller, WW non-Australia/New Zealand (generation 2)
Board, Controller, Australia/New Zealand (generation 2)
Parts Catalog 5-5
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4036-304
Assembly 2 (cont.): Lower Scanner
5
4
3
2
8
1
6
7
9
11
10
17
19
12
18
16
20
15
13
14
2
23
24
5-6 Service Manual
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4036-304
Assembly 2 (cont.): Lower Scanner
Asm-
Index
Part
Number
Units Description
19
19
20
21
22
23
24
NS
NS
NS
12G9063
56P2406
56P9910
56P2112
56P2110
56P2042
56P1808
56P0558
56P0559
56P1211
1
1
1
1
1
1
1
1
1
1
Fan, CPU Cooling (used only with generation 1 controller board)
Fan, CPU Cooling (used only with generation 2 controller board)
Card Assembly, 128MB DIMM
Cable, 15 pin User Interface
Cable, 14 pin User Interface
Cable, 7 pin User Interface
Fan, Controller Cage Cooling
Cable, RJ11 with Torriod
Cable, RJ45 with Torriod
Adapter, UK phone
Note:
•
•
Refer to LED pattern images on page “MFD Controller Errors” on page 2-1 to identify
controller board generation.
If replacing a generation 1 MFD controller board with a generation 2 board, the following must
be performed. The 1394 communications board and generation 1 1394 communications cable
should be removed and discarded. In place of the discarded parts, a generation 2 1394
communications cable should be installed to connect the generation 2 MFD controller board to
the main scanner control board. Included with the generation 2 1394 communications cable is
an insulator which must be installed on a metal standoff on the controller cage. Instructions for
installation are included with the generation 2 communications cable FRU.
Parts Catalog 5-7
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5-8 Service Manual
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Index
A
S
Abbreviations 1-9
Safety Information v-v
C
Cleaning
T
Theory of Operation
ADF Unit 3-1
Mechanical Operation 1-5
System Description 1-5
Troubleshooting 2-7
Cover and Glass 3-1
Touch Screen 3-1
Connector Locations 4-1
U
Unit 3-1
E
Error Codes
Part Numbers
MFD Controller 2-1
Scanner 2-5
11D0328 5-5
11D0329 5-5
11D0330 5-5
11D0331 5-5
11D0332 5-5
11D0333 5-5
11D0334 5-5
11D0335 5-5
11D0336 5-5
11D0337 5-5
11D0338 5-5
11D0339 5-5
12G6918 5-5
12G9063 5-7
56P0020 5-3
56P0021 5-5
56P0022 5-5
56P0023 5-3
56P0024 5-3
56P0025 5-3
56P0026 5-3
56P0027 5-3
56P0028 5-3
56P0029 5-3
56P0030 5-3
56P0031 5-5
56P0032 5-3
56P0033 5-5
56P0034 5-5
56P0035 5-5
56P0036 5-5
56P0037 5-5
56P0042 5-5
56P0079 5-3
56P0192 5-5
56P0308 5-5
M
Maintenance 3-1
Maintenance Tools 3-2
O
Overview 1-1
P
Parts Catalog 5-1
Parts Replacement 3-2
Problem Solving 2-1
Product Description 1-1
Product Features 1-1
Product Specifications 1-3
R
Removals
ADF Cover 3-5
ADF Optical CCD Unit 3-6
ADF Snap-in Pad Module 3-4
ADF Unit 3-7
Carriage Belt Pulley Assembly 3-16
Carriage Motor Assembly 3-16
Communications Card, 1394 3-19
Document Cover 3-5
Flatbed CCD Optical Unit 3-14
Hard Disk Drive 3-19
Main Control Board 3-21
MFD Controller Cage 3-16
MFD Controller Card 3-19
Power Distribution Board 3-19
Upper Housing 3-12
User Interface 3-9
I-1
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4036-304
56P0558 5-7
56P0559 5-7
56P1211 5-7
56P1466 5-5
56P1472 5-5
56P1473 5-5
56P1808 5-7
56P2042 5-7
56P2110 5-7
56P2112 5-7
56P2401 5-3
56P2406 5-7
56P2467 5-5
56P2554 5-5
56P2555 5-5
56P2717 5-3
56P9910 5-7
99A0471 5-5
I-2 Service Manual
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