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X4500 Scanner 4036-304
· Table of Contents · Problem Solving · Safety and Notices · Trademarks · Index
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
4036-304
Edition: March 2002
The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION "AS IS" WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 2002. All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550. U.S.A.
P/N 12G9084
4036-304
Table of Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Service Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ease of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Copier and Full-function Fax Machine . . . . . . . . . . . . . . . . . . . . . . . . . . Network Scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duplex Scanning through the Auto Document Feeder (ADF) . . . . . . . . . . . . . . Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scanner Mechanism Overview and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MFD Controller Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scanner Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-3 1-5 1-5 1-5 1-7 1-7 1-8 1-9 2-1 2-1 2-4 2-6
Problem Solving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
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 ADF Snap-in Pad Module Removal and Mounting . . . . . . . . . . . . . . . . . . . . . . 3-4 Document Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ADF Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ADF Optical CCD Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ADF Unit (Upper and Lower Unit) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 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
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Hard Disk Drive, MFD Controller Card, 1394 Communications Card and Power 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
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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.
· ·
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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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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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Service Manual
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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
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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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Product Specifications
The scanner is designed to meet the following product specifications:
Scanner
Scanner Type Optical Resolution Enhanced Resolution Scan Speed Scan Method Light Source CPU Scan Area Display Image Types Flatbed Scanner with ADF built in Flatbed: 300x600 dpi ADF: 300x300 dpi 9600x9600 dpi 10 ppm at 300 dpi color for single page scanning 20 ppm at 300 dpi line-art, duplex for ADF Color Charge-Coupled Device (CCD) Cold Cathode Fluorescent Lamp (CCFL) Arm 7 KS32C41000 Max. 8.5 x 14.0 inch (legal size) for ADF 640x480 color VGA touch screen 42-bit color (internal) 14-bit gray (internal) 1-bit line-art, Dither, Error Diffusion Flatbed ADF <-1 ~ +2 mm <2.5 ~ +2.5 mm <-1 ~ +2 mm <2.5 ~ +2.5 mm <1 mm <2 mm -1.5% ~ +1.5% -1.5% ~ +1.5%
Scan Accuracy 1. Leading Edge 2. Side Edge 3. Skew 4. Magnification Rate Tolerance (Horizontal and Vertical) Physical Dimension Weight
Width: 570 mm Depth: 430 mm Height: 315 mm 14 kg
Overview
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Environment: -Operating -Storage Random Vibration: -Unpacked non-op -Package -Bump -Drop
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) 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 Severity: 25g/6ms, 1000 times in each direction Must meet NSTA specification Drop Point: 1 corner, 3 edges and 6 surfaces Total 10 times Operating: 58 dB or less EC 1000-4-2 ESD Standard UL, CSA, TUV/GS, SEMKO FCC Part 15 Subchapter J Class A CE Marking, C-Tick
Acoustic Noise Electrostatic Discharge Safety Regulation EMC regulation
ADF
General Specifications: -Optical Resolution -Document Capacity Document: -Document Size -Thickness 300x300 dpi 50 sheets Max. 8.5 x 14 inch (W x L) Min. 4.5 x 5.5 inch (W x L) 0.05~0.15 mm
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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, 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 chargecoupled 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.
Overview
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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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Scanner Mechanism Overview and Locations
This section contains an overview of the major components of the scanner hardware.
External View
Overview
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Internal Components
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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
Overview
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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 (visible on the lower left side of the MFD controller card). 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. There are two rows of four LEDs. The LEDs are visible with the MFD controller cage detached from the scanner. The LED pattern depicts which LEDs are illuminated in the two rows. Use caution when removing the cage from the scanner while the system is powered up.
Error Number
21
Number of Beeps
2
LED Pattern
Error Message Displayed to UI
Modem not found
Action
Modem on the MFD controller card is not found. Replace the MFD controller board.
22
2
PCI Bus failure
Replace the MFD controller board.
24
2
Serial Port failure
Problem with TTY/ Serial Port. Replace the MFD controller board.
Problem Solving
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Error Number
28
Number of Beeps
2
LED Pattern
Error Message Displayed to UI
Problem with the CPU
Action
Replace the MFD controller board.
31
3
(No Hard Drive Found) Note: Error code message not displayed on the user interface. Only beep code and LED patterns are generated for this error.
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, replace the hard disk drive. The OS is not found. Replace or reformat the hard drive.
32
3
(Missing OS) Note: Error code message not displayed on the user interface. Only beep code and LED patterns are generated for this error. Hard Drive failure
34
3
There was an error writing to the hard drive or the OS is corrupt. Replace or reformat the hard disk drive. The scanner image processing board was not found. Check connections to the interface board. If connections are good, replace the 1394 communications board. The memory DIMM was not detected or not functioning. Replace the memory DIMM.
41
4
Scanner Interface not found
51
5
(No Memory) Note: Error code message not displayed on the user interface. Only beep code and LED patterns are generated for this error.
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Error Number
52
Number of Beeps
5
LED Pattern
Error Message Displayed to UI
Not Enough Memory
Action
The memory DIMM was found, but not enough memory is present. Replace the memory DIMM. A problem was detected with the user interface. Check the connection of all cables connecting the UI to the MFD controller board. If cables are okay, replace the user interface. If problem persists, replace the MFD controller board.
71
7
User Interface failure
Problem Solving
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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
1 2 3 4
Error Message Displayed to UI
Oasis 1 SDRAM failure Oasis 2 SDRAM failure CPU SDRAM failure Flatbed A/D Dark Calibration Error
Action
Replace the main scanner board. Replace the main scanner board. Replace the main scanner board. Replace the flatbed optical unit assembly. If problem persists, replace the main scanner board. Replace the ADF optical unit. If problem persists, replace the main scanner board. 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. 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. Replace the main scanner board. Replace the main scanner board.
5
ADF A/D Dark Calibration Error Home Sensor failure
6
7
Flatbed Lamp failure
8
ADF Lamp failure
None None
SCSI Command Not Supported Invalid field in CDB
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Number of CCD Lamp Flashes
None
Error Message Displayed to UI
Could not match scanner, aborting
Action
The MFD controller cage could not find the rest of the scanner. Make sure the USBstyle 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.
Problem Solving
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Troubleshooting
The tables in this section provide detailed troubleshooting information.
The Power does not come on
Cause
Unplugged from outlet AC power unplugged at power supply Power switch is OFF Power supply power distribution board connection failure Power supply output voltage failure Power distribution board MFD controller board
Relevant Unit
None
Check *
Visual check
Action
Insert the ac plug into the outlet. Insert the ac cable into power supply. Turn the power switch on. Connect the connector.
LVPS
Visual check
None None
Visual check Visual check
LVPS
Tester check the LVPS (+5V +12V, +24V, GND) Tester check (+5V, GND)
Replace the power supply.
Power distribution board MFD controller board
Replace the failed power distribution board. If problem still exists, replace MFD controller board.
None
* 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.)
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Scan module does not move to lock position
Cause
Home position sensor board failure Motor-main control PCBA connection failure Motor failure Power supplymain control board connection failure Power supply fails.
Relevant Unit
CCD board
Check
Tester check
Action
Replace the CCD PCBA.
None
Visual check
Connect the connector.
Carrier motor None
Visual check Visual check
Replace the carrier motor. Connect the connector.
Power supply
Tester check (+24V, GND)
Replace the power supply.
Problem Solving
2-7
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Scan module does not move to the home position
Cause
Home position sensor boardmain control PCBA connection failure Home position sensor board failure Power supplymain control board connection failure Power supply fails Lamp failure
Relevant Unit
None
Check
Visual check
Action
Connect the connector.
Sensor in the flatbed CCD assembly None
Tester check
Replace the flatbed CCD optical unit. Connect the connector.
Visual check
Power supply
Tester check (+5V, +24V, GND) Visual check
Replace the power supply. Replace the flatbed CCD optical unit. Replace the flatbed CCD optical unit. Connect the connector.
Lamp
Inverter failure CCD boardmain scanner board connection failure CCD board fails
Inverter
Visual check
None
Visual check
CCD board
Tester check
Replace the flatbed CCD optical unit.
2-8 Service Manual
4036-304
Scan module does not move to the flatbed position
Cause
Power supplymain scanner board connection failure Power supply fails Motor-main scanner board connection failure Motor failure Belt broken or loose
Relevant Unit
None
Check
Visual check
Action
Connect the connector.
Power supply
Tester check (+5V, +24V, GND) Visual check
Replace the power supply. Connect the connector.
None
Carrier motor Carrier belt
Visual check Visual check
Replace the carrier motor. Reposition belt or replace if defective.
Reading is not performed
Cause
ADF cover open
Relevant Unit
ADF cover
Check
Visual check
Action
Close the ADF cover.
Problem Solving
2-9
4036-304
Image does not appear
Cause
ADF cover open 1394 Communication boardmain control board connection failure Lamp Inverter failure CCD boardmain scanner board connection failure CCD board fails
Relevant Unit
ADF cover None
Check
Visual check Visual check
Action
Close the ADF cover. Connect the connector.
Lamp inverter
Visual check
Replace the CCD optical unit. Connect the connector.
None
Visual check
CCD board
Visual check
Replace the optical unit.
2-10 Service Manual
4036-304
Large jitter
Cause
1394 Communication - main control board connection failure Motor-main scanner PCBA connection failure Motor failure
Relevant Unit
None
Check
Visual check
Action
Connect the connector.
None
Visual check
Connect the connector.
Carrier motor
Visual check
Replace the carrier motor.
Problem Solving
2-11
4036-304
Reading position deviation
Cause
Motor-main scanner PCBA connection failure Motor failure Home position sensor boardmain scanner PCBA cable failure Home position sensor board failure
Relevant Unit
None
Check
Visual check
Action
Connect the connector.
Carrier motor Flatbed CCD optical unit cable
Visual check Tester or visual check
Replace the carrier motor. Replace the flatbed CCD optical unit cable.
Flatbed CCD optical unit
Tester check
Replace the flatbed CCD optical unit.
2-12 Service Manual
4036-304
Image unclear
Cause
Lamp too dark Dirt on calibration reference plate Dirt on the mirrors
Relevant Unit
Lamp Calibration reference plate Mirrors
Check
Visual check Visual check
Action
Replace CCD optical unit. Clean the flatbed glass with isopropyl alcohol. Clean the mirrors with isopropyl alcohol. Clean the lens with isopropyl alcohol.
Visual check
Dirt on the lens
Lens
Visual check
Problem Solving
2-13
4036-304
Strange Sound Generated (flatbed)
Cause
Motor unit failure Main scanner card failure Scanning module
Relevant Unit
Motor unit Main scanner card Scanning module
Check
Visual check Replace the main scanner card. Check if scanning module is loose. Visual check
Action
Replace the carrier motor. Replace the main scanner card. Replace the flatbed CCD optical unit. Clean the rail with isopropyl alcohol.
Dirt on rail
None
Frequent paper jam, double feed or skew
Cause
Paper setting failure
Relevant Unit
Operation error
Check
Is the paper correctly set in the paper chute? Is the specified paper used? Visual check of motor rotation Check the pad assembly for wear and tear. Replace the ADF unit.
Action
Teach users to properly position the paper. None
Paper failure
Operation error ADF unit
ADF connector slip-off Pad assembly failure
Connect the connector. Clean/replace the pad assembly/touch spring unit Replace the ADF unit.
Pad assembly
ADF unit failure
ADF unit
2-14 Service Manual
4036-304
Strange sound generated (ADF)
Cause
Paper setting failure
Relevant Unit
Operation error
Check
Is the paper correctly set in the paper chute? Is the specified paper used? Visual check of motor rotation Replace the ADF unit.
Action
Teach users to properly position the paper. None
Paper failure
Operation error ADF unit
ADF connector slip-off ADF unit failure
Connect the connector. Replace the ADF unit.
ADF unit
Problem Solving
2-15
4036-304
2-16 Service Manual
4036-304
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
4036-304
Maintenance Tools
The following table describes the tools necessary for the maintenance of this scanner.
Name
Flathead screwdriver Phillips screwdriver (magnetic) Nut driver Digital voltmeter Chip Puller
Description
Idler pulley module screw Nominal No.2 M3, M4 6 mm 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.
3-2 Service Manual
4036-304
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
4036-304
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.
3-4 Service Manual
4036-304
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
4036-304
ADF Optical CCD Unit Removal
Warning: Do not loosen any screws with red coating. 1. Remove the ADF cover. Go to "ADF Cover Removal" on page 3-5. Remove the 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.
3-6 Service Manual
4036-304
4. Disconnect the two CCD connectors.
5. Remove the ADF optical CCD unit.
ADF Unit (Upper and Lower Unit) Removal
1. Remove the ADF optical CCD unit. Go to "ADF Optical CCD Unit Removal" on page 3-6. 2. Remove the screws located at the four corners of the ADF unit.
Maintenance
3-7
4036-304
3. Disconnect 15PIN ADF motor/sensor cable from ADF motor/sensor card.
4. Lift the ADF unit and remove it.
3-8 Service Manual
4036-304
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
4036-304
4. Place the scanner right side up and slide the user interface forward.
5. Disconnect the cables.
3-10 Service Manual
4036-304
6. Remove the right side touch screen support bracket to disconnect the ground wire.
7. Remove the user interface gently.
Maintenance
3-11
4036-304
Upper Housing Removal
1. Remove the ADF unit. Go to "ADF Unit (Upper and Lower Unit) Removal" on page 3-7. 2. Remove the user interface. Go to "User Interface Removal" on page 3-9. 3. Remove the four rubber pads with a flat screwdriver. 4. Remove the screws beneath the rubber pads.
3-12 Service Manual
4036-304
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
4036-304
Flatbed CCD Optical Unit Removal
Warning: Do not loosen any screws with red coating. 1. Remove the upper housing. Go to "Upper Housing Removal" on page 3-12. 2. Press the pulley on the carriage belt pulley assembly toward the center of the unit and remove the carriage belt from the pulley.
3-14 Service Manual
4036-304
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
4036-304
Carriage Motor Assembly Removal
1. Remove the upper housing unit. Go to "Upper Housing Removal" on page 3-12. 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.
3-16 Service Manual
4036-304
4. Lower MFD controller cage and disconnect the three connectors and ground wire.
Maintenance
3-17
4036-304
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.
3-18 Service Manual
4036-304
Hard Disk Drive, MFD Controller Card, 1394 Communications Card and Power Distribution Board Removal
1. Remove the MFD controller cage. Go to "MFD Controller Cage Removal" on page 3-16. 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
4036-304
4. Remove the component you want from within the MFD cage.
3-20 Service Manual
4036-304
Main Control Board Removal
1. Remove the MFD controller cage. Go to "MFD Controller Cage Removal" on page 3-16. 2. Remove the screws securing the main control board.
3. Disconnect the cables and remove the board.
Maintenance
3-21
4036-304
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
1234-XXX
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.
1 3 5
Assignment
Ground Ground Ground
ADF Video Circuit J8:
Pin No.
1 2 3 4 5 9 12 13 14
Assignment
Ground +24V dc Ground Ground Ground +5V dc Ground Ground +24V dc
Flatbed Video Circuit J9:
Pin No.
14 15
Assignment
+24V dc Analog Ground
Connector Locations 4-1
1234-XXX
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.
1 2 3 4 5 6 7 8 9 10 11 12
Wire Color
Black Black Black Black Black Black White Red Yellow Red Red Red
Assignment
Ground Ground Ground Ground Ground Ground +24V dc +5V dc +12V dc +5V dc +5V dc +5V dc
4-2
Service Manual
4036-304
5. Parts Catalog
Parts Catalog
5-1
4036-304
Assembly 1: Upper Scanner
5-2 Service Manual
4036-304
Assembly 1: Upper Scanner
AsmIndex Part Number Units Description
1 2 3 4 5 6 7 8 9 10 11 12
56P0170 56P0024 56P0032 56P0020 56P0030 56P0023 56P0025 56P0029 56P0079 56P0028 56P0027 56P0026
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 Sensor, Paper Feed Sensor, Paper Present Board, ADF Motor/Sensor
Parts Catalog
5-3
4036-304
Assembly 2: Lower Scanner
5-4 Service Manual
4036-304
Assembly 2: Lower Scanner
AsmIndex Part Number Units Description
1 2 3 4 5 6 7 8 9 10 11 11 11 11 11 11 11 11 11 11 11 11 11 12 13 14 15 15
56P0036 56P0035 56P0033 56P0031 56P0308 56P0037 56P0042 56P0034 56P0021 12G6918 11D0328 11D0329 11D0330 11D0331 11D0332 11D0333 11D0334 11D0335 11D0336 11D0337 11D0338 11D0339 99A0471 56P0192 56P0022 56P0076 56P0064 56P0065
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 Card Assembly, Flatbed CCD Lamp Invertor Belt, Carriage Cable, Flatbed Optical Unit Motor Assembly, Carriage Board, Main Scanner Control Power Supply, Universal, External 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 Drive Assembly, Hard Disk Board, Controller, WW non-Australia/New Zealand Board, Controller, Australia/New Zealand
Parts Catalog
5-5
4036-304
Assembly 2 (cont.): Lower Scanner
5-6 Service Manual
4036-304
Assembly 2 (cont.): Lower Scanner
AsmIndex Part Number Units Description
16 17 NS NS
12G9063 56P9910 56P0558 56P0559
1 1 1 1
Fan, CPU Cooling Card Assembly, 128MB DIMM Cable, RJ11 with Toriod Cable, RJ45 with Toriod
Parts Catalog
5-7
4036-304
5-8 Service Manual
4036-304
Index
A
Abbreviations 1-9
S
Safety Information v
C
Cleaning ADF Unit 3-1 Cover and Glass 3-1 Touch Screen 3-1 Connector Locations 4-1
T
Theory of Operation Mechanical Operation 1-5 System Description 1-5 Troubleshooting 2-6
E
Error Codes MFD Controller 2-1 Scanner 2-4
U
Unit 3-1
Part Numbers
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 56P0064 5-5 56P0065 5-5 56P0076 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
4036-304
56P0079 5-3 56P0170 5-3 56P0192 5-5 56P0308 5-5 56P0558 5-7 56P0559 5-7 56P9910 5-7 99A0471 5-5
I-2 Service Manual