Synergix Scanner Service Manual

Transmittal Page Product

Title

Part Number

Synergix Scan System

Service Manual

701P37410

Status

Date

SUPERSEDES

This service manual replaces 701P36546.

December 2001

Synergix Scan System

Synergix Scan System

Synergix Scan System Service Log

Date

Service Meter

CSE #

OTHERS (SPECIFY)

SENSOR

USER INTERFACE

POWER CORD

SCANNER MAIN PWB

PIVOT CLUTCH

PLATEN GLASS

MYLAR STRIPS

MOTOR

MOTOR CONTROL PWB

LAMP

LAMP BALLAST PWB

IMAGE MODULE

IMAGE PROCESSING PWB

DRIVE SHATF, REAR

FIRMWARE UPGRADE

DRIVE SHAFT, FRONT

CATCH INTERLOCK

DC POWER SUPPLY

BELTS

Serial # : Install Date: Account Information:

CABLES/HARNESSES

SCANNER COMPONENTS

Reason for Call:

PLEASE PRINT

PLEASE PRINT

PLEASE PRINT

PLEASE PRINT

PLEASE PRINT

PLEASE PRINT

PLEASE PRINT

Action Codes : Reason for Call :

X = check / perform DT = Doc Transpt

R = replace

IQ = Image Quality

U = upgrade firmware

CM = Commumications

C = clean

Ret = Retrofit

Oth = Other

THE DOCUMENT COMPANY XEROX

Synergix Scan System Service Manual

CAUTION Certain components in the Synergix Scan System are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage.

701P37410 DECEMBER 2001

NOTICE While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox Corporation arising out of any inaccuracies or omissions.

NOTICE All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified product trained service personal only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.

Prepared by: Xerox Corporation 800 Phillips Road Bldg. 845-17S Webster, New York 14580-9791 USA © 2001 by Xerox Corporation. All rights reserved. Xerox®, XES®, AccXES®, and The Document Company® are registered trademarks of Xerox Corporation. Xerox product names mentioned in this publication are trademarks of the XEROX CORPORATION.

Revision Control List Product

Title

Part Number

Date

Synergix Scan System

Service Manual

701P37410

12/2001

Page No.

Rev.

1-5

10/2001

1-6

10/2001

4-14

10/2001

4-69

10/2001

4-70

10/2001

4-75

10/2001

5-1-5-16

10/2001

6-3

10/2001

6-4

10/2001

6-6

10/2001

6-16

10/2001

6-21

10/2001

6-23

10/2001

6-28

10/2001

6-38

10/2001

6-51

10/2001

6-53

10/2001

7-15

10/2001

Introduction About This Manual .......................................................................................................... Organization.................................................................................................................... How To Use This Manual................................................................................................ Multinational Configuration Differences .......................................................................... Repair Analysis Procedures (RAPs) ............................................................................... Repair / Adjustment Procedures ..................................................................................... Reference Symbology.....................................................................................................

iii iii iv v v vi vii

Introduction Synergix Scan System

1

Introduction 2

Synergix Scan System

About This Manual

Organization

This manual is a part of a documentation system for an associated controlling system for the Scanner. The documentation system includes manuals for a host controller or other computer system, and a printer. The service manual for the controlling system should be placed first in the binder because it is the entry point for service on the system.

The manual is divided into eight sections:

Section 1. Service Call Procedures This section contains the following information:

This manual contains Service Call Procedures, Diagnostic Procedures, Status Indicator Repair Analysis Procedures, Repair and Adjustment Procedures, Parts Lists and General Procedures or Information.

Call Flow Procedure The Call Flow Procedure is a list of the procedures to follow on each service call. Initial Actions / Systems Checks

This information will help a Service Representative repair and maintain this device.

The Initial Actions identify how to collect the information necessary and how to verify, classify and proceed with the service call. Message Display Entry Chart This chart contains a list of Messages, their Cause, the corresponding Clearance Procedure, and the Go to reference. Maintenance Procedures The Maintenance Procedures lists the items that have to be serviced based on the type of call to be performed. Final Action The purpose of this procedure is to record the media feet count and to make a record in the machine log book of the service activities that were performed. Final Action is designed to test the image quality under stress and repair any image quality problems

Section 2. Repair Analysis Procedures (RAPs) This section contains the Repair Analysis Procedures (RAPs) that are necessary to repair the faults other than the image quality defects. When using a RAP, stop the repairs when the fault is isolated and repaired, and check the device for correct operation. Do not perform the remaining steps in the RAP. If the device still malfunctions, begin from the top of the RAP to isolate these faults.

Section 3. Image Quality RAPs This section contains a listing of image quality defects and samples to assist in classifying the defects. When the defect has been classified, a checklist is then used to repair the cause of the defect. The checklists are arranged in the sequence of most probable to least probable cause with the corresponding corrective action for each cause.

Section 4. Repair / Adjustment Procedures This section contains the repairs and adjustments for the unit.

Section 5. Parts List This section contains the detailed Parts Lists for the unit.

Introduction Synergix Scan System

iii

Section 6. General Procedures

How To Use This Manual

This section contains the Diagnostic Procedures, Product Specifications, Supplemental Tools and Supplies, Generic RAPs, Installation and Removal procedures, and other information.

Always begin with the Service Call Procedures, Section 1. Perform the Initial Actions to identify and classify the problem.

Section 7. Wiring Data

Then, proceed to one of the following sections of the manual to correct the problem.

This section contains the Block Schematic Diagrams. Section 2 contains the Status Indicator RAPs. Use these RAPS if the unit is not operational, such as when a Status Code is displayed, or there is an improper indication or “blank” display, etc. Section 3 is used to troubleshoot Image Quality problems. If you are not sure of the type of image quality defect that is occurring, use the contents page in Section 3 to find a defect that the best represents the type of defect that is on the copy. When using Section 2 or Section 3, you may be directed to Section 4 to perform repair or adjustment procedures, or to Section 5, Parts List. Next, perform the Normal Call procedures. After performing Normal Call procedure, perform Final Actions to ensure that the unit meets the copy specifications.

Introduction iv

Synergix Scan System

Multinational Configuration Differences

Repair Analysis Procedures (RAPs)

This manual contains information that applies to USO/NACO (USA), EO (European Operations), XCL Canada and XLA/AO (Latin America).

A RAP is either a table of faults and possible solutions, or a series of steps designed to lead you to the cause of a problem. In each step, you will perform an action or observe an occurrence. For fault tree RAPS, at each step, a statement is made that has a Yes (Y) or No (N) answer. If the answer is NO, perform the action following the NO. If the answer is YES, proceed to the next step. When several items are listed, perform them in the order listed. Proceed through the steps only until the observed problem is isolated and solved. Then evaluate the unit for proper performance. If a further defect is observed, go to the appropriate RAP and perform the steps it contains until the additional fault is located and repaired.

Introduction Synergix Scan System

v

Repair / Adjustment Procedures The repair procedures provide detailed steps on how to remove and replace components. The adjustment procedures provide detailed steps on how to check and adjust components. Some units have been modified by various design changes. Each change or modification is labeled with a Tag/ MOD (modification) number. The Tag/ MOD numbers are identified in the Change Tag/ MOD Index in Section 6 of this Service Manual. When a modification affects how a particular procedure is performed, the procedure or steps are identified with either a W/ Tag/ MOD or a W/ O Tag/ MOD statement. Each procedure or step that is affected by a modification is identified with the statement, W/ Tag/ MOD, followed by the modification number. The W/ in the statement indicates that this step must be performed on units that are assembled with that specific modification. When the procedure or steps are not affected by a particular modification, they are identified with the statement, W/ O Tag/ MOD, followed by the modification number. The W/ O in the statement indicates that this step must be performed on units assembled without that specific modification.

Introduction vi

Synergix Scan System

Reference Symbology

(Figure 1): The following symbols are used in this document:

Figure 1 Reference Symbology (1 of 2)

Introduction Synergix Scan System

vii

(Figure 2): Reference Symbology, cont’d.

Figure 2 Refrerence Symbology (2 of 2)

Introduction viii

Synergix Scan System

1 Service Call Procedures Introduction ..................................................................................................................... Call Flow Procedure........................................................................................................ Scanner Fault Code Entry Chart ..................................................................................... Maintenance Procedures ................................................................................................ Call Back ......................................................................................................................... Final Action .....................................................................................................................

1-3 1-4 1-5 1-13 1-13 1-14

Service Call Procedures 1-1

Service Call Procedures 1-2

Introduction

Maintenance Procedures

The Synergix Scanning System functions as an Information Input Terminal (IIT), working in conjunction with an AccXES controller. The Controller takes the image signal from the Scanner and processes it into a form understandable by the Printer. Some image processing is done inside the Scanner, while other such processing is done by the Controller.

This procedure contains the tasks that are performed after the main cause for the service call has been corrected. The tasks identified in the procedure are performed at the interval indicated. The interval may be after a specified number of feet, for example, 10K. The interval may also be specified as a Normal Call (NC).

The Scanner Control Panel acts as the User Interface (UI). It is connected to the Main PWB in the Scanner. Some messages displayed on the Scanner Control Panel come directly from the Main PWB, while others arrive through the connection to the Controller.

Normal Call activities are designed to be performed on all service calls. The specific interval and Normal Call activities include cleaning and replacing parts that require more frequent service and inspections The maintenance Procedure activities are designed to restore the device to an initially clean and functional condition.

The Service Call Procedures, Section 1, are designed to assist the Service Representative to identify faults, perform the necessary corrective action, and perform the correct Maintenance Procedures. The Service Call Procedures are designed to be used with the Interceptor Service Manual and are the entry level for all service calls.

Final Action The purpose of this procedure is to record the media feet count and to make a record in the machine log book of the service activities that were performed. Final Action is designed to test the image quality under stress and repair any image quality problems. A copy of test pattern 82E5980 or 499T286 is made and compared with the image copy quality specifications located in Section 3 of the manual.

The service manual for the product is the entry point for the fault isolation process at the systems level. Begin the service call with the Systems Level Call Flow Diagram within the Service Call Procedures, Section 1. The Call Flow Diagram will help you isolate the problem down to the system module. The diagram may direct you to a section in the Interceptor service manual or direct you to other service manuals to continue identify and repair the problem. In the case of a standalone host computer / Interceptor configuration, the CSE must isolate the fault to the Interceptor Scanner and then go to

in the Interceptor Service Manual.

Call Flow Procedure This procedure outlines the major activities that are performed when a service call is made. The Initial Actions System Checks assist the Customer Service Representative through the customer interface and help to identify the problem. The procedure also directs the CSE to verify, classify, repair the problem, and perform the correct Maintenance Procedure.

Initial Actions / System Checks This diagram is designed to identify and classify the scanner problem and to refer you to the appropriate RAP in order to repair the problem. When the problem has been repaired, perform the Final Action.

Message Display Entry Chart This chart contains a list of Messages, their Cause, the corresponding Clearance Procedure, and the Go To reference. The charts are designed to direct the Representative to the appropriate Clearance Procedure. If the Procedure does not clear the Status Code, the Representative refers to the Go To column. This column contains the information to be followed in order to repair the problem. When the problem has been repaired, go to the Call Flow Procedure and continue the Service Call.

Service Call Procedures 1-3

Introduction

Call Flow Procedure Procedure Perform the following: 1.

Ask the operator to describe the problem.

2.

Review the logbook for previous service on the Scanner.

3.

If a message or fault code is displayed on the screen of the Scanner Control Panel indicating that a fault or an error condition exists then go to the Scanner Fault Code Entry Chart in this section.

4.

If no message or fault code is displayed, but an image can be captured, go to Section 3 of this manual.

5.

If no message or fault code is displayed, and no image can be captured, go to Section 2 of this manual.

6.

If less than 5 working days, or less than 500 feet (150 metres) of documents have been scanned, then perform the Maintenance Procedures; otherwise, perform the Call Backprocedure.

7.

Go to Final Action.

Service Call Procedures

Call Flow Procedure

1-4

Scanner Fault Code Entry Chart

Fault codes other than POST fault codes are displayed in the fault log. To view the log, go to the diagnostic test (Scanner Faults (Ordered)).

Scanner Fault Codes, except Power On Self Test (POST) codes, are shown on the Scanner Control Panel. (POST) codes are displayed on the 7-segment display on the rear of the Scanner. Each POST code is normally displayed briefly while the test is performed; if a test fails, the code remains displayed, and no further POST tests are performed.

Some fault codes in the LL series are also displayed on the Scanner Control Panel. Additional information may be found in the fault log. When switching on the Scanner and looking for fault code displays, it is essential to follow the complete to switch on the Controller only after the POST code display stops advancing or after P is displayed; otherwise, the expected codes may not be displayed.

If the Power On Self Test stops at 5 or later, diagnostics will operate and error codes can be displayed on the control panel. Switch on the AccXES controller and wait for a dot (.) to appear after the POST code. Shortly afterward, the Controller completes its startup routine, and any applicable error code is displayed on the Control Panel Display. Diagnostics may then be entered and operated. E

(Table 1) shows Scanner fault messages, the probable cause, what to do to clear the fault, and a reference to consult if the problem still exists.

Table 1 Message Display Entry Chart FAULT CODE DISPLAYED

FAULT DESCRIPTION

POST all seg- Scanner Main PWB boot fault ments lit

COMPONENT DESIGNATOR U10

POST no seg- 1. Power supply fault: 5.0 volts or 3.3 ments lit volts. 2. Scanner Main PWB boot fault POST 0

Scanner Main PWB - RAM

POST 1

Scanner Main PWB - Boot Flash Checksum incorrect

POST 2

Scanner Main PWB - serial controller (SCC) fault

POST 3

Scanner Main PWB - IEEE-1394 communications fault

POST 4

POST 5

U10, Main PWB

CLEARANCE PROCEDURE

IF THE PROBLEM STILL EXISTS

BSD REF

PL REF

Check that U10 is correctly seated.

Replace the Scanner Main PWB.

1.4

1. Perform GP 8 power off/on cycle.

1. Troubleshoot the Power Supply PS1 1.4, 1.5 and cables. Go to GP 5 Generic PWB Checkout, Section 6. 2. Replace the Scanner Main PWB

1.4 1.4

Perform GP 8 power off/power on cycle. Replace the Scanner Main PWB Check that U10 on the Main PWB is correctly seated.+

1.4

Perform GP 8 power off/power on cycle. Check that integrated circuit U10 is correctly seated. Replace the Scanner Main PWB

1.4

Perform GP 8 power off/power on cycle

Replace the Scanner Main PWB

1.4

Check that the IEEE 1394 communica- Replace the Scanner Main PWB tions cable to the Controller is not inserted reversed. Perform a power off/ power on cycle.

1.4

Application checksum invalid - Scanner Main PWB. NOTE: When Post 4 fails, POST code U is displayed after a few seconds.

Upload the current firmware to the Scanner.

Replace the Scanner Main PWB

1.4

The Checksum in the Non Volatile RAM U28 (NVR) is invalid -- Scanner Main PWB

Reset the NVR to default settings using GP 14 Scanner Diagnostic access using a Laptop. If necessary refer to "If the Problem still Exists".

Replace NVR IC U28 on the Main PWB. Perform the Clearance Procedure again. If the problem still exists, replace the Scanner Main PWB Then perform the clearance procedure again.

1.4

U18

Service Call Procedures 1-5

Scanner Fault Code Entry Chart

Table 1 Message Display Entry Chart FAULT CODE DISPLAYED

FAULT DESCRIPTION

COMPONENT DESIGNATOR

CLEARANCE PROCEDURE

IF THE PROBLEM STILL EXISTS

BSD REF

PL REF

Upload the current firmware to the Scanner again.

Replace the Scanner Main PWB

1.4

PS1

1. Open wire on J406 on the Scanner Main PWB 2. Defective Power Supply PS1 3. Internal fault in Scanner Main PWB

Go to Section 2, RAP 1.1 DC Power.

1.4

Lamp Test failed

Lamp, Lamp Ballast PWB, Main PWB

Go to Section 2, RAP LL96.

POST 9

Motor test failed

MOT2, Motor Con- Perform GP 8 System Power Up Procetrol PWB, dure.

POST A

1.

Video cables from J 414, J 415, or J 416 on the Main PWB open or shorted to ground,

2.

Main PWB internal fault

3.

Image Module internal fault.

POST 6

Video code checksum invalid -- Scanner Main PWB 1. Partial download of Scanner firmware. 2. Scanner Main PWB failed.

POST 7

24 VDC Power Supply - no output

POST 8

POST B

POST C

1.

Image Processor PWB not seated.

2.

Malfunction in Image Processor PWB.

3.

Main PWB internal fault.

1.

Image Processor PWB not seated.

2.

Image Processor PWB - internal fault.

3.

Main PWB internal fault.

Check that cables are seated. Check that there is no short circuit to ground at the connectors on the Image Module end. If LL91, LL92, or LL93 is displayed, go to that entry in this table.

Perform a System Power Up Cycle GP 8 System Power Up Procedure

Perform a System Power Up Cycle GP 8 System Power Up Procedure.

Service Call Procedures

Scanner Fault Code Entry Chart

1-6

1.2,

Replace the Main PWB [REP 3.1 Main PWB]. Replace the Image Module [REP 9.2 Image Module].

1.

Remove and reseat the Image Processor PWB.

2.

Replace the Image Processor PWB.

3.

Replace the Main PWB [REP 3.1 Main PWB].

1.

Remove and reseat the Image Processor PWB.

2.

Replace the Image Processor PWB.

3.

Replace the Main PWB [REP 3.1 Main PWB].

Table 1 Message Display Entry Chart FAULT CODE DISPLAYED POST D

FAULT DESCRIPTION 1.

Fault in video cables from A1J 414, A1J 415, or A1J 416.

2.

Image Processor PWB - internal fault.

3.

Main PWB - internal fault

4.

Image Module - internal fault.

COMPONENT DESIGNATOR

CLEARANCE PROCEDURE

IF THE PROBLEM STILL EXISTS

Perform GP 8 System Power Up Proce- 1. dure

Check that video cables from A1J 414, A1J 415, or A1J 416 are correctly seated and have no short circuit to ground at the Image Module end.

2.

Switch off the system. Reseat the Image Processor PWB. Switch on the system [GP 8 System Power Up Procedure].

3.

Replace the Main PWB [REP 3.1 Main PWB].

4.

Replace the Image Module [REP 9.2 Image Module].

POST E

No communications with the Scanner Control Panel

Scanner Control Panel, Scanner Main PWB

Ensure continuity of connections Replace the Scanner Control Panel. between Scanner Main PWB and Scan- Replace the Scanner Main PWB [REP ner Control Panel. 3.1 Main PWB].

POST U

1. Scanner receiving firmware update.

1. None

1. Wait for the update to complete.

2. If POST code 4 was displayed for a 2. Scanner Main few seconds immediately before POST PWB U, then there is an incorrect checksum at the end of the POST tests.

POST tests completed; awaiting communications with Controller

IEEE 1394 cable, Scanner Main PWB

Ensure that the cable is seated at both ends. Ensure that the Scanner displayed P before switching on the Controller.

POST P.

POST tests completed; communications established.

none

If still no operation, perform a complete system (Scanner, Printer, Controller) power off/power on cycle. [GP 8 System Power Up Procedure]

Q4

Remove document; check that the feed path is clear. Check that the document drive operates in the forward direction. If not, go to section 2, [RAP OF-1 Document Transportation].

A1 - 00 MEDIA JAM

PL REF

2.1

14.1 1. Send the update again. If not successful, replace the Scanner Main PWB [REP 3.1 Main PWB]. 2. Switch off the Scanner. Switch on the 2. Resend the current firmware update Scanner, and allow the POST to run again. If still not successful, replace the again. Scanner Main PWB [REP 3.1 Main PWB].

POST P

00 - 01

BSD REF

Check for a fault in the Controller. Replace the Scanner Main PWB [REP 3.1 Main PWB].

14.1

Enter diagnostic mode; perform the Sensors Input test to check operation. Clean Sensor Q4. Check the wires. Replace Sensor Q4.

4.1

Normal power up routine. This is not a fault. Appears in fault log only. Paper jam at Edge Present Sensor.

PL 1.2A

Service Call Procedures 1-7

Scanner Fault Code Entry Chart

Table 1 Message Display Entry Chart FAULT CODE DISPLAYED

FAULT DESCRIPTION

COMPONENT DESIGNATOR

CLEARANCE PROCEDURE

IF THE PROBLEM STILL EXISTS

BSD REF

PL REF

A1 - 01 MEDIA JAM

Paper jam at Registration Sensor.

Q3

Remove document; check that the feed path is clear. Check that the document drive operates in the forward direction. If not, go to section 2, [RAP OF-1 Document Transportation].

Enter diagnostic mode; perform the Sensors Input test to check operation. Clean Sensor Q3. Check the wires. Replace Sensor Q3.

4.1

PL 1.2A

A1 - 02 MEDIA JAM

Paper jam at Exit Sensor.

Q2

Remove document; check that the feed Enter diagnostic mode; perform the path is clear. Sensors Input test to check operation. Clean Sensor Q2. Check the wires. Replace Sensor Q2.

4.1

PL 1.2A

A1 - 04

Calibration Extrusion failed to sense home position.

Q1

Switch off the System. Switch on the system.

6.3 Enter diagnostic mode; perform the Sensors input test test to check operation. Clean Sensor Q1. Check the wiring. Replace Sensor Q1 (PL 1.2B).

PL 1.2B

A1 - 05

Calibration Extrusion failed on move. Root cause: LL-30. Also possible: open interlock switch.

MOT2

Switch off the System. Switch on the System and ensure that POST 9 completes. If not, check the power cable to the Motor Control PWB and the communications cable to the Motor Control PWB, Check that 24 VDC is available on the Motor Control PWB.

If the motor does not operate, enter the 6.3 diagnostics mode and perform the Calibration Motor test while checking for motor operation. Check the Motor Control PWB and the wires to the Motor. Check the motor for open circuits. If the test fails, the Scanner Main PWB may have a fault.

PL 1.2B

A2 - 00

Interlock open

Q10

Ensure that the Upper Document Trans- Go to the BSD and troubleshoot the port is fully down. Q10 sensor circuit (BSD 6.4).

Q11

Clean Illumination Sensor Q11 (PL 1.3). If the Lamp Sensor Q11 was removed or adjusted, perform ADJ 6.1 Exposure Lamp Initialization.

LL - 10 Exposure Lamp Failure - lamp bright(displayed in ness could not be adjusted to at least Fault Log Only. 70% of new lamp brightness. Root cause: LL47 or LL-49.)

Service Call Procedures

Scanner Fault Code Entry Chart

1-8

6.4

1.1

Go to the Scanner Diagnostics. Per6.1 form the Lamp test. Observe the Illumination Sensor value. It should be greater than 10 when the Lamp is on, and less than 5 when the Lamp is off. If not, check the sensor wires. If the wires are good, replace Q11. If the sensor output values are correct, replace the Lamp [REP 6.4 Exposure Lamp] and perform the ADJ 6.1 Exposure Lamp Initialization. If the problem still exists, replace the Scanner Main PWB [REP 3.1 Main PWB].

1.3

Table 1 Message Display Entry Chart FAULT CODE DISPLAYED LL - 11

FAULT DESCRIPTION Exposure Lamp Failure - lamp is too dark.

COMPONENT DESIGNATOR

CLEARANCE PROCEDURE

IF THE PROBLEM STILL EXISTS

BSD REF

PL REF

Lamp, Q11

1. Clean Illumination Sensor Q11 .

Enter the diagnostic mode and perform 6.1 the Lamp test. The SENSOR value varies from 0 (dark) - 256 (extremely bright). If the Lamp is lit, but the SENSOR value is zero or nearly so, troubleshoot the sensor and sensor wiring. If these are correct, replace the Lamp [REP 6.4 Exposure Lamp]. If the problem still exists, replace the Scanner Main PWB [REP 3.1 Main PWB].

1.3

Q11

Check that the Lamp is lit.

Enter the diagnostic mode and perform 6.1 the Lamp test. The SENSOR value varies from 0 (dark) - 256 (bright). If the Lamp is lit, but the SENSOR value is zero or nearly so, troubleshoot the sensor and sensor wiring. If these are correct, replace the Lamp. If not, check Sensor Q11 and associated wires. If Lamp or Q11 is replaced, perform ADJ 6.1 Exposure Lamp Initialization. Replace the Scanner Main PWB [REP 3.1 Main PWB].

1.3

Motor Driver Failure - Read response time out.

Remove any document from document feed path. Check the Scanner Faults (Ordered) for an A1-xx code. Perform the actions in this table for the A1-xx code.

Enter the diagnostics and perform motor communications test. Troubleshoot the motor and motor control circuitry.

4.1

1.4

LL - 31

Motor Driver Failure - Unexpected reset.

Remove media from document feed path.

Enter the diagnostics and perform motor communications test. Troubleshoot the motor and motor control circuitry.

4.1

1.4

LL - 32

Motor Driver Failure. The Calibration Extrusion has a motion problem.

Remove media from document feed path. Perform GP 8 System Power Up Procedure.

Enter the diagnostics and perform the 4.1 Document Drive Motor test. Check that all the tests are successful. If not, troubleshoot the Calibration Motor circuits and the Motor Control PWB A3 (PL 1.4).

1.4

LL - 33

Motor Driver Failure - Calibration Extrusion unknown state. The Calibration Extrusion has been moved during the scan of the document.

Open Upper Transport; remove media; close transport.

Try scanning the thick document with the Thick Document Lever raised one more position.

1.4

LL - 34

Motor Driver Failure - Calibration Extru- MOT2, Motor Con- Check that Calibration Extrusion can be sion overcurrent. trol PWB manually rotated. If not, repair the cause. Perform GP 8 System Power Up Procedure.

NOTE: when the Lamp has less than 70% of brightness when new.

LL - 12

LL - 30 [fault log only]

Exposure Lamp Failure - Illumination Sensor Q11 failed.

6.3

Go to BSD 6.3 and troubleshoot the DC 6.3 Drive circuit from A3P 308. Check Motor M2 (Calibration Motor) for open circuits or short circuits.

PL 1.2B

Service Call Procedures 1-9

Scanner Fault Code Entry Chart

Table 1 Message Display Entry Chart FAULT CODE DISPLAYED

FAULT DESCRIPTION

LL - 39

Motor Driver Failure -Simultaneous write.

LL - 40

Calibration Failure - Set integration time failure. (uniformly darker image)

LL - 41

COMPONENT DESIGNATOR

NOTE: LL-40 displayed only momentarily on Scanner Control Panel. Dark Calibration Failure -Range adjust failure on Channel 1. (Lighter streaking in process direction) NOTE: LL-41 displayed only momentarily on Scanner Control Panel.

LL - 42

Dark Calibration Failure - Range adjust failure on Channel 2. (Lighter streaking in process direction)

NOTE: LL-42 displayed only momentarily on Scanner Control Panel. LL - 43

Dark Calibration Failure -Range adjust failure on Channel 3. (Lighter streaking in process direction)

NOTE: LL-43 displayed only momentarily on Scanner Control Panel.

CLEARANCE PROCEDURE

IF THE PROBLEM STILL EXISTS

1. Clean Calibration Target Strip and Check that the lamp is installed with Platen Glass. correct orientation. 2. Ensure that there is no contamination on Selfoc Lens.

BSD REF

6.3

Check that the Upper document Transport is closed. Observe the lamp for 2 minutes and check that it switches briefly off, then on during dark calibration.

Enter the Scanner Diagnostics. Per6.2 form the Scan Bar Calibration Test. If the test fails for any segment of the Image Module (Scan Bar), switch off the Scanner. Switch the video cables between channel 1 and channel 2. Switch on the Scanner. If the fault occurs on a different channel, a cable, or the Image Module, has a fault. Otherwise, replace the Scanner Main PWB [REP 3.1 Main PWB].

Check that the Upper document Transport is closed. Observe the lamp for 2 minutes and check that it switches briefly off, then on during dark calibration.

Switch off the Scanner. Switch the video cables between channel 1 and channel 2. Switch on the Scanner. If the fault occurs on a different channel, a cable, or the Image Module, have a fault. Otherwise, replace the Scanner Main PWB [REP 3.1 Main PWB].

6.2

Check that the Upper document Transport is closed. Observe the lamp for 2 minutes and check that it switches briefly off, then on during dark calibration.

Switch off the Scanner. Switch the video cables between channel 3 and channel 2. Switch on the Scanner. If the fault occurs on a different channel, a cable, or the Image Module, has a fault. Otherwise, replace the Scanner Main PWB [REP 3.1 Main PWB].

6.2

LL - 44

Dark Calibration Failure - Offset adjust SelfFoc Lens failure on Channel 1. (Lighter streaking Platen Glass in process direction) Target Calibration Strip NOTE: LL-44 displayed only momentarily on Scanner Control Panel. Old Lamp

Clean these parts. Perform GP 8 System Power Up Procedure.

Switch off the Scanner. Switch the video cables between channel 1 and channel 2. Switch on the Scanner. If the fault occurs on a different channel, a cable, or the Image Moduler, has a fault. Otherwise, replace the Scanner Main PWB [REP 3.1 Main PWB].

6.2

LL - 45

Dark Calibration Failure - Offset adjust SelfFoc Lens failure on Channel 2. (Lighter streaking Platen Glass Target Calibration in process direction) Strip NOTE: LL-45 displayed only momentarily on Scanner Control Panel.

Clean these parts. Perform GP 8 System Power Up Procedure.

Switch off the Scanner. Switch the video cables between channel 1 and channel 2. Switch on the Scanner. If the fault occurs on a different channel, a cable, or the Image Module, has a fault. Otherwise, replace the Scanner Main PWB [REP 3.1 Main PWB].

6.2

Service Call Procedures

Scanner Fault Code Entry Chart

1-10

PL REF

Table 1 Message Display Entry Chart FAULT CODE DISPLAYED

FAULT DESCRIPTION

COMPONENT DESIGNATOR

CLEARANCE PROCEDURE

IF THE PROBLEM STILL EXISTS

BSD REF

LL - 46

Dark Calibration Failure - Offset adjust SelfFoc Lens failure on Channel 3. (Lighter streaking Platen Glass in process direction) Target Calibration Strip NOTE: LL-46 displayed only momentarily on Scanner Control Panel.

Clean these parts. Perform GP 8 System Power Up Procedure.

Switch off the Scanner. Switch the video cables between channel 1 and channel 2. Switch on the Scanner. If the fault occurs on a different channel, a cable, or the Image Module, has a fault. Otherwise, replace the Scanner Main PWB [REP 3.1 Main PWB].

LL - 47

Gain calibration failure on Channel 1. (Dark streaks).

Examine the Calibration Target Strip, the SelfFoc Lens, and the Platen Glass for dirt or contamination; clean if required. Use the Calibration Motor test in Scanner Diagnostics to rotate the Calibration Extrusion and gain access to the target strip. Replace the Lamp [REP 6.4 Exposure Lamp], particularly if the lamp has discoloration at the ends.

Go to the Scanner Diagnostics and do 6.2 the Full System Test. Troubleshoot any failures. Do the Scan Bar Calibration Test. Troubleshoot any failures. If the problem still exists, replace the Scanner Main PWB [REP 3.1 Main PWB]. If the problem still exists, replace the Image Module [REP 9.2 Image Module].

Examine the Calibration Target Strip, the Selfoc Lens, and the Platen Glass for dirt or contamination; clean if required. Use the Calibration Motor test in Scanner Diagnostics to rotate the Calibration Extrusion and gain access to the target strip.

Go to the Scanner Diagnostics and do 6.2 the Full System Test. Troubleshoot any failures. Do the Scan Bar Calibration Test. Troubleshoot any failures. If the problem still exists, replace the Scanner Main PWB [REP 3.1 Main PWB]. If the problem still exists, replace the Image Module [REP 9.2 Image Module].

Examine the Calibration Target Strip, the Selfoc Lens, and the Platen Glass for dirt or contamination; clean if required. Use the Calibration Motor test in Scanner Diagnostics to rotate the Calibration Extrusion and gain access to the target strip. Replace the Lamp [REP 6.4 Exposure Lamp], particularly if the lamp has discoloration at the ends.

Go to the Scanner Diagnostics and do the Full System Test. Troubleshoot any failures. Do the Scan Bar Calibration Test. Troubleshoot any failures. If the problem still exists, replace the Scanner Main PWB [REP 3.1 Main PWB]. If the problem still exists, replace the Image Module [REP 9.2 Image Module]. Thick document sensor actuated intermittently. Check that the Thick Document Lever is firmly down.

NOTE: LL-47 displayed only momentarily on Scanner Control Panel.

LL - 48

Gain calibration failure on Channel 2. (Dark streaks).

NOTE: LL-48 displayed only momentarily on Scanner Control Panel.

LL - 49

Gain calibration failure on Channel 3. (Dark streaks).

NOTE: LL-49 displayed only momentarily on Scanner Control Panel.

LL - 80

Miscellaneous Failure - Invalid scan parameters. 4 i.p.s. scan speed requested, but 4 i.p.s. feature key not installed.

Print a Configuration Sheet to check if the feature key is installed.

LL - 81

Miscellaneous Failure -Fault detected during Power up.

Perform GP 8 System Power Up Proce- View the Scanner Faults (Ordered) log dure. to check for other errors that occurred. Check this table for applicable procedures.

PL REF

6.2

Service Call Procedures 1-11

Scanner Fault Code Entry Chart

Table 1 Message Display Entry Chart FAULT CODE DISPLAYED

FAULT DESCRIPTION

COMPONENT DESIGNATOR

CLEARANCE PROCEDURE

IF THE PROBLEM STILL EXISTS

LL - 82

Miscellaneous Failure -Scan engine task event time out.

LL - 83

Image processing error.

Image Processing Scan the document again. PWB

Switch off the system. Reseat the Image Processor PWB. Perform GP 8 System Power Up Procedure. Scan the document again. If the problem still exists, replace the Image Processor PWB.

LL - 90

POST Failure - SCVM POST failure.

Main PWB.

Hardware fault on Main PWB.

Replace the Main PWB [REP 3.1 Main PWB].

LL - 91

POST Failure - Image Bar 1 failure.

Cable fault, Main PWB, Image Bar Assembly

Check that A1P/J 414 is seated.

Go to RAP LL91, LL92, LL93.

LL - 92

POST Failure - Image Bar 2 failure.

Cable fault, Main PWB, Image Bar Assembly

Check that A1P/J 415 is seated.

Go RAP LL91, LL92, LL93.

LL - 93

POST Failure - Image Bar 3 failure.

Cable fault, Main PWB, Image Bar Assembly

Check that A1P/J 416 is seated.

Go to RAP LL91, LL92, LL93.

LL - 94

POST Failure - PMI POST failure.

Image Processor PWB

Remove and reseat the Image Processor PWB.

Replace the Image Processor PWB. If the problem still exists, replace the Main PWB [REP 3.1 Main PWB].

LL - 95

POST Failure - Video POST failure.

Main PWB

Hardware fault. Replace the Main PWB.

LL - 96

POST Failure - Motor Driver POST failed.

PL REF

Check IEEE 1394 communications cable. If disconnected, reconnect. Perform GP 8 System Power Up Procedure.

Go to POST 7 in this table.

Service Call Procedures

Scanner Fault Code Entry Chart

BSD REF

1-12

Go to RAP LL96.

1.4

Maintenance Procedures

Call Back

Perform the Tasks at the Interval indicated in the table. Perform NC (Normal Call) tasks on every call. The task with specific intervals should be done only at the interval indicated.

1.

Follow the Call Flow Diagram and resolve the problem that caused the Call Back.

2.

Perform the Final Action. Do not perform the Maintenance Procedures.

Table 1 INTERVAL

TASK

REASON

NC

Clean the Platen Glass, the Platen Roll, and Print/Image Quality the Document Drive Rolls. Inspect the Document Feed Shelf, and clean it if required. Clean the parts with 43P81 Lens and Mirror Cleaner using the cleaning pads 600S4372.

NC

If there is evidence of magnification error in the process direction go to ADJ 4.1 Document Drive Motor Speed (DS system only).

Print/Image Quality

NC

Clean the Calibration Target Strip, using 8R27 Film Remover

Print/Image Quality

NC

Check the Platen Glass for scratches or Print/Image Quality chips. If found, and image quality is affected, replace the Platen Glass.

NC

Go to ADJ 8.2 Lead Edge / Trail Edge Adjust- Print/Image Quality ment (DS system only). Calibrate Document Registration. Check the document registration and adjust if necessary.

Service Call Procedures 1-13

Maintenance Procedures, Call Back

Final Action 1.

2.

Make one D (A1) size copy on 20 lb (80 gsm) bond paper of Test Pattern 82E5890. a.

Evaluate the copy and ensure that the copy meets the Image Quality Specifications. Go to IQ-1 Image Quality RAP in Section 3.

b.

If the copy is not within the specification, go to IQ-1 Image Quality RAP in Section 3 of this service manual and follow the procedure to eliminate any defects.

c.

Evaluate the copy for any visible defects.

d.

If the copy exhibits any visible defects, go to IQ-1 Image Quality RAP in Section 3, and follow that procedure to eliminate the defects.

Make a copy.

3.

Ensure that the copy count meters on the Image Output Terminal (IOT) have advanced.

4.

Fill out the Service Call Report. Record all activities in the service log.

5.

If new developer material was installed in the IOT, write the developer batch number in the Service Log.

6.

Give appropriate copy credits to the customer.

7.

If service was performed on the IOT or the Scanner, use the serial numbers of the IOT or the Scanner to close the call. Report both the IOT Meters (A and B) when closing the call.

Service Call Procedures

Final Action

1-14

2 Status Indicator RAPS RAP 1.1 DC Power ......................................................................................................... RAP LL91, LL92, LL93.................................................................................................... RAP LL96........................................................................................................................ RAP OF-1 Document Transportation ..............................................................................

2-3 2-5 2-6 2-8

Status Indicator RAPS Synergix Scan System

2-1

Status Indicator RAPS 2-2

Synergix Scan System

A

RAP 1.1 DC Power This RAP is used to isolate faults in the DC Power Generation and Distribution Chain.

Table 1

NOTE: The power supply PS1 contains switching power supplies for all but the 5 VDC Standby signal. A1P404-14 must be grounded to obtain +3.3, +5, and +12 VDC output. A1P405-2 must also be grounded to obtain +24 VDC output. The pins can be connected to one of the black ground wires on the connector or to the power supply chassis. +5 VDC Standby is always available.

A1 P404 Pin

Volts DC Reading

1, 2, 11

+3.2 to +3.4

4, 6, 19, 20

+4.9 to +5.1

Initial Actions Insure that the Power Cord is connected to Power Supply PS1 and to the correct source of AC power.

10

+11.9 to +12.1

Procedure

The voltages are present and correct. Y N Replace Power Supply PS1.

Switch off the System. Open the Electronics Drawer (REP 4.2 Electronics Drawer). Switch on the Scanner. Examine LED CR7 (+5 VDC STBY), on the A1 Main PWB (Figure 1. Main PWB). The LED is on. Y N Connect the (-) lead of the DMM to the chassis of the Electronics Drawer. Connect the (+) lead to A1P 404--9 (BSD 1.2, F6) . +5 VDC is present Y N Disconnect A1P 404. +5 VDC is present. Y N Replace Power Supply PS1.

Check Connector A1P 404 for bent pins or faulty continuity. Repair any problems found.

NOTE: Overcurrent on any of the three supplies, +3.3, +5, and +12, will cause all three to shut down. If the problem still exists, use BSDs 1.2 - 1.5 to troubleshoot each voltage signal for short or open circuits. Examine LED CR2 (+24 V) located on Main PWB A1. The LED is on. Y N Connect the (+) lead to A1P 405 pin 2. The signal is low. Y N Check A1P 405 pin 2 for continuity. If correct, replace the Main PWB.

Troubleshoot the distribution of the +5 VDC standby signal, using the BSDs. Connector P404 is seated correctly and has continuity. Y N Repair any defective pin. If the problem still exists, replace Power Supply PS1.

Switch off the Scanner. Disconnect Connector A1P 405. Connect A1P 405 pin 2 to A1P 405 pin 3 or to the chassis of the Electronics Drawer. Connect the (-) lead of the DVM to the chassis of the Electronics drawer. Refer to [Table 2], and measure each voltage.

Replace the Main PWB. Table 2

Examine LEDs CR9 (+12 V), CR10 (+5 V), and CR8 (+3.3V). The LEDs are all on. Y N Connect the (+) lead of the DMM to A1P 404-14 (BSD 1.2, J5). The signal is low. Y N Replace the Main PWB. Switch off the Scanner. Disconnect connector A1P 404. Connect A1P 404-14 to A1P 404-13 or to the chassis of the Electronics Drawer. Switch on the Scanner. Refer to [Table 1] and measure each voltage.

A1P 405 Pin

Volts DC Reading

1

+23 to +25

4

+23 to +25

The voltages are correct. Y N Replace Power Supply PS-1.

A

B

C Status Indicator RAPS

Synergix Scan System

2-3

RAP 1.1 DC Power

B

C Check Connector A1P 405 for bent pins or lack of continuity. Repair any problems found. If the problem still exists, use BSD 1.2 to troubleshoot the 24 VDC signal for short circuits.

Power Supply PS1 is good. Connect the (-) lead of the DVM to the chassis on the Electronics Drawer. Connect the (+) lead to the +2.5 V test point on the Main PWB. +2.5 VDC is present. Y N Replace the Main PWB [REP 3.1 Main PWB]. Connect the (+) lead of the DMM to the test points on the Main PWB shown in [Table 3].

Table 3 Test Point

VDC Reading

+5A

+4.9 to +5.2

-5.2A

-4.9 to -5.2

The voltages are correct. Y N Disconnect ribbon cables P/J 414, 415, and 416 from the Main PWB A1. Measure the voltages in [Table 3 ] again. The voltages are correct. Y N Replace the Main PWB. Check the ribbon cables for a short circuit to the chassis at the connectors entering the Image Bar Assembly. If a short circuit is found, correct the problem. If no short circuit is found, replace the Image Bar Assembly.

Figure 1 Main PWB

Disconnect the cable from the IEEE-1394 connector on the rear of the Electronics Drawer. Connect the (+) Lead to Pin 3 (upper right when looking into the connector) of the IEEE-1394 connector. 3.3 VDC is present. Y N Replace the Main PWB [REP 3.1 Main PWB]. Connect the (+) lead to A1P 403-4. +15 VDC is present. Y N Disconnect Connector A1P 403. Connect the (+) lead of the DMM to A1J 403-4. +15 VDC is present. Y N Replace the Main PWB [REP 3.1 Main PWB]. Refer to BSD 6.1 and check the wires to the Illumination Sensor for a short Circuit. If the wires are good, replace Illumination Sensor Q11 (PL 1.3). The DC Power generation circuits are operating correctly.

Status Indicator RAPS

RAP 1.1 DC Power

2-4

Synergix Scan System

RAP LL91, LL92, LL93 This RAP isolates faults that can cause the calibration test of the Image Module to fail. Such a failure causes an LL91 (Image Bar 1), LL92 (Image Bar 2) or LL93 (Image Bar 3) status code to be displayed.

Initial Actions Open the Electronics Drawer [REP 4.2 Electronics Drawer]. Check that the video cables connected to A1P 414, A1P 415, and A1P 416 are firmly seated.

Procedure Switch off the system. Switch on the Scanner and observe the POST 7-segment display. The Exposure Lamp switches on briefly when 8 is displayed, and switches off when 9 is displayed. Y N Switch off the Scanner. Set the DMM to read 24 Volts DC. Connect the (+) lead to A1P 407 on the Main PWB. Connect the (-) lead to the chassis ground. Switch on the Scanner. The signal goes low when 8 is displayed on the POST 7-segment display, and goes high when 9 is displayed. Y N Replace the Main PWB (A1). Replace the Lamp Ballast PWB (A5) (PL 1.4). Go to the [ RAP 1.1 DC Power ]. The DC Power generation and distribution is good. Y N Isolate the problem in these circuits, using the RAP 1.1 DC Power procedure and the BSDs. Switch off the Scanner. Go to BSD 6.2 and identify the video cable associated with the LL91, LL92, or LL93 status code displayed. Disconnect the video cable associated with the fault from the Main PWB. Disconnect another adjacent video cable. Connect the first video cable to the second cable’s connector on the Main PWB. Connect the second cable to the first cable’s connector. Switch on the Scanner. After the POST code on the 7-segment display has advanced to A, switch on the Controller. The LL status code has changed to a different code in the LL-91-93 range. Y N Replace the Main PWB [REP 3.1 Main PWB]. Replace the video cable associated with the LL9x code. If the problem still exists, replace the Image Module Assembly. (REP 9.2)

Status Indicator RAPS Synergix Scan System

2-5

RAP LL91, LL92, LL93

A

B

RAP LL96

Y

This RAP isolates faults that can cause the Calibration Extrusion not to rotate to the Home Position or to fail to be detected as having arrived at the Home Position.

N Examine LED CR2 (24 V) (BSD 1.2, G2) on the Main PWB A1. The LED is on. Y N Go to RAP 1.1 DC Power.

Initial Actions Go to BSD 1.2 and troubleshoot the wires from A1P/J 406 to A3P/J 300. The wires have continuity, and +24 VDC is present between A3P 300-1 and A3P 300-6. Y N Repair the wires.

Perform GP 8 System Power Up Procedure. If LL96 is still displayed, perform the following Repair Analysis Procedure.

Procedure Examine the 7-segment LED on the Rear Panel of the Electronics Drawer. POST code P. is displayed. Y N POST code 5 is displayed. Y N POST code 9 is displayed. Y N Check fuse A5F1 on the Lamp Ballast PWB (BSD 1.2, P2). The Fuse is open. Y N Enter the Diagnostics and go to the Lamp Test (Section 6) and check that the Exposure Lamp LP1 operates. The Lamp operates. Y N Check that the Exposure Lamp is firmly seated in its connectors and is installed with the clear window facing forward and slightly up. The Lamp is correctly installed. Y N Reinstall the Exposure Lamp and the Lamp Jacket correctly.

Replace the Motor Control PWB A3 (PL 1.4). Examine CR2 (12 V) on the Motor Control PWB A3. The LED is on. Y N Examine LED CR9 (12 V) on the Main PWB A1. The LED is on. Y N Go to RAP 1.1 DC Power. Go to BSD 1.3 and troubleshoot the wires from A1P/J 406 to A3P/J 300. 12 VDC is present between A3P 300-4 and A3P 300-6. Y N Repair the wires. Replace the Motor Control PWB A3 (PL 1.4). Examine CR3 (5 V) on Motor Control PWB A3. The LED is on. Y N Examine CR10 (5 V) on the Main PWB A1. The LED is on. Y N Go to RAP 1.1 DC Power.

Check wires from A5J 22 and A5J 21 between Lamp and Lamp Ballast PWB (BSD 6.1, F2, H2) for continuity. The wires have continuity and the connectors are seated. Y N Correct the condition. Replace Exposure Lamp LP1. Lamp Initialization.

Go to BSD 1.5 and troubleshoot the wires from A1P/J 406 to A3P/J 300. The wires have continuity, and +5 VDC is present between A3P 300-5 and A3P 300-6. Y N Repair the wires.

Then perform ADJ 6.1 Exposure

Go to BSD 6.1 and check the wires to Illumination Sensor Q11. The wires and connectors have continuity. Y N Repair the wires.

Replace the Motor Control PWB A3 (PL 1.4). Enter the diagnostics and go to the Calibration Motor test. Operate the test. The Calibration Extrusion rotates. Y N

Replace Sensor Q11 (PL 1.3). Then perform ADJ 6.1 Exposure Lamp Initialization.

Enter the diagnostics, Component Tests, [ Loopback Communications ] test. Operate the test The test is successful. Y N Replace the Main PWB A1.

Replace Lamp Ballast PWB A3 (PL 1.4).

Examine LED CR1 (24V) on the Motor Control PWB A3 (PL 1.4). The LED is on. A B Status Indicator RAPS

RAP LL96

A 2-6

B

C

D Synergix Scan System

A

B

C

D Switch off the System. Remove the Loopback Connector from A1j 408. Perform the Power On Procedure [GP 8]. Go to BSD 6.3 and check the wires between A1P 408 and A3P301. The wires are good. Y N Repair the wires. Check the wires from A3P 305 to Motor MOT2 (PL 1.2B). The wires are good. Y N Repair the wires. Check the gears for damage. Replace damaged parts. If Calibration Motor MOT2 does not rotate when the Calibration Motor test is run, replace Motor MOT2 (PL 1.2B).

Go to BSD 6.3 and check the voltage on J 400-14 and J 400-16. The voltage goes low when the window in the Encoder Disk is aligned with the sensor, and high otherwise. Y N The wires between A1P 400-14, -15, and -16, and Sensor Q11 have continuity. Y N Repair the wires. Replace Illumination Sensor Q11 (PL 1.3). Perform ADJ 6.1 Exposure Lamp Initialization. Replace the Main PWB A1. Enter the diagnostics. Perform the Reset NVR Defaults test (section 6). Perform GP 8 System Power Up Procedure. If POST code 5 is still displayed, replace NVR integrated circuit U28 on the Main PWB A1. Perform the earlier steps in this paragraph again. If the problem still exists, replace the Main PWB [REP 3.1 Main PWB]. Go to RAP 1.1 DC Power.

Status Indicator RAPS Synergix Scan System

2-7

RAP LL96

RAP OF-1 Document Transportation

Initial Actions

This RAP describes corrective actions for faults that prevent correct transportation of inserted documents.

Ensure that the customer inserts documents such that the document is centered in the document path. If a MEDIA JAM message is displayed on the Scanner Control Panel, lift the Upper Document Handler and remove any document material from the document path. Lower the Upper Document Handler and try to scan the document again.

Procedure Refer to [Table 1] for faults, probable causes, and corrective actions.

Table 1

Problem

Probable Cause

Corrective Action

BSD Reference

The Control Panel Display indicates READY but there is no response when a document is inserted. Document Drive Motor MOT1 does NOT operate.

1.

Edge Presence Sensor Q4.

1.

Enter the scanner diagnostics. Choose Scanner Control Panel from the Component Tests. Actuate Sensor Q4. If the sensor does not operate, remove the top cover and clean the sensor with a lint-free cloth. If the problem still exists, go to the BSD and troubleshoot the fault in the sensor circuit (BSD 4.1).

4.1

2.

Motor Control PWB A3 or Document Drive Motor.

2.

Enter the diagnostics and choose Component Tests, Document Drive Motor. Set the Document Drive motor to operate at speed 500, forward direction. Start the test. The motor should operate. If not, troubleshoot the connections to Document Drive Motor MOT1. If good, replace MOT1 (PL 1.5).

1.

Document Right Side Sensor Q6 or Left Side Sensor Q5 are dirty or faulty.

1.

Enter the scanner diagnostics. Choose Scanner Control Panel from the Component Tests. Actuate Sensor Q5 and Q6. If a sensor does not operate, remove the top cover and clean the sensor with a lint-free cloth. If the problem still exists, go to the BSD and troubleshoot the fault in the sensor circuit (BSD 6.4).

2.

Platen Roll is dirty.

2.

Clean the Platen Roll, using a lint-free cloth and Film Remover.

Frequent auto width detection failures

1.

6.4

2.

6.3 (N4)

Document is accepted when inserted, but doesn’t stage properly. MEDIA JAM is displayed.

Edge Registered Sensor Q3

Enter the scanner diagnostics. Choose Scanner Control Panel from the Component Tests. Actuate Sensor Q3. If the sensor does not operate, remove the top cover and clean the sensor with a lint-free cloth. If the problem still exists, go to the BSD and troubleshoot the fault in the sensor circuit (BSD 4.1).

4.1 (R1)

Display indicates READY; document is inserted. Doc. Drive Motor MOT1 operates, but the document is not transported.

Drive belts.

Examine the drive belts for damage. Ensure that the belt tension is correct. If not, go to Section 4, Adjustments, and perform ADJ 8.1 Main Drive Belt / Document Drive Belt Tension.

4.1 (T5)

Status Indicator RAPS

RAP OF-1

2-8

Synergix Scan System

3 Image Quality RAPS IQ-1 Image Quality RAP..................................................................................................

3-3

Image Quality RAPS Synergix Scan System

3-1

Image Quality RAPS 3-2

Synergix Scan System

IQ-1 Image Quality RAP

Additionally, many problems are caused by dirt on the Calibration Target Strip. Clean this part with a lint-free cloth and Film Remover 8R27 (Isopropyl Alcohol).

The Image Quality RAP contains a table with descriptions of Image quality problems, probable causes, and corrective actions.

Procedure Refer to [Table 1].

Initial Actions Many image quality problems are caused by dirt on the Platen Glass, the SelFoc lens, or the Platen Roll. Inspect these parts carefully. Clean the glass and the lens with Lens and Mirror Cleaner 43P 81 and a lint-free cloth. Clean the Platen Roll using a lint-free cloth with Film Remover 8R27 or isopropyl alcohol. Table 1

BSD Reference

Problem

Probable Cause

Corrective Action

Lines on copies in process direction.

Chipped or worn Platen Glass

Replace the Platen Glass.

Compressed zones in image, perpendicular to process direction

1.

Dirt on Document Drive Rolls.

1.

Clean the rolls with Film Remover 8R27.

4.1

2.

If thick document, Document Thickness Lever and associated mechanism

2.

Ensure that the customer uses the minimum adjustment of the Document Thickness Lever to scan thick documents without drag.

6.4

White streaks, process direction

Dirty Calibration Target Strip

Clean the Calibration Target Strip using Film Remover 8R27. Perform a power off - power on cycle [GP 8].

6.3

Skewed image

1. Dirt on Document Drive Rolls.

1. Clean the rolls with Film Remover 8R27.

4.1

Image out of focus

Interference with complete closure of the Upper Document Transport.

1.

Ensure that the Platen Roll in the Upper Document Transport moves up and down freely.

4.1

2.

Ensure that the plastic clamps that hold down the Platen Glass are correctly seated.

Image Quality RAPS Synergix Scan System

3-3

IQ-1

Image Quality RAPS

IQ-1

3-4

Synergix Scan System

4. Repairs and Adjustments Repairs REP 1.1 Power Supply.................................................................................................... REP 3.1 Main PWB......................................................................................................... REP 3.2 Image Processing PWB.................................................................................... REP 4.2 Electronics Drawer........................................................................................... REP 6.2 Platen Glass ..................................................................................................... REP 6.3 Video Cables 1, 2, 3 ......................................................................................... REP 6.4 Exposure Lamp................................................................................................. REP 8.1 Front Drive Shaft Assembly .............................................................................. REP 8.2 Rear Drive Shaft Assembly............................................................................... REP 8.4 Upper Document Transport .............................................................................. REP 8.5 Platen Roll / Calibration Extrusion .................................................................... REP 8.6 Upper Document Transport Latches and Interlock Switch ............................... REP 9.2 Image Module ................................................................................................... REP 9.3 Thick Document Shaft ...................................................................................... REP 14.1 Scanner End Covers....................................................................................... REP 14.2 Scanner Back Cover ....................................................................................... REP 14.3 Upper Document Transport Cover.................................................................. REP 14.4 Scanner Feed-In Shelf....................................................................................

4-3 4-5 4-8 4-10 4-14 4-15 4-18 4-20 4-26 4-35 4-42 4-58 4-61 4-64 4-68 4-68 4-69 4-70

Adjustments ADJ 4.1 Document Drive Motor Speed (DS system only).............................................. ADJ 6.1 Exposure Lamp Initialization ............................................................................. ADJ 8.1 Main Drive Belt / Document Drive Belt Tension ................................................ ADJ 8.2 Lead Edge / Trail Edge Adjustment (DS system only) .....................................

4-73 4-75 4-76 4-78

Repairs and Adjustments 4-1

Repairs and Adjustments 4-2

REP 1.1 Power Supply

3.

Parts List on PL 1.4 Removal

(Figure 2): Disconnect the two Power Supply connectors that attach to the Main PWB: •

A1P9 (20 pin connector) from J404 on the Main PWB

•

A1P10 (6 pin connector) from J405 on the Main PWB

WARNING

2 Remove the two 5.5mm Mount Screws

Switch off the Scanner power and disconnect the power cord. 1.

Go to REP 4.2 Electronics Drawer. Perform steps 1 through 5.

2.

(Figure 1): Install a Static Band to your wrist and attach the ground wire to an unpainted area of the Scanner chassis securely. Main PWB Power Supply

1 Disconnect A1P9, A1P10 Figure 2 Disconnecting the Main PWB Connectors 4.

Route the wires leading from A1P9 and A1P10 back out through the plastic wire bundles on the rear wall of the Electronics Drawer.

5.

Remove the two 5.5mm hex screws that mount the Power Supply to the floor of the Electronics Drawer.

Figure 1 Installing the Static Band and Ground Strap

Repairs and Adjustments 4-3

REP 1.1

6.

Replacement

(Figure 3): Remove the four slot-head screws that mount the Power Supply to the wall of the Electronics Drawer.

Remove the four mount screws

Figure 3 Removing the Four Mount Screws on the Electronics Drawer 7.

Lift the Power Supply out of the Electronics Drawer.

Repairs and Adjustments

REP 1.1

4-4

1.

The replacement or reinstallation of the Main PWB is the reverse of the Removal procedure.

2.

Power up the Scanner, Controller and Printer and verify correct machine operation.

REP 3.1 Main PWB

CAUTION The Image Processing PWB is located on the left side of the Electronics Drawer (as viewed from the rear of the Scanner). It is secured to the Main PWB by 5 screws. The Image Processing PWB also attaches to the Main PWB by means of three integral connectors. Exercise caution when removing this PWB from the Main PWB as these connectors can be damaged if handled incorrectly. 3. (Figure 2): Remove the Image Processing PWB from the Main PWB.

Parts List on PL 1.4 Removal WARNING Switch off the Scanner power and disconnect the power cord. 1.

Go to REP 4.2 Electronics Drawer. Perform steps 1 through 5.

2.

(Figure 1): Install a Static Band to your wrist and attach the ground wire to an unpainted area of the Scanner chassis securely.

1 Remove the five screws

2 Carefully lift the Image Processing PWB off of the Main PWB

Image Processing PWB

Main PWB

Figure 1 Installing the Static Band and Ground Strap Integral connectors to Main PWB Figure 2 Removing the Image Processing PWB

Repairs and Adjustments 4-5

REP 3.1

(Figure 3): Standing at the rear of the Scanner, dislocate the spring from the left drawer Slide and gently guide the left side of the Electronics Drawer out an additional 12 mm. This will provide additional room to disconnect the three ribbon cables on the Image Processing PWB.

4.

(Figure 4): Disconnect the following connectors from the Scanner Main PWB.

J414

NOTE: When guiding the Electronics Drawer back into the Scanner (at the completion of this REP) it will be necessary to pull out the retaining spring again slightly as the drawer is guided back into the Scanner frame.

J415

J416

J400

J403 J413 J404

J405

J408

J407

Figure 4 Disconnecting the Main PWB Connectors

1

2

Gently pull retaining spring outward about 5 mm

Guide left side of Electronics Drawer out about 12 mm

Figure 3 Disconnecting the Slide Spring

Repairs and Adjustments

REP 3.1

4-6

J406

5.

Replacement

(Figure 5): Remove the seven mount screws and carefully lift the Main PWB from the Electronics Drawer.

NVR Chip

1.

The replacement or reinstallation of the Main PWB is the reverse of the Removal procedure.

2.

Power up the Scanner, Controller and Printer and verify correct machine operation.

3.

If the Main PWB has been replaced, any installed feature keys must be re-installed again. A new feature key file must be created, using the new hardware address of the replacement Main PWB. Print a configuration sheet to obtain the hardware address of the Scanner. Follow the process contained in the documentation shipped with the feature key, or go to the website at www.xes.com/keys and choose Get a replacement Feature Key. After obtaining the new file, send it to the printer. Then, restart the system to enable the feature key.

Figure 5 Removing the Main PWB 6.

(Figure 5): If the Main PWB is being replaced, remove the NVR (Non-Volatile Random Access Memory) Chip from the old Main PWB and install it on the new Main PWB prior to placing the Main PWB on the Scanner.

Repairs and Adjustments 4-7

REP 3.1

REP 3.2 Image Processing PWB

CAUTION The Image Processing PWB is located on the left side of the Electronics Drawer (as viewed from the rear of the Scanner). It is secured to the Main PWB by 5 screws. The Image Processing PWB also attaches to the Main PWB by means of three integral connectors. Exercise caution when removing this PWB from the Main PWB as these connectors can be damaged if handled incorrectly. 3. (Figure 2): Remove the Image Processing PWB from the Main PWB.

Parts List on PL 1.4 Removal WARNING Switch off the Scanner power and disconnect the power cord. 1.

Go to REP 4.2 Electronics Drawer. Perform steps 1 through 5.

2.

(Figure 1): Install a Static Band to your wrist and attach the ground wire to an unpainted area of the Scanner chassis securely.

1 Remove the five screws

2 Carefully lift the Image Processing PWB off of the Main PWB

Image Processing PWB

Main PWB

Figure 1 Installing the Static Band and Ground Strap Integral connectors to Main PWB Figure 2 Removing the Image Processing PWB

Repairs and Adjustments

REP 3.2

4-8

Replacement 1.

The replacement or reinstallation of the Image Processing PWB is the reverse of the Removal procedure.

2.

Power up the Scanner, Controller and Printer and verify correct machine operation.

Repairs and Adjustments 4-9

REP 3.2

REP 4.2 Electronics Drawer

3.

Parts List on PL 1.4 Removal

(Figure 2): Remove the Catch Tray from the Scanner.

1 Remove the retaining screw at either end of the Catch Tray Mounting Bracket

WARNING Switch off the Scanner power and disconnect the power cord. 1.

Disconnect the IEEE1394 cable and the Scanner power cord.

2.

(Figure 1): Remove the two Catch Tray Supports at the back of the Scanner, and lower the Catch Tray down to the Organizer Tray.

1 Remove the Catch Tray Supports (2)

2 Lift the Catch Tray Mounting Bracket and the Catch Tray away from the Scanner

Figure 1 Removing the Catch Tray Supports Figure 2 Removing the Catch Tray

Repairs and Adjustments

REP 4.2

4-10

4.

(Figure 3): Remove two screws at the back of the Scanner and pull out the Electronics Drawer.

5.

(Figure 4): Remove the four screws on the Electronics Drawer Top Cover and remove the cover.

1

1

Remove the two screws

Remove the four screws from the Electronics Drawer Top Cover

3

2

Pull out the Electronics Drawer

Let the ground strap hang free from the Electronics Drawer

2 Lift off the Top Cover

Figure 3 Accessing the Electronics Drawer Figure 4 Removing the Electronics Drawer Top Cover

NOTE: The remainder of this procedure describes the complete removal of the Electronics Drawer. If the technical representative desires only to gain access to the Electronics Drawer (for removal of a PWB), stop at this point. Return to the REP that directed you here.

Repairs and Adjustments 4-11

REP 4.2

6.

(Figure 5): Install a Static Band to your wrist and attach the ground wire to an unpainted area of the Scanner chassis securely.

7.

(Figure 6): Standing at the rear of the Scanner, dislocate the springs from the left and right drawer Slides and gently guide the Electronics Drawer out an additional 12 mm. This will provide additional room to disconnect the three ribbon cables on the Image Processing PWB (J414, J415, J416).

NOTE: When guiding the Electronics Drawer back into the Scanner (at the completion of this REP) it will be necessary to pull out the retaining springs again slightly as the drawer is guided back into the Scanner frame.

Figure 5 Installing the Static Band and Ground Strap

1

2

Gently pull retaining spring outward about 5 mm

Guide left side of Electronics Drawer out about 12 mm

Figure 6 Disconnecting the Slide Spring

Repairs and Adjustments

REP 4.2

4-12

8.

Replacement

(Figure 7): Disconnect the following connectors from the Scanner Electronics Drawer.

J305

A0P100

J414

J415

J416

J500

1.

The replacement of the Scanner Electronics Drawer is the reverse of the Removal procedure.

2.

Power up the Scanner, Controller and Printer and verify correct machine operation.

J304

Figure 7 Disconnecting the Scanner Electronics Drawer 9.

Pull the Electronics Drawer out from the Synergix Scanner and place it on a flat and level surface.

Repairs and Adjustments 4-13

REP 4.2

REP 6.2 Platen Glass

WARNING The Exposure Lamp may be hot. Allow the Lamp to cool before removal.

Parts List on 1.1 Removal

2.

(Figure 2): Remove the Platen Glass.

WARNING Switch off the Scanner power and disconnect the power cord. 1.

(Figure 1): Lift the Upper Document Transport.

2 Lift off the Glass Clip (one each side)

Lift the Upper Document Transport

3 Lift out the Platen Glass

1 Remove the screw (one each side)

Figure 2 Removing the Platen Glass

Replacement

Figure 1 Lifting the Upper Document Transport

Repairs and Adjustments

REP 6.2

4-14

1.

Clean the Platen Glass with Glass Cleaner.

2.

(Figure 3): Correctly position the Platen Glass in the Scanner.

REP 6.3 Video Cables 1, 2, 3 1 Reinstall this edge of the Platen Glass towards the operator, sharp edge down

Parts List on PL 1.1 Removal

Platen Glass

WARNING Switch off the Scanner power and disconnect the power cord. 1.

Perform REP 4.2 Electronics Drawer.

2.

Raise the Platen Cover.

3.

(Figure 1): Remove the Right and Left End Covers by removing the two retaining screws on each End Cover.

2

1

Pull the Platen Glass forward until it stops up against the Feed In Shelf

Scanner End Cover

Remove one screw from the inside of the End Cover

Figure 3 Correct Positioning of Platen Glass CAUTION In the following step, ensure that the Platen Glass is positioned squarely between the bevels of the Glass Clips prior to tightening the clips down. 3. Reinstall the Glass Clip at each end of the Platen Glass.

2 Remove one screw from the back of the Scanner frame

Figure 1 Removing the Right and Left End Covers

Repairs and Adjustments 4-15

REP 6.2, REP 6.3

4.

Remove the Feed-In shelf (REP 14.4 Scanner Feed-In Shelf).

5.

(Figure 2): Lower the Video Cable Housing (PL 1.1) down from the underside of the Image Module. Let it rest upon the lower Scanner Frame.

NOTE: The Video Cable Housing is a folded sheet steel platform that supports the three Video Cables beneath the Image Module.

1 Disengage the Video Cable Housing by bending the three folded tabs outward slightly, and lowering the platform

Rear of Scanner

Figure 2 Lowering the Video Cable Housing

Repairs and Adjustments

REP 6.3

4-16

6.

Replacement

(Figure 3): Remove the Video Cables from the Scanner.

1

1.

Reinstall the Video Cables on their connectors.

2.

(Figure 4): Reinstall the Video Cables on the Video Cable Housing in the correct order. A simplified drawing is provided below to aid in this step.

Any of the three Video Cables can now be disconnected at this point

3 Pull the rear edge of the Video Cable Housing upwards and snap it into locked position on the rear edge of the Image Module

Rear of Scanner

2 Video Cable 1

Video Cable 2

Engage the hooked front edge of the VCM on to the front edge of the Image Module

Video Cable 3

1

Video Cable Housing Video Cable 1

Front of Scanner Figure 3 Removing the Video Cables

Replace Video Cables in correct order and string the cables out the front of the VCM

Figure 4 Replacing the Video Cable Housing 3.

Reinstall the Scanner Feed-In Shelf.

4.

Reinstall the Platen Glass Clips. Ensure that the Platen Glass is clean and positioned squarely between the bevels of the Glass Clips prior to tightening the clips down.

5.

Reinstall the Scanner End Covers.

6.

Close the Scanner Cover.

7.

Perform REP 4.2 Electronics Drawer to reinstall the Electronics Drawer.

8.

Return the Scanner to normal operation.

Repairs and Adjustments 4-17

REP 6.3

REP 6.4 Exposure Lamp

WARNING The Exposure Lamp may be hot. Allow the Lamp to cool before removal.

Parts List on PL 1.3 Removal

2.

(Figure 2): Remove the Platen Glass.

WARNING Switch off the Scanner power and disconnect the power cord. 1.

(Figure 1): Lift the Upper Document Transport.

2 Lift off the Glass Clip (one each side)

Lift the Upper Document Transport

3 Lift out the Platen Glass

1 Remove the screw (one each side)

Figure 2 Removing the Platen Glass

NOTE: Note the positioning of the Exposure Lamp in the Image Module. The lamp will need to be reinstalled in the same position. Figure 1 Lifting the Upper Document Transport

Repairs and Adjustments

REP 6.4

4-18

3.

Rotate the Exposure Lamp and lift it out of the Scanner.

4.

Remove the black Lamp Jacket from the Exposure Lamp.

Replacement

CAUTION If the fluorescent lamp has been replaced, perform all the steps in this procedure in order to reset the NVR (Non-Volatile Random Access Memory) settings for the new lamp. Failure to heed this caution could result in image quality problems. 9. If the fluorescent lamp has been replaced, go to ADJ 6.1 Exposure Lamp Initialization to complete this replacement. If the fluorescent lamp has only been reinstalled, continue on with this procedure. 10. Run a copy of Test Target #82E5980 to confirm the correct operation and copy quality of the Scanner. 11. Return the Scanner to normal operation.

NOTE: When reinstalling the Lamp Jacket on the Fluorescent Lamp ensure that the Lamp Jacket does not cover the light window on that lamp. The edge of the Lamp Jacket should be about 2mm from the edge of the lamp’s light window. 1.

Reinstall the Lamp Jacket on the Fluorescent Lamp.

2.

Reinstall the Fluorescent Lamp in the Scanner.

3.

Rotate the lamp counter-clockwise about one-half turn, until positively engaged.

NOTE: When correctly positioned, the clear portion of the fluorescent lamp will face upward and towards the front of the Scanner. 4.

Clean the Platen Glass with Glass Cleaner.

5.

(Figure 3): Correctly position the Platen Glass in the Scanner.

1 Reinstall this edge of the Platen Glass towards the operator, sharp edge down

Platen Glass

2 Pull the Platen Glass forward until it stops up against the Feed In Shelf

Figure 3 Correct Positioning of Platen Glass CAUTION In the following step, ensure that the Platen Glass is positioned squarely between the bevels of the Glass Clips prior to tightening the clips down. 6. Reinstall the Glass Clip at each end of the Platen Glass. 7. Close the Upper Document Transport. 8. Reboot the Scanner system by switching off the Scanner and Printer for about 15 seconds. Power on the system in the following order: Scanner, Controller (if accessible), Printer.

Repairs and Adjustments 4-19

REP 6.4

REP 8.1 Front Drive Shaft Assembly

CAUTION Use caution when removing/reinstalling the screws on the Feed In Shelf. The screws are selftapping and can be cross threaded if caution is not exercised. 3. (Figure 2): Remove the Right and Left End Covers by removing the two retaining screws on each End Cover.

Parts List on PL 1.3 Removal WARNING Switch off the Scanner power and disconnect the power cord. 1.

Lift the Upper Document Transport.

2.

(Figure 1): Remove the Platen Glass.

2 Lift off the Right and Left Glass Clips

1 Remove one screw from the inside of the End Cover

2

3 Lift out the Platen Glass

Remove one screw from the back of the Scanner frame

1 Remove the screw (right and left sides)

Figure 2 Removing the Right and Left End Covers Figure 1 Removing the Platen Glass

4.

Remove the Feed In Shelf (REP 14.4 Scanner Feed-In Shelf).

CAUTION Take care when loosening or tightening the screws that retain the Bearing Clamps. The screws are self-tapping, and are threaded into an aluminum casting. There is a possibility of stripping the screws if they are misaligned or overtightened.

NOTE: Note the following when removing or reinstalling the Front Drive Shaft Assembly Bearing Clamps: • The Bearing End Clamps at the outer edges of the Front Drive Shaft Assembly are retained by two screws each. • The two inner Bearing Clamps are retained by only one screw. • The left inner Bearing Clamp also contains a ground strap. 5.

Repairs and Adjustments

REP 8.1

4-20

(Figure 3): Locate and remove the Bearing Clamps on the Front Drive Shaft Assembly.

6.

(Figure 4): Remove the small O-Ring Drive Belt from the left side of the Front Drive Shaft Assembly.

Bearing Clamps (4) O-Ring Drive Belt

Ground Strap

Figure 3 Location of Bearing Clamps on Front Drive Shaft Assembly

Figure 4 Removing the Small O-Ring Drive Belt

Repairs and Adjustments 4-21

REP 8.1

7.

(Figure 5): Remove the Document Drive Belt from the right side of the Scanner.

3 Remove the Document Drive Belt

2 Remove the screw, Extension Spring, and Tension Pulley

1 Remove the screw

Figure 5 Removing the Document Drive Belt

Repairs and Adjustments

REP 8.1

4-22

8.

Replacement

(Figure 6): Remove the Belt Guard from the right side of the Scanner.

1.

If a new Front Drive Shaft Assembly is being installed, place the E-ring and Pulley from the old Front Drive Shaft Assembly on the new Front Drive Shaft Assembly.

2.

Reinstall the Front Drive Shaft Assembly on its mounts.

CAUTION The Drive Shaft Bearings can be damaged by installing them incorrectly. The two tabs on each Drive Shaft Bearing must fully engage the slots in the Bearing Clamps prior to tightening down the Bearing Clamps 3. (Figure 7): Reposition and tighten down the two Bearing Clamps on the right side of the Front Drive Shaft Assembly. Ensure that the two tabs on each bearing fully engage the slots in the Bearing Clamp prior to tightening down the clamp.

1 Carefully slide the Belt Guard up and around the pulleys

Screws mount to Frame

Bearing Clamps Figure 6 Removing the Belt Guard CAUTION Ensure that the small plastic bearings on either end of the Front Drive Shaft are not lost when removing the shaft. 9. Remove the Front Drive Shaft Assembly by lifting it out of the Scanner. 10. If the Front Drive Shaft Assembly is being replaced, remove the E-ring and pulley from the old Front Drive Shaft Assembly.

Bearings Inner Bearing Clamp Configuration

Bearing End Clamp Configuration

Figure 7 Correct Installation of Inner and Outer Bearing Clamps

Repairs and Adjustments 4-23

REP 8.1

4.

(Figure 8): Reinstall the O-ring Drive Belt and Bearing Clamps.

6.

(Figure 9): Reinstall the right side components.

1 Reinstall the O-ring Drive Belt over the Drive Pulley and the Drive Shaft Pulley

4 Reinstall the Document Drive Belt

2 Reinstall the two left side Bearing Clamps

1 Reinstall the screw

5 Fully tighten screw

3 Reinstall the spring

2 Loosely reinstall the Tension Pulley and screw

Figure 8 Installing the Left Side Belt and Bearing Clamps 5.

Slide the Belt Guard back into position on the right side of the Scanner.

Figure 9 Reinstalling the Right Side Components 7.

Reinstall the Feed In Shelf.

8.

Reinstall the Left and Right End Covers.

CAUTION In the following step, ensure that the Platen Glass is positioned squarely between the bevels of the Glass Clips prior to tightening the clips down. 9. (Figure 10): Clean and reinstall the Platen Glass.

Repairs and Adjustments

REP 8.1

4-24

2 Reinstall the Right and Left Glass Clips

1 Place the Platen Glass as shown, biasing it slightly forward.

3 Reinstall the screw (right and left sides)

Figure 10 Reinstalling the Platen Glass 10. Close the Upper Document Transport. 11. Return the Scanner to normal operation.

Repairs and Adjustments 4-25

REP 8.1

REP 8.2 Rear Drive Shaft Assembly

2.

Parts List on PL 1.3 Removal

(Figure 2): Remove the Right and Left End Covers by removing the two retaining screws on each End Cover.

WARNING Switch off the Scanner power and disconnect the power cord. 1.

(Figure 1): Lift the Upper Document Transport.

Lift the Upper Document Transport

2 Remove one screw from the back of the Scanner frame

1 Remove one screw from the inside of the End Cover

Figure 2 Removing the Right and Left End Covers Figure 1 Lifting the Upper Document Transport

Repairs and Adjustments

REP 8.2

4-26

3.

(Figure 3): Remove the Platen Glass.

5.

(Figure 4): Remove the Left Slide Bracket and Left Pivot Bracket.

4 Remove the Left Pivot Clutch Assembly

2 Lift off the Glass Clip (one each side)

1 Remove two Kclips and one washer

2 Remove the Slide Bracket

3 Lift out the Platen Glass

1 Remove the screw (one each side)

3 Remove the two screws, Bearing Clamp and Bearing

Figure 3 Removing the Platen Glass Figure 4 Removing the Left Slide Bracket and Left Pivot Clutch Assembly 4.

Close the Upper Document Transport. 6.

Disconnect the two ground straps, located behind the Right and Left Pivot Clutch Assemblies, by removing the screws.

Repairs and Adjustments 4-27

REP 8.2

7.

(Figure 5): Remove the following components on the right side of the Scanner.

8.

(Figure 6): Remove the Belt Guard from the right side of the Scanner.

1 Carefully slide the Belt Guard up and around the pulleys Belt Guard

1 Remove the screw, spring and Tension Pulley

3 Remove the mount screw

Figure 6 Removing the Belt Guard

2 Remove the belt Figure 5 Removing the Right Side Components

Repairs and Adjustments

REP 8.2

4-28

NOTE: In the following illustration the two large pulleys on the right side have been omitted for clarity. They should remain on the Scanner for the duration of this procedure, however. 9.

10. (Figure 8): Remove the Scanner Back Cover.

(Figure 7): Remove the Right Side Pivot Clutch.

3 2

Remove the Right Pivot Clutch and Bracket

Remove the Bearing Clamp

Remove the five screws

1 Remove the two mount screws

Figure 8 Removing the Scanner Back Cover

Figure 7 Removing the Right Pivot Clutch

Repairs and Adjustments 4-29

REP 8.2

11. (Figure 9): Slide out the Electronics Drawer from the back of the Scanner.

12. (Figure 10): Lift and reposition the Upper Document Transport for access to the Rear Drive Shaft Assembly.

1 Route the group of cables out around the right side of the Rear Drive Shaft. Do not disconnect any of the cables.

Slide the Electronics Drawer out from the back of the Scanner

Figure 9 Sliding out the Electronics Drawer

2

3

Move the Upper Document Transport forward, so that it rests on the Feed In Shelf

Ensure that the Rear Drive Shaft Assembly can be accessed

Figure 10 Repositioning the Upper Document Transport

Repairs and Adjustments

REP 8.2

4-30

13. (Figure 11): Remove the Rear Exit Baffle.

CAUTION Take care when loosening or tightening the screws that retain the Bearing Clamps. The screws are self-tapping, and are threaded into an aluminum casting. There is a possibility of stripping the screws if they are inadvertently misaligned or overtightened. 14. (Figure 12): Locate the Bearing Clamps on the Rear Drive Shaft Assembly.

1 Remove the mount screw at both ends of the Rear Exit Baffle

Bearing Clamps (2)

2 Lift off the Rear Exit Baffle

Figure 11 Removing the Rear Exit Baffle Figure 12 Location of Bearing Clamps on Rear Drive Shaft Assembly

Repairs and Adjustments 4-31

REP 8.2

NOTE: One of the inner Bearing Clamps also contains a ground strap. Ensure that this ground strap is disconnected prior to removing the Rear Drive Shaft Assembly.

Replacement

15. (Figure 13): Remove the Bearing Clamps (4) from the Rear Drive Shaft Assembly.

CAUTION The Rear Drive Shaft Bearings can be damaged by installing them incorrectly. The two tabs on each Drive Shaft Bearing must fully engage the slots in the Bearing Clamps prior to tightening down the Bearing clamps 2. (Figure 14): Reposition and tighten down the two Bearing Clamps in the center of the Rear Drive Shaft Assembly. Ensure that the two tabs on each bearing fully engage the slots in the Bearing Clamp prior to tightening down the clamp.

1.

1 Loosen the mount screws (4)

Reinstall the Rear Drive Shaft Assembly on to the Image Module.

Mount screw into frame

2

Bearing

Swing the Bearing Clamps off the Rear Drive Shaft Assembly, but do not remove them

Figure 14 Correct Installation of Bearing Clamp

Figure 13 Removing the Bearing Clamps

3.

16. Remove the Rear Drive Shaft Assembly.

NOTE: If the Rear Drive Shaft Assembly is to be replaced, remove the Timing Pulley and C-Clip from the old Rear Drive Shaft Assembly and place these items on the replacement shaft prior to reinstallation on the Scanner.

Repairs and Adjustments

REP 8.2

Bearing Clamp

4-32

Reinstall the Rear Exit Baffle.

4.

(Figure 15): Reposition the Upper Document Transport over the Rear Drive Shaft Assembly.

7.

(Figure 16): Reinstall the Right Bearing Clamp and Right Pivot Clutch.

3 4

1

Depress the pawl to engage the Right Pivot Clutch

Route the cables back to the inside of the Rear Drive Shaft

Reinstall the Right Pivot Clutch and Bracket with the two mount screws

2 Reinstall the Bearing Clamp on the Bearing

2 1

Reposition the Upper Document Transport back over the Image Module

Reinstall the Bearing on the Rear Drive Shaft Figure 16 Reinstalling the Right Bearing Clamp and Right Pivot Clutch

Figure 15 Repositioning the Upper Document Transport 5.

Slide the Electronics Drawer back into the Scanner.

6.

Reinstall the Scanner Back Cover.

8.

Reinstall the Belt Guard on the right side of the Scanner.

9.

Reinstall the pulleys and belt on the right side of the Scanner.

CAUTION The Rear Drive Shaft Bearings can be damaged by installing them incorrectly. The two tabs on each Drive Shaft Bearing must fully engage the slots in the Bearing Clamps prior to tightening down the Bearing clamps

Repairs and Adjustments 4-33

REP 8.2

10. (Figure 17): Reinstall the Left Bearing Clamp and Left Pivot Clutch.

11. (Figure 18): Reinstall the Slide Bracket on the left side of the Scanner.

4

2

Depress the pawl to engage the Left Pivot Clutch

Reinstall the two K-clips and washer

3 Reinstall the Left Pivot Clutch and Bracket with two mount screws

1

2

Reinstall the Bearing on the Rear Drive Shaft

Reinstall the Bearing Clamp over the Bearing

1 Reinstall the Slide Bracket

Figure 18 Reinstalling the Slide Bracket 12. Open the Upper Document Transport. CAUTION In the following step, ensure that the Platen Glass is clean, and that it is positioned squarely between the bevels of the Glass Clips prior to tightening the clips down. 13. Reinstall the Platen Glass and the Right and Left Glass Clips. 14. Reinstall the Right and Left End Covers. 15. Close the Upper Document Transport. 16. Return the Scanner to normal operation.

Figure 17 Reinstalling the Left Bearing Clamp and Left Pivot Clutch

Repairs and Adjustments

REP 8.2

4-34

REP 8.4 Upper Document Transport

3.

Parts List on PL 1.2A, 1.2B Removal

(Figure 2): Remove the Right and Left End Covers by removing the two retaining screws on each End Cover.

WARNING Switch off the Scanner power and disconnect the power cord. 1.

Lift the Upper Document Transport.

2.

(Figure 1): Remove the Platen Glass.

2

1

Lift off the Right and Left Glass Clips

Remove one screw from the inside of the End Cover

2 Remove one screw from the back of the Scanner frame

3 Lift out the Platen Glass

1

Figure 2 Removing the Right and Left End Covers

Remove the screw (right and left sides)

4.

Remove the Feed In Shelf (REP 14.4 Scanner Feed-In Shelf).

Figure 1 Removing the Platen Glass

Repairs and Adjustments 4-35

REP 8.4

5.

(Figure 3): Disconnect the Illumination Sensor and feed the wires down through the channel.

1 Disconnect the Illumination Sensor

2 Feed the wires down through the channel and out the back of the Scanner

Figure 3 Disconnecting the Illumination Sensor (Q11P1)

Repairs and Adjustments

REP 8.4

4-36

6.

(Figure 4): Remove the Left Slide Bracket and Left Pivot Clutch Assembly.

8.

(Figure 5): Remove the Document Drive Belt.

4 Remove the Left Pivot Clutch Assembly

1 Remove two K-clips and one washer

3 Remove the belt

3 Remove two screws

2 Remove the Slide Bracket

1 2 Remove the mount screw

Figure 4 Removing the Left Slide Bracket and Left Pivot Clutch Assembly 7.

Disconnect the two ground straps located at the rear of the right and left sides of the Scanner. (Remove the lower mount screws only.)

Remove the screw, Extension Spring and Tension Pulley

Figure 5 Removing the Document Drive Belt

Repairs and Adjustments 4-37

REP 8.4

9.

(Figure 6): Remove the Belt Guard by lifting it off the Front and Rear Drive Shafts.

10. (Figure 7): Remove the Right Pivot Clutch Assembly.

2 3 Remove the Bearing Clamp

1 Carefully slide the Belt Guard up and around the pulleys

Remove the Right Pivot Clutch Assembly

1 Remove the two mount screws

Figure 7 Removing the Right Pivot Clutch Assembly

Figure 6 Removing the Belt Guard

NOTE: At this point the small brown bearing underneath the Right Bearing Clamp will be free floating. It is not necessary to remove this bearing.

Repairs and Adjustments

REP 8.4

4-38

11. (Figure 8): Remove the Scanner Back Cover.

13. (Figure 9): Disconnect the Upper Document Transport connectors and ground strap from the Electronics Drawer.

2

1

Disconnect P305

Disconnect A0P100

Remove the five screws

Figure 8 Removing the Scanner Back Cover 12. Slide out the Electronics Drawer from the back of the Scanner. Figure 9 Disconnecting the Upper Document Transport Connectors and Ground Strap 14. Ensure that the connectors previously disconnected can pass freely through the Scanner. 15. Remove the Upper Document Transport from the Scanner and place it on a clean, flat surface.

Repairs and Adjustments 4-39

REP 8.4

Replacement

7.

1.

Place the Upper Document Transport back on the Scanner, making sure that the connectors and ground strap pass unobstructed out the back of the Upper Document Transport.

2.

Reconnect the connectors A0P 100 and XXXX. Reconnect the ground strap to the back of the Scanner.

3.

Close the Electronics Drawer.

4.

Reinstall the Scanner Back Cover (five screws).

5.

(Figure 10): Reinstall the Right Pivot Clutch Assembly.

(Figure 11): Reinstall the right side components.

4 Reinstall the Drive Belt

2 Reinstall the Right Pivot Clutch Assembly

3

1 Reinstall the screw

Reinstall the two mount screws

3 Reinstall the spring

2 Reinstall the Tension Pulley and screw

1 Reinstall the Bearing Clamp

Figure 11 Reinstalling the Right Side Components 8.

Figure 10 Reinstalling the Right Pivot Clutch Assembly 6.

Reinstall the Belt Guard on the Front and Rear Drive Shafts.

Repairs and Adjustments

REP 8.4

4-40

Reconnect the ground strap near the Left Pivot Clutch Assembly.

9.

(Figure 12): Reinstall the Left Slide Bracket and the Left Pivot Clutch Assembly.

1 Reinstall the Left Pivot Clutch Assembly

4 Reinstall the washer and two Kclips

2 Reinstall the two screws

3 Reinstall the Slide Bracket

Figure 12 Reinstalling the Left Slide Bracket and Left Pivot Clutch Assembly 10. Reinstall the Right and Left End Covers. 11. Return the Scanner to normal operation.

Repairs and Adjustments 4-41

REP 8.4

REP 8.5 Platen Roll / Calibration Extrusion

3.

(Figure 2): Prepare to remove the Upper Document Transport Cover.

Parts List on PL 1.2A Removal

2 Pivot the Document Thickness Lever to its highest position

WARNING Switch off the Scanner power and disconnect the power cord.

NOTE: Perform steps 1 through 21 to remove the Platen Roll. To remove the Calibration Extrusion for replacement, perform steps 1 through 22. 1.

Upper Document Transport Cover

(Figure 1): Remove the Scanner Control Panel from the Scanner.

1 Loosen the center screw

1 Remove the screws (three per side) Figure 2 Preparing to Remove the Upper Document Transport Cover

2 Tilt back the Scanner Control Panel and disconnect the connector U2P1 beneath the console Figure 1 Removing the User Interface 2.

Raise the Upper Document Transport from the Feed In Shelf.

Repairs and Adjustments

REP 8.5

4-42

4.

Lower the Upper Document Transport (UDT) and lift the UDT cover off the Scanner, starting from the rear of the machine, and working towards the front.

5.

Feed the Scanner Control Panel harness down through the cutout in the Upper Document Transport Cover.

6.

(Figure 3): Remove the Right and Left End Covers by removing the two retaining screws on each End Cover.

7.

(Figure 4): Prepare to remove the Right Side Belt Guard.

3 Remove the belt

1 Remove one screw from the inside of the End Cover

2 Remove one screw from the back of the Scanner frame

1 2 Remove the mount screw

Remove the screw, Extension Spring and Tension Pulley

Figure 4 Preparing to Remove the Right Side Belt Guard

Figure 3 Removing the Right and Left End Covers

Repairs and Adjustments 4-43

REP 8.5

8.

(Figure 5): Remove the Belt Guard by lifting it off the Front and Rear Drive Shafts.

9.

(Figure 6): Remove the right side components of the Platen Roll Shaft.

1 Carefully slide the Belt Guard up and around the pulleys

1 Remove the K-clip and the white nylon bushing

Figure 6 Removing the Right Side Components Figure 5 Removing the Belt Guard

10. Lower the Upper Document Transport.

Repairs and Adjustments

REP 8.5

4-44

11. (Figure 7): Remove the Left Slide Bracket and Left Pivot Clutch Assembly.

4

1

Remove the Left Pivot Clutch Assembly

Remove two K-clips and one washer

12. (Figure 8): Remove the following hardware from the left side of the Scanner.

2 Remove the Ering and bearing

1 3 Remove the two screws, Bearing Clamp and Bearing

Remove the K-clip and white nylon bushing

2 Remove the Slide Bracket

Figure 8 Removing the hardware Figure 7 Removing the Left Slide Bracket and Left Pivot Clutch Assembly

Repairs and Adjustments 4-45

REP 8.5

13. (Figure 9): Pull the Left Side Plate off the Scanner.

14. (Figure 10): Remove the left side Platen Roll Shaft components.

Left Side Plate

1 Remove the K-Clip

3 Remove the spring washer

2 Remove the brass bushing

Figure 10 Removing the Left Side Platen Roll Components

Figure 9 Removing the Left Side Plate

Repairs and Adjustments

REP 8.5

4-46

15. (Figure 11): Remove the right side Platen Roll Shaft components.

CAUTION In the following steps it is important to exercise caution when removing the Calibration Extrusion Assembly, as it can be easily scratched while being removed from the Scanner, negatively affecting print quality. 17. (Figure 12): Dislocate the two cable ties indicated in the illustration below. This will allow more room to remove the Calibration Extrusion.

1

2 Remove the K-Clip

Remove the Thick Document Indicator Bracket by pulling upwards

1 Use pliers to dislocate the plastic ties from the machine frame

3 Remove the brass bearing

Figure 11 Removing the Right Side Platen Roll Shaft Components Cardboard or paper placed under Upper Document Transport

16. Protect the Platen Glass by sliding a large piece of paper or cardboard under the Upper Document Transport. This will help to avoid damage to the glass while the Calibration Extrusion Assembly is being removed in the following steps.

Figure 12 Dislocating the Cable Ties

Repairs and Adjustments 4-47

REP 8.5

NOTE: The Calibration Extrusion Assembly will be removed in the following steps. Ensure that this assembly (and its component parts) does not get dirty or scratched, as print quality problems will result.

19. (Figure 14): Prepare to remove the left side End Cap from the Calibration Extrusion Assembly.

NOTE: The Left Side End Cap is distinguishable from the Right Side End Cap by the presence of the Rubber Drive Wheel on the left side.

18. (Figure 13): Remove the Calibration Extrusion Assembly from the Scanner frame by carefully sliding it out the left side of the Scanner. Set it down upon a clean, flat surface.

End Cap Assembly

1

1 Remove the two screws

Carefully slide the Calibration Extrusion Assembly out of the Scanner frame

2 Remove the Rubber Drive Wheel (and attached sleeve), noting the clockwise direction of the Drive Wheel rubber spokes

Scrap Paper to protect Platen Glass Figure 14 Preparing to Remove the Left Side End Cap 20. Remove the Left Side End Cap from the Calibration Extrusion Assembly by sliding it off the shaft.

Figure 13 Removing the Calibration Extrusion Assembly

Repairs and Adjustments

REP 8.5

4-48

Replacement

21. (Figure 15): Remove the Platen Roll from the Calibration Extrusion Assembly by sliding it out, and placing it on a clean, flat surface.

CAUTION Be very careful while handling the Platen Roll. Any dirt, dust, or scratches will adversely affect scan quality. 1. If the Calibration Extrusion has been replaced, reinstall the Right Side End Cap on the new Calibration Extrusion. Otherwise, proceed on to Step 2.

NOTE: At this point the Platen Roll has been successfully removed from the Scanner. The step that follows will continue the product disassembly to separate the Right Side End Cap from the Calibration Extrusion. (This only needs to be done in cases where the Calibration Extrusion is in need of replacement.)

NOTE: When reinstalling End Caps on the Calibration Extrusion, a good rule of thumb is: The slot-head screw is installed directly adjacent to the small slot in the End Cap. Calibration Extrusion (black plastic shell)

2.

Clean off the Platen Roll and the Calibration Target Strip on the Calibration Extrusion by wiping them with a clean, damp cloth. Ensure that the parts are dry prior to reinstallation.

3.

(Figure 16): Reinstall the Platen Roll into the Calibration Extrusion by placing the short end of the Platen Roll Shaft into the Right Side End Cap. Stand the Calibration Extrusion Assembly on end as shown, with the left side facing upwards.

Calibration Target Strip must be on left side of Calibration Extrusion prior to reinstalling Left End Cap

Long end of Platen Roll Shaft Platen Roll

Figure 15 Calibration Extrusion Assembly - Component Parts 22. Remove the Right Side End Cap from the Calibration Extrusion by removing the two screws at that end.

Figure 16 Preparing to Reinstall the Left End Cap

Repairs and Adjustments 4-49

REP 8.5

4.

(Figure 17): Reinstall the Left End Cap on the Calibration Extrusion Assembly.

5.

(Figure 18): Reinstall the Rubber Drive Wheel and Sleeve onto the Left Side of the Platen Roll Shaft.

2 2

1

Reinstall the countersunk screw on the left side

Reinstall the slot-head screw directly adjacent to the small slot in the Left Side End Cap

Slide Drive Wheel down on the Platen Roll Shaft until the Drive Wheel is flush with the Platen Roll Shaft

Rubber Drive Wheel and Sleeve

Platen Roll Shaft

Left End Cap

1

Figure 17 Reinstalling the Left End Cap

Ensure that the cutouts on the Sleeve line up with the flat edges of the Platen Roll Shaft

NOTE: In the following steps, ensure that the Rubber Drive Wheel and shaft are reinstalled flush with the edge of the Platen Roll Shaft.

Figure 18 Reinstalling the Rubber Drive Wheel and Sleeve

Repairs and Adjustments

REP 8.5

4-50

CAUTION Be careful when reinstalling the Calibration Extrusion Assembly on the Scanner frame. Any scratches or nicks on the white area of the assembly will negatively affect scan quality. 6. (Figure 19): Reinstall the Calibration Extrusion Assembly back into the Scanner frame. Ensure that the Rubber Drive Wheel (Left Side of Calibration Extrusion Assembly) is mounted on the left side of the Scanner.

8.

(Figure 20): Reinstall the following components on the right side of the Platen Roll Shaft.

1 Reinstall the brass bushing and K-Clip on to the end of the Platen Roll Shaft

1 Carefully guide the Calibration Extrusion Assembly into the Scanner from the left side

Cable Ties (2 sets)

Figure 20 Reinstalling the Right Side Components

Figure 19 Reinstalling the Calibration Extrusion Assembly 7.

(Figure 19): Reinstall the two cable ties that were previously dislocated from their frame mounts above the Calibration Extrusion Assembly.

Repairs and Adjustments 4-51

REP 8.5

9.

(Figure 21): Lift the left end of the Platen Roll Shaft. Reinstall the brass bushing on the end of the shaft and set it back down into the Scanner frame.

11. (Figure 22): Reinstall the shaft hardware onto the Upper Document Transport right side.

2 Reinstall the K-Clip

1 Reinstall the white plastic bushing

1 Reinstall the brass bushing and the spring washer

2 Reinstall the KClip

Figure 22 Reinstalling the Shaft Hardware on the Upper Document Transport Right Side

Figure 21 Securing the Left Side of the Platen Roll Shaft 10. Reinstall the cable harnesses above the Calibration Extrusion Assembly to the Scanner frame.

Repairs and Adjustments

REP 8.5

4-52

12. (Figure 23): Reinstall the Thick Document Indicator by pushing it back down over its mounting bracket on the Right Side Slide Plate.

14. (Figure 24): Push the Left Side Slide Plate back to its furthest position prior to reinstalling the Left Side Plate on the Scanner.

1 Push the Left Side Slide Plate forward on the Side Plate Side Plate (metal)

1 Push indicator down onto the mounts on the Slide Plate

Figure 24 Pushing the Left Side Slide Plate Back to its Furthest Position

Figure 23 Reinstalling the Thick Document indicator 13. Ensure that the Thick Document Lever (on right side of Upper Document Transport) is completely lowered.

Repairs and Adjustments 4-53

REP 8.5

15. (Figure 25): Reinstall the Left Side Plate back onto the Scanner left side.

1

2

Guide the two shafts into the slots molded in the Left Slide Plate Assembly.

Guide the Thick Document Shaft into the cutout hole.

16. (Figure 26): Align the left side of the Thick Document Shaft to the Left Side Plate prior to reinstalling the bushings.

1 Set the Thick Document Shaft the required distance from the Baffle Edge

2 Ensure that one tooth of the Thick Document Shaft Gear overhangs the last tooth of the Left Slide Rail

Baffle Edge

1 inch (25.4 mm)

Thick Document Shaft

Figure 25 Reinstalling the Left Side Plate

Figure 26 Aligning the Left Side of the Thick Document Shaft

Repairs and Adjustments

REP 8.5

4-54

17. (Figure 27): Complete the Left Side Plate Reinstallation.

CAUTION The Rear Drive Shaft Bearings can be damaged by installing them incorrectly. The two tabs on each Drive Shaft Bearing must fully engage the slots in the Bearing Clamps prior to tightening down the Bearing clamps CAUTION Take care when loosening or tightening the screws that retain the Bearing Clamps. These screws are self-tapping, and are threaded into an aluminum casting. There is a possibility of stripping the screws if they are inadvertently misaligned or overtightened. 18. (Figure 28): Reinstall the Left Pivot Clutch Assembly.

1 Reinstall the white bushing and K-clip

4 Depress the pawl to engage the Left Pivot Clutch

2 Reinstall the white bushing and E-ring

3 Reinstall the Left Pivot Clutch Assembly with two (2) mount screws

Figure 27 Completing the Left Side Plate Reinstallation

1

2

Reinstall the Bearing on the Rear Drive Shaft

Place the Bearing Clamp over the Bearing Figure 28 Reinstalling the Left Pivot Clutch Assembly

Repairs and Adjustments 4-55

REP 8.5

21. (Figure 30): Reinstall the Scanner right side components.

19. (Figure 29): Reinstall the Slide Bracket on the left side of the Scanner.

1

2

Reinstall the Drive Belt

Reinstall the two K-clips and one washer

Slide Bracket

1 Reinstall the Slide Bracket

2

Figure 29 Reinstalling the Slide Bracket 20. Place the Right Belt Guard Plate back into position on the Right Side of the Scanner.

Reinstall the screw, Extension Spring, and Tension Pulley

3 Reinstall the screw

Figure 30 Reinstalling the Right Side Components

Repairs and Adjustments

REP 8.5

4-56

22. Reinstall the Scanner Right and Left End Covers. 23. Reinstall the Scanner Top Cover cover by performing the following steps: a.

Hold the Scanner Top Cover above the Scanner.

b.

Feed the Scanner Control Panel cable up through the cutout hole in the Scanner Top Cover.

c.

(Figure 31): Rotate the Thick Document Adjustment Handle to its highest position.

1 Lift handle to highest position

Figure 31 Rotating the Thick Document Adjustment Handle d.

Guide the Thick Document Adjustment Handle upward through the slot in the Scanner Top Cover, and work the Top Cover down onto the Scanner.

e.

Lower the Thick Document Adjustment Handle once the Top Cover has been correctly positioned.

f.

Reinstall the 6 screws (three screws per side) that secure the Scanner Top Cover.

24. Reinstall the Scanner Control Panel on the Scanner. 25. Reconnect the Scanner power cable and return the Scanner to normal operation.

Repairs and Adjustments 4-57

REP 8.5

REP 8.6 Upper Document Transport Latches and Interlock Switch

2.

Perform REP 14.1 Scanner End Covers .

NOTE: The procedure for removing the right and left side UDT latches is mechanically similar. The left side of the Scanner does not have a drive mechanism, or a Belt Guard. The left latch does not include an Interlock Switch.

Parts List on PL 1.1 Removal

3.

WARNING

(Figure 2): Remove the Document Drive Belt from the right side of the Scanner.

Switch off the Scanner power and disconnect the power cord. 1.

3

(Figure 1): Lift the Upper Document Transport.

Remove the Document Drive Belt

Lift the Upper Document Transport

Figure 1 Lifting the Upper Document Transport

1 Remove the screw

2 Remove the screw, spring, and Idler Pulley

Figure 2 Removing the Document Drive Belt

Repairs and Adjustments

REP 8.6

4-58

4.

(Figure 3): Remove the Belt Guard from the right side of the Scanner.

5.

(Figure 4): Remove the Upper Document Transport Latch.

2 Remove the two screws and lift the Latch off the Scanner

Figure 3 Removing the Belt Guard

3

1 Note the color and position of the switch connectors

Disconnect the connectors from the Interlock Switch

Figure 4 Removing the UDT Interlock Switch

Repairs and Adjustments 4-59

REP 8.6

Replacement

4.

Reinstall the Scanner End Covers

1.

Reinstall the Upper Document Transport Latch and Interlock Switch.

5.

Close the Upper Document Transport.

2.

Reinstall the Belt Guard on the right side of the Scanner.

6.

Return the Scanner to normal operation.

3.

(Figure 5): Reinstall the Document Drive Belt on the right side of the Scanner.

4

3

Reinstall the tension spring and fully tighten the retaining screw

Reinstall the Document Drive Belt

1

2

Reinstall the screw

Reinstall the screw and Idler Pulley

Figure 5 Reinstalling the Document Drive Belt

Repairs and Adjustments

REP 8.6

4-60

REP 9.2 Image Module

3.

Parts List on PL 1.3 Removal

(Figure 2): On the left side of the Scanner, remove the Stub Shaft Bracket.

1 Remove the hex nut

WARNING Switch off the Scanner power and disconnect the power cord. 1.

Perform REP 8.4 Upper Document Transport to remove the Upper Document Transport.

2.

(Figure 1): Prepare the Image Module for removal.

3 Remove the two hex nuts

2 Remove the Rear Exit Baffle (one screw at either end of baffle)

1 Disconnect the connector at either end of the Image Module

2 Remove the Stub Shaft Bracket Figure 2 Removing the Stub Shaft Bracket

Right / Front of Scanner

Figure 1 Preparing the Image Module for Removal (Right Side)

Repairs and Adjustments 4-61

REP 9.2

4.

Lift the Image Module up from the machine frame and gently turn it over, resting it temporarily on its side.

5.

(Figure 3): Remove the Video Cable Housing from the back of the Image Module. No tools are required for this task.

Replacement NOTE: If you are replacing the old Image Module, transfer the following non-spared parts from the old Image Module to the new one: • Front Drive Shaft Assembly and all associated hold-down mechanisms • Rear Drive Shaft Assembly and all associated hold-down mechanisms • Idler Pulley and Document Drive Belt • Fluorescent Lamp • Left and Right Lamp Sockets • Illumination Sensor and Mount Bracket 1.

CAUTION Exercise caution when reinstalling the Video Cable Housing. The video cables can be damaged very easily if pinched by the housing. 2. Reinstall the Video Cable Housing to the underside of the Image Module. 3. Return the Image Module to its original position on the Scanner frame. 4. Reinstall the Rear Exit Baffle. 5. Reinstall the Stub Shaft Bracket on the left side of the Scanner.Tighten down the hex nut.

Video Cable Housing

Figure 3 Removing the Video Cable Housing 6.

(Figure 4): Disconnect the three video cables from the underside of the Image Module.

Disconnect the three video cables

Figure 4 Disconnecting the Video Cables

Repairs and Adjustments

REP 9.2

Reconnect the three video cables that run beneath the Image Module.

4-62

6.

(Figure 5): Reinstall the Image Module on the Scanner.

1 Reinstall the two hex nuts

Figure 5 Reinstalling the Image Module 7.

Perform REP 8.4 Upper Document Transport to reinstall the Upper Document Transport onto the Scanner.

8.

Perform ADJ 6.1 Exposure Lamp Initialization Procedure.

9.

Return the Scanner to normal operation.

Repairs and Adjustments 4-63

REP 9.2

REP 9.3 Thick Document Shaft

3.

(Figure 2): Prepare to remove the Upper Document Transport.

Parts List on PL1.2A, 1.2B Removal

2 Pivot the Document Thickness Lever to its highest position

WARNING Switch off the Scanner power and disconnect the power cord. 1.

(Figure 1): Remove the Scanner Control Panel from the Scanner. Upper Document Transport Cover

1 Loosen the center screw

1 Remove the screws (three per side) Figure 2 Preparing to Remove the Upper Document Transport Cover

2 Tilt back the Scanner Control Panel and disconnect the connector U2P1 beneath the console Figure 1 Removing the User Interface 2.

Raise the Upper Document Transport from the Feed In Shelf.

Repairs and Adjustments

REP 9.3

4-64

4.

Feed the Scanner Control Panel harness down through the cutout in the Upper Document Transport Cover and carefully lift the cover off the Scanner.

5.

Lower the Document Thickness Lever.

6.

(Figure 3): Remove the Right and Left End Covers by removing the two retaining screws on each End Cover.

7.

(Figure 4): Remove the bushing and E-ring from both the right and left sides of the Thick Document Shaft.

2 Remove one screw from the back of the Scanner frame

1 Remove one screw from the inside of the End Cover

1 Remove the Bushing and E-ring (both sides)

Figure 3 Removing the Right and Left End Covers

Figure 4 Removing the Bushing and E-Ring from the Thick Document Shaft

NOTE: It may be necessary to gently press the Right or Left Side Plates slightly aside to achieve enough clearance for removal of the Thick Document Shaft. 8.

Remove the Thick Document Shaft from the Scanner.

Repairs and Adjustments 4-65

REP 9.3

Replacement

3.

(Figure 6): Align the right side of the Thick Document Shaft in the Scanner.

CAUTION It is imperative that the Thick Document Shaft be reinstalled in the Scanner exactly as described in this procedure. Image quality problems or document feed problems will result if the Thick Document Shaft is not reinstalled/replaced as described. 1.

(Figure 5): Ensure that the Right and Left Slide Plates are moved as far towards the rear of the Scanner as possible.

1

2

Raise the Upper Document Transport slightly

Align the Thick Document Handle with the angle of the Right Side Plate

1 Press the Right and Left Slide Rails as far to the rear of the Scanner as possible

Baffle Edge Left Slide Rail

Figure 5 Moving the Side Plates to the Rear of the Scanner 2.

1 inch (25.4 mm)

Thick Document Shaft

Set the Thick Document Shaft loosely back into the Scanner. Move the Right and Left Side Plates as necessary to accomplish this.

3

4

5

Loosely reinstall the right side bushing, enough to allow some adjustment of shaft position

Mount the Thick Document Shaft on the Right Slide Rail the required distance from the Baffle Edge

Reinstall the right side Bushing and E-Ring

Figure 6 Aligning the Right Side of the Thick Document Shaft

Repairs and Adjustments

REP 9.3

4-66

4.

(Figure 7): Align the left side of the Thick Document Shaft in the Scanner.

6.

Reinstall the Upper Document Transport Cover by performing the following steps: a.

Hold the Upper Document Transport Cover over the Scanner and feed the Scanner Control Panel connector A2P1 up through the cutout in the Upper Document Transport Cover.

1

2

b.

Reinstall the Upper Document Transport Cover screws (3 screws per side).

Close the Upper Document Transport

Set the Thick Document Shaft the required distance from the Baffle Edge

c.

Lower the Document Thickness Lever to its lowest position.

7.

3 Ensure that one tooth of the Thick Document Shaft Gear overhangs the last tooth of the Left Slide Rail

Baffle Edge

(Figure 8): Check the installation and positioning of the Thick Document Shaft. If the display in the Document Thickness Indicator Window is not correct, remove the Upper Document Transport Cover and adjust the positioning of the Thick Document Shaft on the Scanner Slide Rails accordingly.

Red strip is flush with the top of the display area

1 inch (25.4 mm)

Red strip is not flush with the top of the display area

Thick Document Shaft

4 Reinstall the left side Bushing and E-Ring

Correct installation of Thick Document Shaft on Slide Rails

Figure 8 Checking the Display in the Document Thickness Indicator Window

Figure 7 Aligning the Left Side of the Thick Document Shaft 5.

Incorrect installation of Thick Document Shaft on Slide Rails

Raise the Document Thickness Lever to its highest position.

8.

Reinstall the User Interface.

9.

Reinstall the Right and Left End Covers.

10. Return the Scanner to normal operation.

Repairs and Adjustments 4-67

REP 9.3

REP 14.1 Scanner End Covers

REP 14.2 Scanner Back Cover

Parts List on PL 1.5 Removal

Parts List on PL 1.5 Removal WARNING

WARNING

Switch off the Scanner power and disconnect the power cord.

Switch off the Scanner power and disconnect the power cord.

NOTE: This procedure is identical for the Right and Left End Covers.

1.

1.

(Figure 1): Remove the Scanner Back Cover.

(Figure 1): Remove the Right or Left End Cover.

1 Remove one screw from the inside of the End Cover

Remove the five screws

Figure 1 Removing the Scanner Back Cover

3

2

Lift End Cover off Scanner

Remove one screw from the back of the Scanner frame

Figure 1 Removing the Right or Left End Cover

Repairs and Adjustments

REP 14.1 , REP 14.2

4-68

REP 14.3 Upper Document Transport Cover

3.

(Figure 2): Prepare to remove the Upper Document Transport Cover.

Parts List on PL 1.2A Removal

2 Pivot the Document Thickness Lever to its highest position

WARNING Switch off the Scanner power and disconnect the power cord. 1.

(Figure 1): Remove the Scanner Control Panel from the Scanner. Upper Document Transport Cover

1 Loosen the center screw

1 Remove the screws (three per side) Figure 2 Preparing to Remove the Upper Document Transport Cover

2 Tilt back the Scanner Control Panel and disconnect the connector U2P1 beneath the console

Lower the Upper Document Transport (UDT) and lift the UDT cover off the Scanner, starting from the rear of the machine, and working towards the front.

5.

Feed the Scanner Control Panel harness down through the cutout in the Upper Document Transport Cover.

Replacement

Figure 1 Removing the User Interface 2.

4.

Reinstall the Scanner Top Cover cover by performing the following steps:

Raise the Upper Document Transport from the Feed In Shelf.

1.

Hold the Scanner Top Cover above the Scanner.

2.

Feed the Scanner Control Panel cable up through the cutout hole in the Scanner Top Cover.

3.

(Figure 3): Rotate the Thick Document Adjustment Handle to its highest position.

Repairs and Adjustments 4-69

REP 14.3

REP 14.4 Scanner Feed-In Shelf Parts List on PL 1.1 Removal Perform the following steps to ,remove the scanner Feed-In shelf

1 Lift handle to highest position

1.

Open the Document Handler.

2.

Remove the Left and Right Covers (REP 14.1 Scanner End Covers).

3.

Remove the Left and Right Platen Glass Clips. Remove the(2) shelf retaining screws on left and right ends of the Feed-In Shelf (Figure 1).

1 Remove the (2) Platen Glass Clips by removing the screws

2 Figure 3 Rotating the Thick Document Adjustment Handle 4.

Guide the Thick Document Adjustment Handle upward through the slot in the Scanner Top Cover, and work the Top Cover down onto the Scanner.

5.

Lower the Thick Document Adjustment Handle once the Top Cover has been correctly positioned.

6.

Reinstall the 6 screws (three screws per side) that secure the Scanner Top Cover.

7.

Reinstall the Scanner Control Panel on the Scanner.

Remove the (2) retaining screws.

3 Remove the (2) screws securing the Latch Bracket and remove the bracket.

Figure 1 Remove the Platen Glass Clips, retaining screws and Latch Bracket.

Repairs and Adjustments

REP 14.3, REP 14.4

4-70

4.

Remove the Latch Bracket (Figure 1).

5.

Shift the shelf to the left and then toward you to remove it (Figure 2).

Figure 2 Shift the shelf left and toward you to remove it.

Repairs and Adjustments 4-71

REP 14.4

Repairs and Adjustments

REP 14.4

4-72

ADJ 4.1 Document Drive Motor Speed (DS system only)

Check

Purpose

1.

Go to GP 13 Creating the System Speed and Lead Edge Detect Test Target. Print out the test target and continue on with this procedure.

2.

After five minutes, measure the line on the printed test target, write this measurement down on the test target, as well as the word “print master”.

3.

On the Scanner Control Panel, select Main Menu > Configuration > Copy Options > Imaging > Auto Rotate (press Enter to select this option).

4.

On the Scanner Control Panel, select Main Menu > Configuration > Scanner Control > Auto Width = OFF. Then return to the Copy screen.

5.

On the Printer Control Panel, check to see if a 24 inch (610 mm) roll of paper is loaded in the printer. If this is the case, change the value stated for that roll to any number other than 24 inches (610 mm). (NOTE: This needs to be done to force a rotation of the test print.)

6.

On the Scanner Control Panel, check to see that the above change has been confirmed by the Scanner:

The purpose of this procedure is to ensure that the Scanner Document Drive Motor is rotating at the correct speed. This is accomplished by running a pattern (line) of measured length through the scanner, and comparing it with values generated by the system software.

NOTE: Perform Document Drive Motor in section six when servicing the XEScan Solution system. NOTE: The Document Drive Motor Speed Test requires that a 36 inch (or equivalent ISO A1 series size) roll of paper be loaded on the Printer. NOTE: This Adjustment requires the System Speed and Lead Edge Detect Test Target. This test target must be downloaded from the laptop computer to the Printer, and then printed out prior to beginning this procedure.

This line will be measured for the Document Drive Motor Speed Test

•

Under Media Selection/Source, check the R1, R2, R3, and R1/R3 values for the paper rolls in those drawers. No drawer should have a value of 24 inches (610 mm).

•

Under Media Selection/Source, there should be a 36-inch (or equivalent) roll of paper present.

7.

After the R1, R2, and R3 values have been checked, ensure that the Media Selection option = AUTO.

8.

Make a copy of the System Speed and Lead Edge Detect Test Target (print master) by feeding it into the scanner Short Edge Feed (SEF), with the broad, darkened edge leading.

9.

Observe the copied image as it leaves the Printer. It should have been rotated ninety degrees, with the measured line exiting parallel with the Printer paper drawers. (This rotation eliminates any chance of the Printer belt speed affecting the measured line length.)

10. Wait five (5) minutes before measuring the line length on the scanned copy. The length of the line should be +/- 2mm of the print master line length. TEST CRITERIA: If the measured difference between the line length on the scanned copy is greater than +/-2 mm from the length of the print master, perform the Document Drive Motor Speed Adjustment.

Figure 1 System Speed and Lead Edge Detect Test Target

Repairs and Adjustments 4-73

ADJ 4.1

Adjustment

8.

1.

This adjustment is password controlled. To enter the Service Diagnostic Password select Main Menu > Diagnostics > Password. Enter the password (6789) and press Enter.

2.

(Figure 2): On the Scanner Control Panel select Main Menu > Diagnostics > Scanner Diagnostics > Component Tests > Motor Speed > Expected Length. The Motor Speed screen will appear.

Exit the Diagnostics mode and return to the Scanner copy mode.

NOTE: In the following steps it will be necessary to copy the print master System Speed and Lead Edge Detect Test Target to ensure test accuracy. 9.

Verify that the Scanner Motor is scanning to the correct speed by making another scan and print of the original test target, and again measuring the 610 mm line on the print that is generated.

NOTE: The margin for error on this test scan is +/- 2mm of the line length measured on the print master. 10. When the measured line length is determined to be satisfactory, reset the following system options. •

Scanner Control Panel: Main Menu > Configuration > Copy Options > Imaging. Return the Auto Rotate function to the customer’s preferred selection (On or OFF).

•

Scanner Control Panel: Main Menu > Configuration > Scanner Control > Auto Width = ON.

•

Printer Control Panel: Reset the width of the 24 inch (or equivalent) paper roll.

11. Return the system to normal operation.

Figure 2 Motor Speed Expected Length Screen (Example) 3.

On the printed test pattern, measure the line marked “610 mm”.

4.

Using the keypad on the Scanner Control Panel, enter the measured value from the previous step in the Expected Length field. Press Enter.

5.

Input the measured length from the copy that was just made from the System Speed and Lead Edge Detect Test Target. Press Enter. Press the Start button on the Scanner Control Panel. (Figure 3): The Document Management System software will run a test of the Scanner Document Drive Motor, and will automatically adjust the Document Drive Motor Speed. The following prompt will appear on the screen when the adjustment has been completed.

6. 7.

Figure 3 Motor Speed Adjustment Screen (Example)

Repairs and Adjustments

ADJ 4.1

4-74

ADJ 6.1 Exposure Lamp Initialization

4.

Purpose

5.

Switch off the Scanner, Controller and Printer for about 15 seconds.

6.

Perform GP 8 System Power Up Proceduree. When the system initializes, it will re-establish the new fluorescent lamp readings and intensity.

7.

Run a copy of Test Target #82E5980 to confirm the correct operation and copy quality of the Scanner.

8.

Return the Scanner to normal operation.

This procedure is used to initialize the Exposure Lamp in cases where the Illumination Sensor Q11 has been repositioned or replaced, or the Exposure Lamp has been repositioned or replaced. Writing a 0 (zero) in location 2 of the NVR forces the Scanner to re-evaluate the lamp brightness and store the appropriate values.

Press the Enter key to confirm the change.

Check 1.

(Figure 1): On the Scanner Control Panel select Main Menu > Diagnostics > Scanner Diagnostics > Write NVR. The following screen appears.

Figure 1 Write NVR Screen (Default) 2.

Use the Enter key and numeric keypad on the Scanner Control Panel to input the values listed in Figure 1. When the EXECUTE:NO field is reached, use the NEXT key to toggle the NO value to YES.

3.

(Figure 2): The screen will then look like this:

Figure 2 Modified NVR Screen

Repairs and Adjustments 4-75

ADJ 6.1

ADJ 8.1 Main Drive Belt / Document Drive Belt Tension

2.

(Figure 2): Set the Scanner Main Drive Belt tension.

Purpose The purpose of this procedure is to enable the Service Representative to correctly adjust the belt tension of both the Scanner Main Drive Belt and Document Drive Belt.

1 Loosen the four (4) Document Drive Motor mount screws

WARNING Switch off the scanner power and disconnect the power cord.

Adjustment 1.

(Figure 1): Remove the Right End Cover by removing the two retaining screws.

Tension Spring

Main Drive Belt

2 Remove one screw from the back of the scanner frame

1 Remove one screw from the inside of the Right End Cover

2

3

Flex the Main Drive Belt to allow the Tension Spring to set the Main Drive Belt tension

Tighten the four (4) Document Drive Motor mount screws.

Figure 1 Removing the Right End Cover Figure 2 Setting the Scanner Main Drive Belt Tension

Repairs and Adjustments

ADJ 8.1

4-76

3.

(Figure 3): Set the Document Drive Belt tension.

1 Loosen the Document Drive Belt Tension Idler screw

3 Tighten down the Tension Idler screw

2 Flex the Document Drive Belt to allow the Tension Idler spring to set the Document Drive Belt tension

Figure 3 Setting the Drive Belt Tension 4.

Reinstall the Right End Cover.

5.

Return the Scanner to normal operation.

Repairs and Adjustments 4-77

ADJ 8.1

ADJ 8.2 Lead Edge / Trail Edge Adjustment (DS system only)

Check 1.

Purpose

(Figure 2): On the Scanner Control Panel select Main Menu > Diagnostics > Scanner Diagnostics > Component Tests > Lead Edge/Trail Edge Adjustment. The following screen will appear.

The purpose of this procedure is to ensure that the Scanner correctly detects the lead and trail edges of the scanned document.

NOTE: Pereform Lead Edge/ Trail Edge in section six when servicing the XEScan Solution system. 1.

(Figure 1): This Adjustment requires the System Speed and Lead Edge Detect Test Target. This test target must be downloaded from the laptop computer to the Printer, and printed out prior to beginning this procedure. Go to

Creating the System Speed and Lead Edge Detect Test Target. Print out the Test Target and continue on with this procedure.

This line will be used for the Lead Edge / Trail Edge Test

Figure 2 Lead Edge / Trail Edge Adjustment Screen 2.

3.

Place the darkened edge of the test target on the scanner Short Edge Feed (SEF). •

Ensure that the test target has the darkened edge feeding into the Scanner.

•

Ensure that the test target is correctly aligned on the 24” markers on the Scanner Feed In Shelf.

(Figure 3): Press the Start button. The following screen will appear.

Figure 1 System Speed and Lead Edge Detect Test Target 2.

After creating the test target, ensure that the lead edge is completely darkened by cutting along the line specified with a pair of scissors. Running a dark felt tip pen along that same lead edge will further enhance edge clarity.

Figure 3 Lead Edge / Trail Edge In Progress Screen

NOTE: As the Scanner diagnostic software begins a check of the lead edge of the document, an audible clicking sound should be heard.

Repairs and Adjustments

ADJ 8.2

4-78

4.

(Figure 4): When the Lead Edge / Trail Edge adjustment has been completed, the test target will be backed out onto the Scanner Feed In Shelf and the following screen will appear.

Figure 4 Lead Edge / Trail Edge Adjustment Completed Screen 5.

Return the Scanner to normal operation.

Repairs and Adjustments 4-79

ADJ 8.2

Repairs and Adjustments

ADJ 8.2

4-80

5 Parts List Overview Introduction ..................................................................................................................... Subsystem Information ................................................................................................... Symbology ......................................................................................................................

5-3 5-4 5-5

Parts Lists Scanner Module Assembly PL 1.1 Scanner Module...................................................................................................

5-7

Upper Document Transport Assembly PL 1.2A Upper Document Transport (Part 1 of 2) ........................................................... PL 1.2B Upper Document Transport (Part 2 of 2) ...........................................................

5-8 5-9

Scanner Module Assembly PL 1.3 Image Module and Document Feed Rollers ........................................................ PL 1.4 Electrical Module ................................................................................................. PL 1.5 Lower Document Transport .................................................................................

5-10 5-11 5-12

Scanner Stand Assembly PL 2.1 Scanner Stand .....................................................................................................

5-13

PL 3.0 Miscellaneous ......................................................................................................

5-14

Common Hardware Common Hardware ......................................................................................................... Part Number Index ..........................................................................................................

5-15 5-15

Parts List Synergix Scan System

5-1

Parts List 5-2

Synergix Scan System

Introduction

Other Information

Overview

Abbreviations Abbreviations are used in the parts lists and the exploded view illustrations to provide information in a limited amount of space. The following abbreviations are used in this manual:

The Parts List section identifies all part numbers and the corresponding location of all spared subsystem components.

Table 1

Organization

Abbreviation

Parts Lists Each item number in the part number listing corresponds to an item number in the related illustration. All the parts in a given subsystem of the machine will be located in the same illustration or in a series of associated illustrations.

Meaning

A3

297 x 594 Millimetres

A4

210 x 297 Millimetres

A5

148 x 210 Millimetres

AD

Auto Duplex

Electrical Connectors and Fasteners

AWG

American Wire Gauge

This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used in the machine. A part number listing of the connectors is included.

EMI

Electro Magnetic Induction

GB

Giga Byte

Common Hardware

KB

Kilo Byte

The common hardware is listed in alphabetical order by the letter or letters used to identify each item in the part number listing and in the illustrations. Dimensions are in millimetres unless otherwise identified.

MB

Mega Byte

MM

Millimetres

Part Number Index This index lists all the spared parts in the machine in numerical order. Each number is followed by a reference to the parts list on which the part may be found.

MOD

Magneto Optical Drive

NOHAD

Noise Ozone Heat Air Dirt

PL

Parts List

P/O

Part of

R/E

Reduction/Enlargement

REF:

Refer to

SCSI

Small Computer Systems Interface

W/

With

W/O

Without Table 2 Operating Companies

Abbreviation AO

Meaning Americas Operations

NASG - US

North American Solutions Group - US

NASG Canada

North American Solutions Group Canada

XE

Xerox Europe

Symbology Symbology used in the Parts List section is identified in the Symbology section.

Service Procedure Referencing If a part or assembly has an associated repair or adjustment procedure, the procedure number will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)

Parts List Synergix Scan System

5-3

Introduction

Subsystem Information Use of the Term " Assembly" The term "assembly" will be used for items in the part number listing that include other itemized parts in the part number listing. When the word "assembly is found in the part number listing, there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly.

Brackets A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The item number of the assembly or kit precedes the bracket; the item numbers of the piece parts follow the bracket.

Tag The notation "W/Tag" in the parts description indicates that the part configuration has been updated. Check the change Tag index in the General Information section of the Service Data for the name and purpose of the modification. In some cases, a part or assembly may be spared in two versions: with the Tag and without the Tag. In those cases, use whichever part is appropriate for the configuration of the machine on which the part is to be installed. If the machine does not have a particular Tag and the only replacement part available is listed as "W/Tag," install the Tag kit or all of the piece parts. The Change Tag Index tells you which kit or piece parts you need. Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate number on the Tag matrix.

Parts List

Subsystem Information

5-4

Synergix Scan System

Symbology

A Tag number within a circle having a shaded bar and pointing to an item number shows that the configuration of the part shown is the configuration before the part was changed by the Tag number within the circle (Figure 2).

A Tag number within a circle pointing to an item number shows that the part has been changed by the tag number within the circle (Figure 1). Information on the modification is in the Change Tag Index.

Figure 2 Without Tag Symbol Figure 1 With Tag Symbol

Parts List Synergix Scan System

5-5

Symbology

A tag number within a circle with no apex shows that the entire drawing has been changed by the tag number within the circle (Figure 3). Information on the modification is in the Change Tag Index.

A tag number within a circle with no apex and having a shaded bar shows that the entire drawing was the configuration before being changed by the tag number within the circle (Figure 4).

Figure 3 Entire Drawing With Tag Symbol

Figure 4 Entire Drawing Without Tag Symbol

Parts List

Symbology

5-6

Synergix Scan System

PL 1.1 Scanner Module Item

Part

Description

1 – – – – – 2 –

892E32360 892E32370 892E32380 892E32390 892E32400 892E32410 101K43451 101K47720

3

–

4 5 6 7 8 9 10 11 12 13 14 15 16 17

962K01520 090E02231 019E47130 019E47110 – – 962K12170 962K12160 962K12150 – – 604K08540 019E47140 –

18

–

Control Panel Label (English) Control Panel Label (French) Control Panel Label (Italian) Control Panel Label (German) Control Panel Label (Spanish) Control Panel Label (Portuguese) Scanner Control Panel Scanner Control Panel (UI for XEScan Solutions) Upper Document Transport Assembly Upper Control Panel Harness Platen Glass Right Glass Clip Left Glass Clip Image Module Assembly Video Cable Housing Video Cable 3 Video Cable 2 Video Cable 1 Electrical Module Lower Document Transport Feed-In Shelf Kit (W/TAG 003) Platen Glass Foam IEEE 1394 Cable (NOTE: Connects to FireBoard 400 Lynx PWB PN 140N05961 (XEScan Solutions), and IEEE 1394 PWB PN 160K79060 (DS AccXES Systems.)) Mounting Bracket (P/O Item 2)

Synergix Scan System

11/01 5-7

Parts List

PL 1.1

PL 1.2A Upper Document Transport (Part 1 of 2) Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

892E31490 056E04650 – 802E21320 892E16370 020K11860 004E20940 015K47571 028E14180 022E24600 809E32080 006E76990 130E05421 055K32880 055K32870 022K69631 014K06880 –

19 20 21 22 23 24

016E06020 016E16100 021K02581 020K11880 – –

Thickness Label Indicator Bezel Guide (P/O PL1.1 Item 3) Top Cover Logo Strip Label Friction Wheel Bumper Left Side Plate Retainer Housing Pinch Roller Spring Shaft Sensor (Q2-Q6) Rear Mylar Strip Front Mylar Strip Platen Roll Calibration Spacer (2 Places) Upper Document Housing (P/O PL1.1 Item 3) Bushing (6mm) Bushing End Cap Calibration Housing Keeper (P/O PL1.5 Item 15) Keeper (P/O PL1.5 Item 17)

Parts List

PL 1.2A

11/01 5-8

Synergix Scan System

PL 1.2B Upper Document Transport (Part 2 of 2) Item 1 2 – 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Part

Description

019E51420 – 105E09000 019E15041 127K40860 130E09690 892E31480 809E43500 032E19371 047E00540 830E72960 007E69160 815E00590 015K47581 007E68160 016E16100 409W02078 007E69500 – 806E00170

Clip Static Eliminator Static Eliminator Clip Calibration Drive Motor (MOT2) Calibration Home Sensor (Q1) Indicator Label Spring Guide Ball Label Bracket Gear (36T) Side Slide Plate Right Side Plate Gear (28T) Bushing (10mm) Spring Pawl Thick Document Handle Thick Document Shaft

Synergix Scan System

11/01 5-9

Parts List

PL 1.2B

PL 1.3 Image Module and Document Feed Rollers Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

– 802E41621 809E31970 006K20580 019E47291 809E32020 802E41611 – 013E18660 020E38280 006K20590 113K02790 122E02640 802K38101 –

16 17 18 19 20 21

130K54470 006K20600 005E15090 035E56510 – –

Rear Exit Baffle (P/O PL1.1 Item 8) Left Pivot Clutch Bearing End Clamp Rear Drive Shaft Shaft Ground Clip Bearing Mid Clamp Right Pivot Clutch Wave Spring (P/O Item 1) Bearing Timing Pulley (72T) Front Drive Shaft Lamp Socket Lamp Image Module Illumination Sensor Bracket (P/O PL1.1 Item 8) Illumination Sensor PWB (Q11) Stub Shaft O-Ring Drive Pulley O-Ring Lamp Jacket (P/O PL1.1 Item 8) Harness (Lamps to Ballast) (Not Spared)

Parts List

PL 1.3

11/01 5-10

Synergix Scan System

PL 1.4 Electrical Module Item

Part

Description

1 2 3 4 5

– 162K65261 105E14291 160K65760 160K65792

6 7 8

160K72091 – –

9 10 11 12 13 14 15

– 104K00053 162K65240 117E22800 733W05871 537K67112 162K65271

Top Cover (P/O PL1.1 Item 13) DC Harness LV Power Supply (PS1) Image Processing PWB Scanner Main PWB (A1) (W/TAG 002) Motor Control PWB (A3) Slide (P/O PL1.1 Item 13) Electrical Module Housing (P/O PL1.1 Item 13) Card Guide (P/O PL1.1 Item 13) Lamp Ballast PWB (A5) Harness (Ballast to Lamps) Power Cord NVM Flash (U28) E-Prom (U10) (W/TAG 002) Main Harness Assembly

Synergix Scan System

11/01 5-11

Parts List

PL 1.4

PL 1.5 Lower Document Transport Item

Part

Description

1 2 3

– 802E21311 –

4 5 6 7 8

127K40860 – – 409W03143 –

9 10 11 12 13 14 15 16 17 18

802E21301 023E21040 020K09370 020E38170 409W03211 023E21050 003K16870 – 003K16860 –

Back Cover (P/O PL1.1 Item 14) Left End Cover Lower Transport Housing (P/O PL1.1 Item 14) Document Drive Motor (MOT1) Motor Bracket (P/O PL1.1 Item 14) Foot (Not Spared) Spring Interlock Harness (P/O PL1.1 Item 14) Right End Cover Main Drive Belt Dual Driven Pulley Tension Idler Spring Document Drive Belt Interlock Assembly Interlock Catch (P/O Item 15) Interlock Assembly Interlock Catch (P/O Item 17)

Parts List

PL 1.5

11/01 5-12

Synergix Scan System

PL 2.1 Scanner Stand Item

Part

Description

1 2 3

– – –

4

–

5 6 7 8 9 10

– 830E76070 – 017E02620 017E02610 021E09960

Catch Tray/Organizer (Not Spared) Catch Tray Support (Not Spared) Scanner Module Assembly (REF: PL1.1) Height Adjustment Bracket (Not Spared) Organizer Support (Not Spared) Organizer Mounting Clip Stand (Not Spared) Swivel Caster Rigid Caster End Cap

Synergix Scan System

11/01 5-13

Parts List

PL 2.1

PL 3.0 Miscellaneous Item 1 2 3 4 5 6

Parts List

PL 3.0

Part

Description

115N00356 140N05961 017E06010 050E10191 121E01402 055K32270

Dongle Fire Board 400 Lynx PWB Copy Stop Front Stacker Latch Magnet Mylar Strip

11/01 5-14

Synergix Scan System

Common Hardware Item A B C D E F G H J K L M N P R S T U V W X Y Z

Part

Description

113W16802 252W31350 354W21052 158W20459 354W21252 158W30359 112W24410 220W00350 201W00355 354W00555 112W25155 102W13556 113W10555 265W01050 251W16655 158W10459 153W27554 265W00850 220W10650 158W40459 158W17552 354W00855 158W20659

Screw (4-40 x 1/2) Washer (M10) E-Ring (8MM) Screw (M4 x 8) E-Ring (10MM) Screw, Thread Rolling Torx (M3 x 6) Screw (6-32 x 1/4) Nut, Hex, Flanged, Self-locking (M3) Nut (M3) K-Clip (6MM) Screw (M3 x 6) Screw, M4 Counter sink Screw, Pan Head (M4 x 12) Spring Washer (M10) Washer (6MM) Screw (M3 x 8) Screw (M4) Spring Washer (8MM) Nut (M6) Screw (M4 x 8) Screw (M4 x 8) K-Clip (8MM) Screw (M4 x 10)

Part Number Index Table 1 Part Number Index Part Number

Part List

003K16860

PL 1.5

003K16870

PL 1.5

004E20940

PL 1.2A

005E15090

PL 1.3

006K20580

PL 1.3

006K20590

PL 1.3

006K20600

PL 1.3

006E76990

PL 1.2A

007E68160

PL 1.2B

007E69160

PL 1.2B

007E69500

PL 1.2B

013E18660

PL 1.3

014K06880

PL 1.2A

015K47571

PL 1.2A

015K47581

PL 1.2B

016E06020

PL 1.2A

016E16100

PL 1.2A

017E02610

PL 2.1

017E02620

PL 2.1

PL 1.2B

Synergix Scan System

11/01 5-15

017E06010

PL 3.0

019E15041

PL 1.2B

019E47110

PL 1.1

019E47130

PL 1.1

019E47140

PL 1.1

019E47291

PL 1.3

019E51420

PL 1.2B

020K09370

PL 1.5

020K11860

PL 1.2A

020K11880

PL 1.2A

020E38170

PL 1.5

020E38280

PL 1.3

021K02581

PL 1.2A

021E09960

PL 2.1

022E24600

PL 1.2A

022K69631

PL 1.2A

023E21040

PL 1.5

023E21050

PL 1.5

028E14180

PL 1.2A Parts List

Common Hardware, Part Number Index

Table 1 Part Number Index

Table 1 Part Number Index

Part Number

Part List

Part Number

Part List

032E19371

PL 1.2B

802E41611

PL 1.3

035E56510

PL 1.3

802E41621

PL 1.3

047E00540

PL 1.2B

806E00170

PL 1.2B

050E10191

PL 3.0

809E31970

PL 1.3

055K32270

PL 3.0

809E32020

PL 1.3

055K32870

PL 1.2A

809E32080

PL 1.2A

055K32880

PL 1.2A

809E43500

PL 1.2B

056E04650

PL 1.2A

815E00590

PL 1.2B

090E02231

PL 1.1

830E72960

PL 1.2B

101K43451

PL 1.1

830E76070

PL 2.1

101K47720

PL 1.1

892E16370

PL 1.2A

104K00053

PL 1.4

892E31480

PL 1.2B

105E09000

PL 1.2B

892E31490

PL 1.2A

105E14291

PL 1.4

892E32360

PL 1.1

113K02790

PL 1.3

892E32370

PL 1.1

115N00356

PL 3.0

892E32380

PL 1.1

117E22800

PL 1.4

892E32390

PL 1.1

121E01402

PL 3.0

892E32400

PL 1.1

122E02640

PL 1.3

892E32410

PL 1.1

127K40860

PL 1.2B

962K01520

PL 1.1

PL 1.5

962K12150

PL 1.1

130E05421

PL 1.2A

962K12160

PL 1.1

130E09690

PL 1.2B

962K12170

PL 1.1

130K54470

PL 1.3

140N05961

PL 3.0

160K65760

PL 1.4

160K65792

PL 1.4

160K72091

PL 1.4

162K65240

PL 1.4

162K65261

PL 1.4

162K65271

PL 1.4

409W02078

PL 1.2B

409W03143

PL 1.5

409W03211

PL 1.5

537K67112

PL 1.4

604K08540

PL 1.1

733W05871

PL 1.4

802E21301

PL 1.5

802E21311

PL 1.5

802E21320

PL 1.2A

802K38101

PL 1.3

Parts List

Part Number Index

11/01 5-16

Synergix Scan System

6 General Procedures Scanner Installation Digital System Scanner Installation................................................................................. XEScan Solution Scanner Installation.............................................................................

GP 13 Creating the System Speed and Lead Edge Detect Test Target ......................... GP 14 Scanner Diagnostic access using a laptop ..........................................................

6-3 6-4

Special Tools

Diagnostics Diagnostics...................................................................................................................... Using the Diagnostic Software - Key Properties ............................................................. Main Menu Tree Structures............................................................................................. Power On Self Test (POST) Diagnostics ........................................................................ Usage Meters.................................................................................................................. Clear Scanner Usage...................................................................................................... Installation Test Print....................................................................................................... Password ........................................................................................................................

6-50 6-51

Special Tools................................................................................................................... 6-7 6-7 6-8 6-12 6-12 6-13 6-13 6-14

6-53

Change Tag/ Mod Index Change Tag/ Mod Index..................................................................................................

6-55

Scanner Diagnostics Entering the Scanner Diagnostics ................................................................................... Image Path Test .............................................................................................................. Scan Bar Calibration Test ............................................................................................... Full System Test ............................................................................................................. Write NVR ....................................................................................................................... Reset NVR Defaults ........................................................................................................ Scanner Reliability Meter ................................................................................................ Scanner Faults (Ordered) ............................................................................................... Scanner Faults (Counts) ................................................................................................. Clear Scanner Fault Log ................................................................................................. Read Non Volatile Random Access Memory (NVR) .......................................................

6-15 6-16 6-16 6-17 6-18 6-18 6-19 6-19 6-20 6-20 6-21

Component Tests Motor Speed Test............................................................................................................ Lead Edge/ Trail Edge ................................................................................................... Sensors ........................................................................................................................... Scanner Control Panel .................................................................................................... Document Motor (Loopback) Communications ............................................................... Document Drive Motor .................................................................................................... Lamp ............................................................................................................................... Calibration Motor.............................................................................................................

6-24 6-24 6-25 6-25 6-27 6-28 6-28 6-29

General Procedures GP 1 How to Check a Short Circuit ................................................................................. GP 2 How to Check an Open Circuit............................................................................... GP 3 How to Check a Sensor ......................................................................................... GP 4 How to Check a Switch and its Associated Wiring................................................. GP 5 Generic PWB Checkout ......................................................................................... GP 8 System Power Up Procedure................................................................................. GP 9 Enabling/Disabling the DDS Option - 8825 / 8830 Printers ................................... GP 10 Enabling/Disabling the DDS Option - 8855 Printer .............................................. GP 11 Catch Tray and Organizer Tray ........................................................................... GP 12 Compact Catch Bins ............................................................................................

6-30 6-31 6-32 6-33 6-34 6-37 6-38 6-38 6-39 6-44

General Procedures 6-1

General Procedures 6-2

Digital System Scanner Installation

7.

Power up the system. Go to the Procedure GP 8 System Power Up Procedure in this section.

NOTE: This procedure assumes the following conditions: • The Printer and Controller are previously installed. • V6.1 software (or greater) has been loaded on the Controller. • The rigger has assembled the Scanner and placed it upon its stand, or on top of the 8855 Printer. (Catch Tray and Organizer Tray not yet installed.)

8.

Perform GP 9 Enabling/Disabling the DDS Option - 8825 / 8830 Printers - 8825/8830 Printers.

9.

System initializes successfully, and the Scanner is ready to copy.

10. Make a copy of Test Target #82E5980 and check the overall copy quality. 11. Make a copy of the Installation Test Print and check the print quality. If the print quality needs to be modified, go to Section 3 of this publication.

1.

Install the Scanner Control Panel and Control Panel labels.

2.

Remove any packing materials, tape, etc. from the outside of the Synergix Scanner. Lift up the Upper Document Transport and remove the material protecting Platen Glass. Close the Upper Document Transport.

3.

Install the Catch Tray and the Organizer Tray (if required).

13. Upon successful installation of the entire system, complete the customer operator training as specified in the System Participant’s Guide.

4.

Install the IEEE1394 PMC Card. Go to the IEEE 1394 PWBA Installation procedure in the AccXES Controller Service Manual.

14. Make a copy of all system Configuration Test Prints and store them in the Printer Service Log.

12. Download/Install any Special Feature Key Options (Refer to special instructions contained within Feature Options kit.)

CAUTION (Figure 1): In the following step it is necessary to correctly position the IEEE 1394 cable with the port at the rear of the Scanner. The cable connectors can be damaged if not installed correctly. 5. Install the IEEE 1394 PMC Cable from the IEEE 1394 Kit.

1 Position the angled edge of the IEEE1394 PMC Cable connector into the angled edge of the Scanner port

Rear of Scanner

Figure 1 Installing the IEEE1394 PMC Cable 6.

Install the power cord from the Scanner Nationalization Kit.

General Procedures 6-3

Digital System Scanner Installation

XEScan Solution Scanner Installation Follow this procedure to install the XEScan Solution standalone scanner and its system software.

Installing the XEScan Solution Control Panel Perform the following steps to install the control panel on the scanner: 1.

Remove the existing large control panel bracket (if necessary).

2.

Install the smaller control panel bracket using the supplied screws (Figure 1).

Install the bracket using the (3) screws. Ensure that the wire harness is threaded throught the hole in the bracket.

Connect the wire harness to the Control Panel connector.

Figure 2 Connect the wire harness to the Control Panel. 4.

Figure 1 Install the XEScan Solution Control Panel bracket 3.

Plug the control panel connector into the bottom of the XEScan Solution Control Panel (Figure 2).

General Procedures

XEScan Solution Scanner Installation

6-4

Secure the Control Panel to the control panel bracket using the screws (Figure 3).

Installing the XEScan software

NOTE: When the scanner is powered up, the communications LED may fail to progress to a P. (P-dot). If the display shows an E, this indicates that the scanner firmware does not support the XEScan Solution smaller control panel. Updating the firmware will resolve this problem.

The XEScan software installation routine will install the XEScan application software, hardlock software, and the Synergix Diagnostics application. The installation is typical of most Windows application installations. CAUTION If the software was previously installed on the host PC, perform the Software Uninstall procedure then this procedure to reinstall the software. When installing the software, follow the installation defaults as you step through the install wizard. Once the XEScan software installation has completed, install the Firteboard 400 drivers. From the Start menus select [Start:Programs:XES Programs:Install Unibrain Firewire Drivers]. Follow the on screen prompts to install the drivers using the default settings. Completely power OFF the PC when finished.

Connecting the scanner Once the software has been installed, connect the Synergix scanner to the host PC. 1.

Power off the host PC.

2.

Connect one end of the IEEE-1394 cable to to one of the connectors on the Fireboard 400 card.

3.

Connect the other end of the cable to one of the IEEE-1394 connectors on the back of the scanner. Secure the cable using the strain relief on the back of the scanner.

4.

Connect the power cable to the receptacle on the back of the scanner. Connect the plug to a dedicated 15A wall plug.

5.

Power on the scanner and observe the communications LED for successful completion of the POST tests. After a period of time a P. (dot) will be displayed

Figure 3 Secure the Control Panel to the bracket using the (2) screws

IEEE-1394 Fireboard 400 installation Perform the following styems to install the Fireboard 400 IEEE-1394 interface card in the host PC

NOTE: If the scanner does not have the correct firmware version to support the standalone scanner control panel, the communications LED will only display an E. Updating the firmeware to the most current version should resolve the problem.

CAUTION Follow electrostatic discharge (ESD) guidelines when working with the electronic components of the computer. Before removing the cover, unplug any power cord that is connencted to the computer. Always wear an ESD wristband that is connected to an exposed metal section of the computer.

Configuring the scanner and software 1.

NOTE: If the host PC is using the Windows NT operating system, disable Plug-n-Play in the system BIOS 1.

Power off the host PC.

2.

Remove all cables and place the PC on a sturdy level surface.

3.

Remove the slot cover for the PCI slot that will receive the Fireboard 400 card.

Clean the scanner Platen Glass. If necessary, access the scanner hardware help for instructions.

2.

Power on the scanner. Ensure that it has completed initialization.

3.

Power on the host PC.

4.

Download and install the latest firmware from the XES website.

5.

Start the XEScan software. The Keycode entry screen will appear.

6.

Place the keycode print into the scanner and click the Scan Keycode button. As an alternative method, you can enter the keycode, found on the document included with the install kit, manually.

4.

Insert the card into the PCI slot. Ensure that the card is seated properly in the slot.

5.

Secure the card using the screw used to secure the slot cover.

7.

Redeem and install any feature keys purchased by the customer.

6.

Reinstall the PC cover and re-connect the PC cables.

8.

7.

Install the Keycode Dongle on the PC parallel connector.

Perform a test scan using the Test Scan/Document Scan routine found in the Synergix Diagnostics application.

8.

Power On the PC to ensure it boots properly.

General Procedures 6-5

XEScan Solution Scanner Installation

XEScan Software uninstall procedure Perform the following steps to properly uninstall the XEScan software: 1.

Select [Start:Settings:Control Panel]. Double click the Add/Remove Programs icon.

2.

On the Install/Uninstall tab scroll the list and select XES XEScan program. Click the [Remove] button.

3.

Scroll the list again and select the Synergix Diagnostics program. Click the [Remove] button.

4.

Click the Finish button to close the dialog. Close the Control Panels window.

5.

Use Explorer or My Computer to navigate to the Program Files folder. Delete the XESystems folder.

6.

Close Explorer or My Computer and restart the system.

General Procedures

XEScan Solution Scanner Installation

6-6

Diagnostics

Passwords

Introduction

There are three passwords associated with the Synergix Digital Solution:

This subsection describes the use of the diagnostics software to isolate faults in the Interceptor Scanner system. The diagnostic software enables access to the diagnostic routines contained in the Scanner.

•

The diagnostic routines are contained either in the firmware for the associated Controller to which the Scanner is connected, or in the firmware of the Scanner. The Scanner Control Panel, located on top of the Scanner, is used to gain access to the diagnostics and operate the features.

To enter this password using the Scanner Control Panel, press the Menu key; select System Administration; press the Enter key; and enter the password. Press the Enter key to confirm the entry. The System Administrator functions are then available, and remain so until the operator exits the Menu mode and returns to normal operation.

To enter the diagnostics mode for the 88xx Synergix Digital Solution and X2 Tech printer, go to Entering the Scanner Diagnostics in this section.

•

Using the Diagnostic Software - Key Properties In order to navigate through the Diagnostics menu, the properties of the buttons located below the LCD must be understood. The following list gives a brief explanation of the properties of the control buttons.

The System Administrator’s Override Password (SAOP). The password is 88300. Use this password when the System Administrator Password has been lost or forgotten. Entering 88300 automatically resets the System Administrator password to 0 (zero). The customer should then immediately change the password to a value of the customer’s choice.

NOTE: The SAOP is hard coded and cannot be changed; therefore, it must never be disclosed to the customer.

NOTE: Some diagnostics, marked with a (*) in, require the entry of the Diagnostic Password. Refer to Password for information about the Service Diagnostic Password and how to enter it.

To enter this password, press the Menu key; select System Administration; press the Enter key; and enter 88300. Press the Enter key to confirm the entry.

NOTE: Ensure that a single short chirp sound is heard when pressing one of the selection keys located beneath the LCD. Three short chirps is an indication of an invalid selection for that particular menu item.

•

The System Administration Password (SAP). The default value is zero (0), and should be changed by the customer to a value of the customer’s choice. As long as the value of the SAP is 0, remote (network connected) administrator sessions using the Web PMT facility never time out, and the administrator functions remain available to any operator who later makes a connection.

•

The Service Diagnostic Password (SDP). The password is 6789. This password is required for access to protected Diagnostic functions. The SDP is hard coded and cannot be changed; therefore, it must never be disclosed to any customer. To enter this password, press the Menu key. Select DIAGNOSTICS, and press the Enter key. Select PASSWORD, and press the Enter key. Enter 6789 and press the Enter key to confirm the entry.

MENU - The MENU key is used to enter and exit the Main Menu. When the Interceptor Scanner Control Panel is in a READY state, pressing this key displays the top menu of the Main Menu Tree. While the Scanner Control Panel is displaying a Main Menu tree screen, pressing this key is equivalent to repeatedly pressing the EXIT key until the Scanner Control Panel returns to the previous READY state.

The SDP remains in force as long as the operator remains inside the DIAGNOSTICS menu.

NOTE: The presence of arrows on the right side of the LCD display indicates that there are additional items at that particular level that will have to be scrolled to in order to be visible. •

PREVIOUS - The PREVIOUS key is used to select the previous item in a list.

•

NEXT - The NEXT key is used to select the next item in a list.

•

ENTER - The ENTER key is used for the entry of a numeric value or lock in the currently selected choice from a list.

•

EXIT - The EXIT key is used to cancel an operation and return to a parent display.

•

MODE - The MODE key is valid only when a Ready screen is displayed. It is used to transition between Ready states. (For example, between Ready-to-Copy and Ready-toScan.) When depressed, the MODE key changes from one state to the next state listed on the display.

General Procedures 6-7

Diagnostics, Using the Diagnostic Software

Main Menu Tree Structures

Configuration Menu NOTE: The following Menu Tree structure views are shown as they will appear with the Feature Keys enabled.

Figure 1 Configuration Menu

General Procedures

Main Menu Tree Structures

6-8

Diagnostics Menu

Figure 2 Diagnostics Menu

General Procedures 6-9

Main Menu Tree Structures

System Information Menu

Figure 3 System Information Menu

General Procedures

Main Menu Tree Structures

6-10

System Administration Menu

Figure 4 System Administration Menu

General Procedures 6-11

Main Menu Tree Structures

Power On Self Test (POST) Diagnostics

Usage Meters

(Table 1): When the Scanner power is switched on, the Scanner performs the following Power On Self Test (POST) routines. The Scanner displays the test code for each test in progress on a 7 segment display on the rear of the Scanner. If any POST fails, the startup process stops, and the code of the test that failed is continuously displayed. The POST tests are shown in the table below.

(Figure 1): This screen will display the following menu. The Scanner Area usage is measured in square units (either feet or meters) for all types of Scanners. The Scanner Usage Meter displayed from this menu is maintained by the AccXES Controller firmware. A usage meter is also maintained by the internal Interceptor Scanner firmware. The Media Usage is provided by the Printer and is tracked in both linear and square units as defined by the Printer.

Table 1 POST Codes Code

Description

0

RAM test

1

Checksum Test - Update FLASH ROM

2

Serial Controller (SCC) test

3

GPLynx register - write/read back test

4

Application checksum test

5

NVR (Non-volatile Random Access Memory) verification test

6

Checksum test - SCVM code

7

24 Volts test

8

Lamp Test

9

Motor communications test

A

SCVM Load and functional test

B

IP card interface test

C

IP card internal test

D

Video path test

E

Scanner Control Panel Communications

U

Flash Update Mode

P

Post tests completed, no IEEE 1394 communications with external controller

P.

IEEE 1394 communications established with external controller.

Figure 1 Usage Meters Screen

General Procedures

Power On Self Test (POST) Diagnostics, Usage

6-12

Clear Scanner Usage

Installation Test Print

This screen permits the CSE to reset the Scanner’s usage meter to zero. This operation is password protected. If the password has not been entered the “INVALID PASSWORD, REENTER” message is displayed, and the operator must return to the password entry screen and enter the service password described in Section 0 before the test will execute. If the password has been entered, the usage will go to 0 and the “USAGE CLEARED” message will be displayed.

This menu will queue an Installation Test Print for use in the Scanner calibration. This test print can only be queued if the diagnostic password has been entered. The Installation Test Print is used to evaluate the adjustment of the print density produced by the Printer.

Figure 1 Clear Scanner Usage Screen Figure 1 Installation Test Print Screen

General Procedures 6-13

Clear Scanner Usage, Installation Test Print

Password This menu item allows the operator to enter the service diagnostic password. This password unlocks the protected diagnostic tests. Enter the password 6789 and press the Enter key. •

If an invalid password is entered, the screen displays INVALID PASSWORD, RE-ENTER.

•

Once entered, the password remains in effect until the operator leaves the Diagnostics menu and returns to normal operation.

Figure 1 Password Screen

General Procedures 6-14

Entering the Scanner Diagnostics

Table 1 List of Diagnostic Tests

Do the following steps to enter the Scanner Diagnostics: 1.

Switch on the Scanner, the Controller, and the Printer, and wait for all of the devices to initialize.

2.

Press the Menu key on the Scanner Control Panel.

3.

Press the Next key until DIAGNOSTICS is highlighted on the Scanner Control Panel.

4.

(Figure 1): Press the Enter key. The DIAGNOSTICS screen is displayed.

Name of Test

Figure 1 Entering Scanner Diagnostics 5.

Press the Next key until SCANNER DIAGNOSTICS is highlighted.

6.

Press the Enter key.

Description

Special

Allows the operator to display the entries contained in the Scanner internal fault log.

NO

Special

Allows the operator to display cumulative counts of each fault type from the Scanner internal fault memory.

NO

Special

Causes the contents of the Scanner fault logs to be erased.

YES

Special

Allows the CSE to adjust the speed of the Document Drive Motor in the Scanner.

YES

Special

Enables the adjustment of the staging position of the lead edge and the correct positioning of the trail edge for documents inserted into the Scanner.

NO

Special

Displays the current state of each of the optical paper sensors in the Interceptor Scanner.

NO

Special

Allows the user to execute the Document Motor Communications Loopback test.

NO

Special

Allows the user to stop and start the Document Drive Motor

NO

Special

Allows the user to turn the Fluorescent Lamp on or off.

NO

Special

Allows the user to control the Calibration Motor and to select the Calibration Motor function.

NO

Special

This menu will queue an Installation Test Print for use in the Scanner calibration.

YES

Special

Displays the contents of the Non-Volatile RAM on the Scanner.

NO

A list of Diagnostics tests is displayed. Press the Next or the Previous key to highlight the desired test, and press the Enter Key to operate that test. Results of the tests are displayed on the scanner control panel. Table 1 List of Diagnostic Tests shows the available tests. Table 1 List of Diagnostic Tests

Name of Test

Password Required?

Type

Description

Special

Tests communications with the Image Bars.

NO

Special

Adjusts the pixels of the Scan bar for uniform response to a target of standard reflectivity.

NO

Runs a series of tests that check for correct operation of the Scanner.

NO

This password-protected diagnostic allows the CSE to modify the contents of the non-volatile memory of the Scanner.

YES

Allows the technician to reset the NVR values to the factory default values.

YES

Allows the operator to view the current value of the usage meter maintained by the Scanner.

NO

Special

Special

Special

Special

Password Required?

Type

General Procedures 6-15

Entering the Scanner Diagnostics

Image Path Test

Scan Bar Calibration Test

Diagnostic password required: NO.

Diagnostic password required: NO.

This test checks the communications with the three Image Bars.

This test checks the response of the light-sensitive elements in the Image Bar (Scan Bar). The Scanner rotates the Calibration Extrusion until the Calibration Target Strip, a surface of known reflectivity, into the view of the Image Bar, and the response of each element is compared to the expected response. The gain of each element is then adjusted so that the response is uniform across the entire scan bar. The process takes less than two seconds.

The test runs the IP Card test and the SCVM test. If the IP Card test is successful, the BOARD ID field contains a numeric value, and the STATUS field indicates PASSED. Communications with the Image Bars are checked using the SCVM test. Each Image Bar is separately evaluated; a successful test is indicated by PASSED.

Select the SCAN BAR CALIBRATION test from the menu of diagnostic tests (Entering the Scanner Diagnostics).

(Figure 1): If the Scanner does not respond to either the IP Card test, the SCVM test, or both, the message NO RESPONSE FROM SCANNER is displayed.

(Figure 1): Press the Start button on the Scanner Control Panel.

NOTE: To perform the test again, reselect the Image Path Test from the Scanner Diagnostics menu.

Figure 1 Scan Bar Calibration The PRESS START TO BEGIN messages changes to RUNNING. If the test is successful, PASS is displayed. If not, ERROR CODE and a hexadecimal error code are displayed. ( Table 1 Error Codes for the Scan Bar Calibration Test) shows the codes and meanings.

Figure 1 Image Path Test

If the test fails, clean the Platen Glass and the Calibration Target Strip, and try the test again. To run the test again, reselect it from the Scanner Diagnostics menu. If the test fails after the above effort, examine the electronic Scanner Fault Log for LL-4x fault codes. Go to Table 1 Message Display Entry Chart, (located in Section 1 of this service manual) for possible causes.

General Procedures

Image Path Test, Scan Bar Calibration Test

6-16

Full System Test Diagnostic password required: NO.

Table 1 Error Codes for the Scan Bar Calibration Test Hex Code

Meaning

Code

Meaning

Dark pixel calibration - Range adjustment error

06

Dark pixel calibration time-out

02

Dark pixel calibration - Range status error

07

Offset calibration - timeout

03

Offset calibration error

08

Gain calibration - timeout

04

Gain calibration error - Video too high

09

Set integration failure

05

Gain calibration error - Video too low.

01

This test performs a series of tests, shown in (Table 1), to check that the Scanner is operating correctly. Select the FULL SYSTEM TEST from the menu of diagnostic tests (Entering the Scanner Diagnostics). (Figure 1): Press the Start key to begin the sequence of tests.

Figure 1 Full System Test A code of R is displayed next to the test code when a test is running. When the test is complete, P is displayed if the test passed; F, if the test failed. Table 1 Test Code

Description

Test Code

Description

A

POST test 5 - NVR Verification

E

POST test 9 -- Interface Image Processing PWB

B

POST test 6 - Motor communications

F

POST test A - Internal test - Image Processing PWB

C

Post test 7 SCVM Code Checksum

G

POST test B - Video path

D

POST 8 SCVM Load and Functional test

General Procedures 6-17

Scan Bar Calibration Test, Full System Test

Write NVR

Reset NVR Defaults

Diagnostic password required: YES.

Diagnostic password required: YES.

This password-protected diagnostic allows the CSE to modify the contents of the non-volatile memory of the Scanner.

This password-protected diagnostic allows the technician to reset the NVR (Non-volatile Random Access Memory) values to the factory default values. All customized NVR default settings will be lost when this procedure is performed. CAUTION Certain customer-defined NVR values will be lost when this reset procedure is performed. Therefore, record the existing NVR values on a piece of paper by using the READ NVR function in the Diagnostics Menu prior to performing this function. The READ NVR location on the Scanner Control Panel is: Main Menu > Diagnostics > Scanner Diagnostics > Read NVR.

Figure 1 Write NVR Screen The SIZE field specifies the size of the data value to written to the memory. Valid entries are 1,2, and 4 indicating the number of bytes to be written. The ADDRESS field specifies the starting location in the NVR RAM to be written. Values correspond to the memory locations in the Read NVR Screen display. The DATA field specifies the value to be written. If the entered value is larger than the specification in the SIZE Field, the least significant portion of the DATA required to fill the SIZE specification is used. The operation is accomplished by scrolling the EXECUTE field to YES and pressing the return key. If the diagnostics password has not been entered when this test is attempted, the operator is prompted to return to the password entry menu and no operation occurs.

NOTE: The fields on this screen may require hexadecimal digits to be entered. To enter Hex A, B, C, D, E, or F, hold down the (.) key while pressing 0, 1, 2, 3, 4, or 5, respectively. If you enter an incorrect digit by mistake, press the EXIT key and begin again.

Figure 1 Reset NVR Defaults Screen The following rules apply to the use of this option: •

If the CSE hits EXIT or ENTER without scrolling the contents of the EXECUTE box to read YES, this function has no effect.

•

If the CSE selects YES in the EXECUTE box and hits the return key, the Scanner resets the contents of the NVRAM to the factory default values (with the exception of the Lamp Initialization value) and the screen returns to the parent menu.

•

If the Reset NVR Defaults is executed three consecutive times, the Lamp Initialization value will also be reset.

•

If the Diagnostics password has not been entered when this test is attempted, the operator is prompted to return to the PASSWORD entry menu and no operation occurs.

•

General Procedures

Write NVR, Reset NVR Defaults

6-18

After resetting the NVR three times, perform the following procedures: 1.

Go to [ADJ 6.1 Exposure Lamp Initialization] and perform the procedure.

2.

Enter the diagnostics. Go to the [ADJ 8.2 Lead Edge / Trail Edge Adjustment (DS system only)] test and perform the procedure.

3.

Go to the [ADJ 4.1 Document Drive Motor Speed (DS system only)] and perform the procedure.

Scanner Reliability Meter

Scanner Faults (Ordered)

Diagnostic password required: NO.

Diagnostic password required: NO.

This user-accessible diagnostic allows the operator to view the current value of the usage meter maintained by the Scanner. The Scanner usage meter is intended for gathering data about reliability of the scanning mechanism. When a fault is recorded in the Scanner Fault Log, the value of this meter at the time is also included.

This user-accessible diagnostic allows the operator to display the entries contained in the Scanner internal fault log. The entries are presented three to a screen. The operator scrolls through the list using the NEXT and PREVIOUS keys on the Scanner Control Panel. The operator may view all valid log entries in the Scanner fault log from this screen. Empty log entries are not displayed.

NOTE: This meter measures linear usage only and is not intended for billing purposes. Press the Next or Previous keys to scroll through the entries. If there are no fault entries, LAST CLEARED XXXX is displayed, where XXXX is the value of the Scanner Reliability meter at the time the log was cleared.

Figure 1 Scanner Reliability Meter Screen •

Units of measure are displayed according to the setting configured in the Scanner NV RAM when the Scanner is installed.

•

The meter may be reset by writing to the appropriate locations in NV RAM. Refer to the diagnostic, Read Non Volatile Random Access Memory (NVR), for a map of the contents of the Scanner Non Volatile Memory.

Figure 1 Scanner Fault Log (Ordered) •

The first column of the display indicates the log entry number.

•

The second column indicates the fault code recorded in the log.

•

The third column is the value of the internal Scanner usage meter at the time that the fault was detected. This value is displayed in decimal format and is the value stored in the Scanner Reliability Meter at the time of the fault.

General Procedures 6-19

Scanner Reliability Meter, Scanner Faults (Or-

Scanner Faults (Counts)

Clear Scanner Fault Log

Diagnostic password required: NO.

Diagnostic password required: YES.

This user accessible diagnostic allows the operator to display cumulative counts of each fault type from the Scanner internal fault memory. The entries are presented with three entries per screen. Each entry displays a count of the total occurrences of the specified fault. As with the chronological fault log listing, the top line of the display indicates when the fault log was last cleared.

This password-protected menu causes the contents of the Scanner fault logs to be erased.

Press the Next or Previous keys to scroll through the entries. If there are no fault entries, LAST CLEARED XXXX is displayed, where XXXX is the value of the Scanner Reliability meter at the time the log was cleared.

Figure 1 Clear Scanner Fault Log Screen

Figure 1 Scanner Fault Log (Counts)

General Procedures

Scanner Faults (Counts), Clear Scanner Fault Log

6-20

•

The Scanner saves the value of its Scanner Reliability Meter to indicate the point at which the Scanner fault logs were erased.

•

If the diagnostics password has not been entered when this test is attempted, the operator is prompted to return to the password entry menu, and no operation occurs.

•

If there are no fault entries, LAST CLEARED XXXX is displayed, where XXXX is the value of the Scanner Reliability meter at the time the log was cleared.

Read Non Volatile Random Access Memory (NVR) Diagnostic password required: NO. (Figure 1): This user-accessible diagnostic displays the contents of the Non-Volatile RAM on the Scanner. The contents of the NVR memory are displayed in the fields containing “XX” in the sample screen below. The operator scrolls the display using the NEXT and PREVIOUS buttons on the Scanner Control Panel.

Figure 1 Read NVR Screen

Table 1 Interceptor Scanner Map of Non Volatile Memory Number

Name

Default Value (Hex)

Range

Number

Comments

0

NVR_VERSION

0000

0000FFFF

This defines the current NVR version. It’s used for automatic NVR upgrade during a new firmware load.

2

ILL_SP_PERCENT

00

00-FF

Illumination setpoint as a percentage of ILL_INSTALL_READ. Set to zero to force ILL_INSTALL_READ to be recalculated (when installing a new fluorescent lamp).

3

ILL_RENULL_THRESH

03

4

ILL_COLD_WARMUP

1

00-FF

Number of minutes required for the lamp to warm up following a cold start.

5

ILL_CONDITION_TIME

3C (60 minutes)

00-FF

Number of minutes the fluorescent lamp must be on following install before the final ILL_INSTALL_READ is taken.

6

ILL_INSTALL_UPTIME

00

00-FF

Number of minutes of conditioning time elapsed. When this value equals ILL_CONDITION_TIME then the final ILL_INSTALL_READ is taken.

7

ILL_INSTALL_READ

00

00 - FF

8

ISO_PACKET_SIZE

0800

A

SCVM_CAL_ENA_MASK

FF

ILL_ ADC counts of drift allowed before renull required.

Contains the Lamp Illumination Sensor reading taken when the lamp is installed. Number of bytes in isochronous packet.

0-FF

Calibration Enable Mask. It is used to enable/disable individual calibration operations. Defaults to all calibrations enabled. Bit assignments are: • 0x01 - Range Adjust •

0x02 - Offset Adjust

•

0x04 - Set Integration Time

•

0x08 - Coarse (stationary) Gain Adjust

•

0x10 - Fine (moving) Gain Adjust

NOTE: Bit Set = Enable. Bit Clear = Disable B

SCVM_INTEG_VAL

20

01-F0

SCVM Integration Time

C

SCVM_DARK_LO_LIMIT

0002

0000 0FFF

SCVM Dark range lower limit.

E

SCVM_DARK_HI_LIMIT

0100

0000 0FFF

SCVM Dark range upper limit.

10

SCVM_PIX_LO_LIMIT

C6

00 - FF

SCVM pixel average low limit for set integration time.

11

SCVM_PIX_HI_LIMIT

CA

00 - FF

SCVM pixel average high limit for set integration time.

12

SCVM_GAIN_OVERRIDE

6D10 (1mV per count) 0100 0FFF

Gain multiplier value used during gain cal override.

General Procedures 6-21

Read Non Volatile Random Access Memory (NVR)

Table 1 Interceptor Scanner Map of Non Volatile Memory Number

Name

Default Value (Hex)

Range

Number

Comments

14

SCVM_GAIN_SETPOINT

367

0000 03FF

Gain cal setpoint.

16

SCAN_SPEED

09

00 - 0C

Default Scan Speed • 0 ips: NVR Value = 0 •

0.125 ips: NVR value = 1

•

0.250 ips: NVR value = 2

•

0.500 ips: NVR value = 3

•

0.750 ips: NVR value = 4

•

1.00 ips: NVR value = 5

•

1.500 ips: NVR value = 6

•

2.00 ips:

NVR value = 7

•

3.00 ips:

NVR value = 8

•

4.00 ips:

NVR value = 9

•

6.00 ips:

NVR value = A

•

8.00 ips:

NVR value = B

17

REG_OFFSET

32

00 - FF

Registration Offset, each count represents.01inch.

18

SCAN_METER_UNITS

00

00, 01, 02

Sets the units for the scan meters. • 0 = Feet •

1 = Yards

•

2 = Meters

19

SCAN_METER_ALL

00000000 FFFFFFFF

This contains the scan meter for the total length scanned.

1D

SCAN_METER_MONO

00000000 FFFFFFFF

Scan meter - Monochrome scans only.

21

SCAN_METER_COLOR

00000000 FFFFFFFF

Scan meter - Color scans only.

25

SCAN_METER_REM

00000000 FFFFFFFF

Scan meter remainder, used to store any partial units (feet, yards, meters) scanned. Used to keep track of when the recent fault log is full.

29

RFLOG_FULL_FLAG

0

0,1

2A

RFLOG_NEXT_INSERT

0

0 - 100

Next available location in the recent fault log.

2B

FHLOG_CLEAR_METER

00000000 FFFFFFFF

Total scan meter reading when the fault history log was last cleared.

2F

POWER_SAVER_TIME

3C

00 - FF

Power Saver timer in minutes.

30

DIST_AWD

8B

32 - 1C2

Distance in Full Steps count from home to AWD rotation. 8B is 50 degrees.

32

CALIBRATION_TIME

5

5 - 5A

How long before Calibration begins (in minutes).

General Procedures

Read Non Volatile Random Access Memory (NVR)

6-22

Table 1 Interceptor Scanner Map of Non Volatile Memory Number 33

Name MOV_CAL_SPEED_IX

Default Value (Hex) 0

Range

Number

0 - FF

Comments Moving the Calibration (Fine Gain Adjustment) is done with the Calibration Extrusion. • 0: rotating at 0.5 ips •

1: rotating at 0.8 ips

•

2 - FF: stationary

34

PERC_SPEED_ADJ

3E8

384 - 44C

Percent of the Nominal Document Speed 3E816 = = 100010 = = 100.0 percent (default)

36

CALZONE_VERSION

2

0-2

0:Ver0:Old Calzone (Not Supported) 1: Ver 1: 1st B1 Home Sensor w/Narrow slot 2: Ver 2: 13.5 degrees different from ver 1 from fixing scratch lens

37

FILTER_TRC_ORDER

0

0-1

0-Filter is done prior to TRC 1-TRC is done prior to Filter

38

HORIZONTAL_SYS_ADJ

0

0-A

Represents 0.1% increments in horizontal magnification performed by Pixel Magic (i.e. 3 = 100.3%, 4 = 100.4%,...). Any value over 0xA is reduced to 0xA

General Procedures 6-23

Read Non Volatile Random Access Memory (NVR)

Motor Speed Test

Lead Edge/ Trail Edge

NOTE: When servicing an XEScan Solution system, follow the instructions in the online hardware help files for this procedure.

NOTE: When servicing an XEScan Solution system, follow the instructions in the online hardware help files for this procedure.

Diagnostic password required: NO.

Diagnostic password required: NO.

This test is found under the menu item, COMPONENT TESTS.

This test is found under the menu item, COMPONENT TESTS.

This password-protected test allows the CSE to adjust the speed of the Document Drive Motor in the Scanner. The speed adjustment corrects the difference between the expected length of a measured line in the document and the length of that line in the output image. The measured line should be oriented parallel to the scanning process direction. The Controller will, when possible, rotate the scanned image 90 degrees before printing, to eliminate the effect of any process speed errors in the Printer.

NOTE: This adjustment calculates both the lead edge and the trail edge of the scanned image. This test enables the adjustment of the staging position of the lead edge and the correct positioning of the trail edge for documents inserted into the Scanner. Select the LEAD EDGE/TRAIL EDGE test from the menu of diagnostic tests (Entering the Scanner Diagnostics).

Select the MOTOR SPEED test from the menu of diagnostic tests (Entering the Scanner Diagnostics). For how to conduct the test, see the adjustment, ADJ 4.1 Document Drive Motor Speed (DS system only). in Section 4 of this service manual.

To perform the test: 1.

Insert a black A-size piece of paper, or a printed copy of the Motor Speed Test Target from the Service CD, into the Scanner, and allow the document to be staged.

NOTE: if you use the printed copy of the System Speed and Lead Edge Detect Test Target, be sure to cut off the end as indicated on the target, before using it. Then insert the target black edge first. 2.

Press the START key.

The document is scanned, and new values are stored in Non-Volatile Random Access Memory (NVR). If the test is successful, the screen displays PASSED. If not, the screen displays FAILED. If the test fails, perform the test again. If the test still fails, isolate and correct the problem, then try the test again.

Figure 1 Motor Speed Test

Figure 1 Lead Edge/Trail Edge

General Procedures

Motor Speed Test, Lead Edge/ Trail Edge

6-24

Sensors

Scanner Control Panel

Diagnostic password required: NO.

Diagnostic password required: NO.

This test is found under the menu item, COMPONENT TESTS.

This diagnostic isolates and tests the operation of the Scanner Control Panel in the following areas: Liquid Crystal Display, Communications, Control Panel LEDs, Control Panel Keys.

This diagnostic displays the current state of the left and right width sensors, the Edge Present (INPUT) sensor, the Edge Registered (REGISTERED) sensor, the Exit Sensor, and the Document Thickness Sensor. It is one of the Component Tests. •

When a sensor is covered (actuated) its status reads ON.

•

When a sensor is uncovered (deactuated) its status reads OFF.

•

The THICK field reads YES when the Thick Document Sensor is activated, and NO when the sensor is not activated.

•

The polling is stopped by pressing the EXIT key, also causing the display to return to the parent menu.

NOTE: If the Scanner Control Panel fails any area of this test, replace it.

Procedure 1.

Ensure that the Scanner is powered off and unplugged.

2.

Loosen the center screw at the rear of the Scanner Control Panel and flip the Control Panel over, resting it on top of the Scanner.

3.

Loosen the two remaining screws at the rear of the Scanner Control Panel and remove the Mounting Bracket from the Control Panel.

4.

(Figure 1): Prepare the Scanner Control Panel PWB for Loopback connector installation.

1 Disconnect A2P1 from the Scanner Control Panel PWB

Figure 1 Sensors Screen

Figure 1 Preparing the Scanner Control Panel PWB for Loopback Connector

General Procedures 6-25

Sensors, Scanner Control Panel

5.

(Figure 2): Attach the Loopback Connector in series to the Scanner Control Panel PWB.

7.

(Figure 3): Power the Scanner back on, and observe the Scanner Control Panel.

NOTE: For the purposes of this test, the Control Panel keys directly beneath the LCD display (Menu, Previous, Next, Enter) will activate the respective tests.

1 Attach the Loopback Connector to A2P1

Figure 3 Scanner Control Panel •

Press the Menu key for a check of all the pixels in the Liquid Crystal Display. The display will be filled from bottom to top, and from left to right. The test will continue until the EXIT key is pressed.

Attach the other end of the Loopback Connector to the Scanner Control Panel PWB

•

Press the Previous key to execute the Communication Loopback Test. When this test is completed the word “Passed” will display on the lower left portion of the screen.

Figure 2 Attaching the Loopback Connector

•

Press the Next key to run a test of the Scanner Control Panel LEDs. One press of the Next button will illuminate all of the LEDs on the Scanner Control Panel. Subsequent depressions of the Next button will cause each LED on the Control Panel to light individually and in sequence from left to right.

•

Press the Enter key to test the keys on the Scanner Control Panel. The first press of the Enter key will cause a graphic representation of the Scanner Control Panel keyboard to be displayed on the LCD. Subsequent depressions of the Enter key will cause a chirp to be heard for each time a particular key is pressed, as well as darken that particular key on the LCD display.

2

6.

Flip the Scanner Control Panel back over and rest it on the Upper Document Transport. Ensure that the display area of the Control Panel can be observed.

8.

Once the test has been completed, press Exit, power off the Scanner and Remove the Loopback Connector wire.

9.

Reconnect the Scanner Control Panel wires and reinstall the Control Panel to its original position on the Scanner.

10. Power on the system and return the Scanner to normal operation.

General Procedures

Scanner Control Panel

6-26

Document Motor (Loopback) Communications

3.

Diagnostic password required: NO. This user-accessible diagnostic allows the user to execute the Document Motor Communications Loopback test. It is one of the Diagnostic Component Tests. This diagnostic checks the communications interface to the Motor Control PWB, but does not check the operation of the Document Drive Motor or the Motor Control PWB. This test isolates the Scanner Main PWB and performs diagnostic tests upon it. If this test fails, replace the Scanner Main PWB. 1.

Go to REP 4.2 Electronics Drawer, and perform the first five steps in that procedure to make the Scanner Main PWB accessible.

2.

(Figure 1): Disconnect J408 on the Scanner Main PWB and install the Loopback Connector on that connector.

Power up the Synergix System in the following order: Scanner, Controller, (if accessible) Printer. •

A POST failure will be generated on the seven-segment display at the back of the Scanner: 9.

•

Additionally, an LL96 fault code will be generated on the Scanner Control Panel.

4.

On the Scanner Control Panel, enter Menu > Diagnostics > Scanner Diagnostics > Component Tests > Motor Communications > Enter.

5.

When this test screen is entered the third line of the display reads “PRESS START TO BEGIN” and the fourth line is blank.

6.

After the operator presses START, the third line reads “STATUS” followed by PASS or FAIL. If a failure is reported, the expected and actual values are presented on line four.

1 Disconnect J408

Figure 2 Document Motor Communications Screen 7.

If the status is PASSED, the fourth line is blank.

8.

To exit this procedure, perform the following:

9.

a.

Exit the Main Menu, power the system down.

b.

Remove the Loopback Test Clip, reinstall J408 on the Scanner Main PWB.

c.

Reverse the first five steps of REP 4.2 Electronics Drawer.

Reboot the Synergix Scan System and return it to normal operation.

2 Install Loopback Connector at same location

Figure 1 Installing the Loopback Connector on the Scanner Main PWB

General Procedures 6-27

Document Motor (Loopback) Communications

Document Drive Motor

Lamp

Diagnostic password required: NO.

Diagnostic password required: NO.

This test is found under the menu item, COMPONENT TESTS.

This test is found under the menu item, COMPONENT TESTS.

This user-accessible diagnostic allows the user to stop and start the Document Drive Motor, and also to change the direction and speed of that motor.

This user-accessible diagnostic allows the user to turn the Lamp on or off. As a result of this function, a feedback from the Illumination Sensor Q11 is transmitted. The value for the SENSOR field ranges from 0 - 255. A value of 0 or 1 is typical when the Lamp is not illuminated; 50 - 150 is typical when the Lamp is on.

NOTE: When changing the speed of the Document Drive Motor, enter the speed change prior to starting the motor.

To operate:

To operate: 1.

Press the Next key to select SPEED (motor speed).

2.

Press the Enter key to confirm the choice.

3.

Press the Next key to set the desired state.

4.

Press the Exit key.

5.

Similarly, set DIRECTION (motor rotation direction) to FORWARD or REVERSE.

6.

Similarly, set MOTOR (motor state) to ON.

7.

Press the Enter key to start the motor.

8.

Repeat steps 1 - 8 as desired.

9.

Press the Exit key to exit the Document Motor test.

1.

Press Next until the desired state of the Lamp (OFF or ON) is displayed.

2.

Press the Enter key to switch to the selected lamp state and read the output of the Illumination Sensor.

3.

Press the Enter key again.

4.

Press the Next key to select another state of the lamp, if desired.

5.

Repeat steps 2 - 4 as desired.

6.

Press the Exit key to exit the Lamp test.

Figure 1 Fluorescent Lamp Screen Figure 1 Document Drive Motor Screen

General Procedures

Document Drive Motor, Lamp

6-28

Calibration Motor Diagnostic password required: NO. This test is found under the menu item, COMPONENT TESTS. This user-accessible diagnostic allows the user to control the Calibration Motor and to select the Calibration Motor function. • •

Selections for the MOTOR field are ON or OFF. Selections for the FUNCTION field are 1.

GO TO WIDTH. The Calibration Extrusion rotates to place the Plate Roll in view of the Image Bar.

2.

GO TO CALIBRATE. The Calibration Extrusion rotates to place the Calibration Target Strip in view of the Image Bar.

3.

GO TO HOME. The Calibration Extrusion rotates to the home position as determined by the alignment of the hole in the right hub of the extrusion with the Calibration Home Sensor.

4.

FIND HOME. The Calibration Extrusion rotates to the home position as determined by assignment of the hole in the right hub of the extrusion with the Calibration Home Sensor.

5.

ROTATE. The Calibration Extrusion rotates continuously until the MOTOR OFF state is selected.

•

The operator must set the FUNCTION field followed by setting the MOTOR field to ON to accomplish the requested operation.

•

When a GO TO or FIND selection is made, the selection for MOTOR will be set to OFF by the AccXES Controller, since the Calibration Motor stops when the destination is reached.

•

When ROTATE is selected (in the FUNCTION field) the motor runs continuously until the operator selects OFF in the MOTOR Field.

•

In the event that the Scanner reports failure accessing the Calibration Motor function, the fourth line of the display will read “FAILURE CODE”, followed by a two-digit hexadecimal number.

Figure 1 Calibration Motor Screen General Procedures 6-29

Calibration Motor

GP 1 How to Check a Short Circuit

Y

This checkout can be used to isolate a short circuit.

WARNING Disconnect the power cord before disconnecting or reconnecting a P/J, reconnect the power cord then switch the copier on.

N Disconnect P/JD on the Distribution PWB. Make a check for 0 Ohms between pin 4 on the harness side of he connector and DC Common (ground). 0Ohms is measured. Y N The short circuit is on the Distribution PWB. INstall a new Distribution PWB, PL X.X. The short circuit is between PD-4 and the circuits XX-3, YY-4,and ZZ-5. Check the wiring of each circuit and if necessary repair the wiring. If the short circuit is found to be on the ZZZ PWB, install a new ZZZ PWB, PL X.X.

Initial Actions Reconnect any circuits that you have disconnected.

THe short circuit is between PB-2 and the circuits VV-01 and WW-02. Check the wiring of each circuit and if necessary repair the wiring. If the short circuit is found to be on YYY PWB, install a new YYY PWB, PL X.X.

Procedure Disconnect P/JB on the Distribution PWB. Make a check for 0 Ohms between pin 2 on the harness side of the connector and 0 V (ground). 0 Ohms is measured.

Figure 1 Circuit Diagram

General Procedures

GP 1

6-30

GP 2 How to Check an Open Circuit

Procedure

This checkout can be used to isolate an open circuit.

Power is available at P/JA-1 on the Distribution PWB. Y N Make a check for continuity on the wire between the power source and P/JA-1. Also check the pins and the crimps of the P/Js to insure a good connection. If necessary repair the wiring. If no wiring fault is found, go to the relevant chain 1 RAP and find the fault.

WARNING Disconnect the power cord before disconnecting or reconnecting a P/J, reconnect the power cord then switch the copier on.

Initial Actions

The voltage is correct at P/JB-2 and P/JD-4 on the Distribution PWB. Y N Install a new Distribution PWB, PL X.X.

Reconnect any circuits that you may have disconnected.

Check the wiring between P/JB-2 on the Distribution PWB and P/JC-3 on the YYY PDWB for continuity. Also check the pins and crimps on the P/Js to ensure a good connection. If necessary, repair the wiring.

Figure 1 Circuit Diagram

General Procedures 6-31

GP 2

A

GP 3 How to Check a Sensor This procedure can be used to check two types of sensors used on the copier. TYPE A: Flag Sensors

Disconnect P/J105. Check the wiring and the connector crimps between P/J105, P/J13, and the Main PWB for an open circuit, or a short circuit. If the fault is in the wiring repair the wiring. IF the problem is in Main PWB replace the Main PWB, If the wiring and the Main PWB are both problem free install a new sensor, PL X.X.

This sensor is actuated by the movement of a mechanical flag, which interrupts the light path between the source and the sensor. •

Q56 ADF Exit Sensor

•

Q51 ADF Nudger Roller Sensor

•

Q56 DADF Exit Sensor

•

Q57 DADF Nudger Roller Sensor

B Switch off the copier. There is continuity between P404-1 on the Main PWB and GND. Y N Check the GND input.

The circuit is currently working properly. Check for loose connectors, bent pins, or damaged wires. Replace the sensor (PL X.X) before replacing the Main PWB .

The sensor is actuated by light reflected from paper or other substances to be detected when it arrives at the sensor. To enable the detection of dark paper, some sensors use a nonreflective black patch as a background to the sensing area. TYPE B: Reflective Sensors •

Q53 ADF Document Registration Sensor

•

Q52 ADF Document Sensor

•

Q59 DADF Document Sensor

Initial Actions NOTE: Due to the generic format of this RAP there will be no specific ADJ, PL, or Diagnostic codes identified. NOTE: The input power source (+5 VDC, + 24 VDC, and GND) will be shown only on the circuit diagrams in the RAPs that are affected by the loss of the +5 VDC, + 24 VDC and GND to the appropriate PWBs. •

Ensure that the sensor is not blocked.

•

Clean the sensor surfaces before using this procedure.

Procedure Sensor Checkout Connect the meter between P/J404-2 (+) and GND (-). Actuate the sensor, using a sheet of white paper. The voltage changes from +5 VDC to 0 VDC or 0 VDC to +5 VDC. Y N Disconnect P/J404. There is +5 VDC at P402- 2 on the Main PWB. Y N There is +5 VDC available P404-3 on the Main PWB. Y N Replace the Main PWB . (If the input power source and returns are shown on the circuit diagram, check the voltage before replacing the Main PWB. Replace or repair the voltage source.) Figure 1 Sensor (generic) Replace the Main PWB

A B General Procedures

GP 3

6-32

A Check the mechanical actuation of the switch. If the switch has an adjustment, perform the adjustment.

GP 4 How to Check a Switch and its Associated Wiring This RAP is an example of the checks required to locate a fault on a switch circuit. The switch can be either the simple mechanical type or the magnetically operated type.

NOTE: Due to the generic format of this RAP there will be no specific ADJ, PL, or Diagnostic codes identified. NOTE: The input power source (+5 VDC, + 24 VDC, and GND) will be shown only on the circuit diagrams in the RAPs that are affected by the loss of the +5 VDC, + 24 VDC and GND to the appropriate PWBs.

Procedure Enter Diagnostics Code N-NN. Actuate the switch. The display changes from high(H) to low(L) or low(L) to high(H). Y N Disconnect P/J115. There is +5VDC available at pin 1 on the harness side of the connector. Y N Disconnect P/J407 on the Main PWB. There is +5VDC available at pin 9 on the Main PWB. Y N Replace the Main PWB (PL X.X). (If the input power source and returns are shown on the circuit diagram, check the voltage before replacing the Main PWB. Replace or repair the voltage source.) Make a check for an open (GP4) or short circuit (GP5) between the harness side of P/J407-9 and the harness side of P/J115-1. If necessary repair the wiring. Turn off the copier. There is continuity between the GND test point and pin 2 on the harness side of the connector. Y N Disconnect P/J407 on the Main PWB. There is +5 VDC between P408-8 (+) and P408-9 (-) on the Main PWB. Y N Replace the Main PWB (PL X.X). (If the input power source and returns are shown on the circuit diagram, check the voltage and continuity before replacing the Main PWB. Replace or repair the voltage source.)

Figure 1 Switch (generic)

Make a check for continuity between the switch side of P/J407-8 and the harness side of P/J115-2. If necessary repair the wiring. Make a continuity check between the switch side of P/J115-1 and /J115-2. There is continuity when the switch is actuated and no continuity when the switch is deactuated. Y N Install a new switch, PL X.X. The Control PWB is not detecting the operation of the switch. Verify the supply voltages to the Control PWB. Install a new Control PWB, PL X.X.

A General Procedures 6-33

GP 4

GP 5 Generic PWB Checkout

Procedure

This procedure is performed to isolate a failing PWB. The applicable PWBs for this procedure are the Main PWB, the Image Processing PWB, the Motor Control PWB, and the Lamp Ballast PWB.

Power on the Scanner. Measure the voltages on the Main PWB. Main PWB Voltages Status LED

Voltage

Tolerance

WARNING

CR2

+24 VDC

+/- 1 VDC

This procedure exposes high voltages. Use care when probing in the Electronics Drawer.

CR9

+12 VDC

+/-.5 VDC

CR8

+3.3 VDC

+/-.15 VDC

CAUTION When extending the Electronics Drawer, ensure that the wiring to the connectors are not damaged.

CR10

+5 VDC switched

+/-.25 VDC

CR7

+5 VDC standby

+/-.25 VDC

Initial Actions 1.

Extend the rear Electronics Drawer.

2.

Unfasten the four screws and remove the metal top cover from the Electronics Drawer.

All the voltages measure the proper value (except 24 VDC before the POST LED displays 4). Y N Power off the Scanner. If the suspected board is the Image Processor PWB, the Motor Control PWB, or Lamp Ballast PWB, disconnect the suspected PWB. Power on the Scanner. Measure the voltages on the Main PWB. All the voltages measure the proper value (except 24 VDC before the POST LED displays 4). Y N Power off the Scanner. Replace the power supply (REP 1.1). Power on the Scanner. Measure the voltages on the Main PWB. All the voltages measure the proper value (except 24 VDC before POST LED displays 4). Y N Power off the Scanner. Replace the Main PWB [REP 3.1 Main PWB]. Power on the Scanner. Measure the voltages on the Main PWB. All the voltages measure the proper value (except 24 VDC before POST LED displays 4). Y N Elevate the problem to the outline. Go to Final Action, Section 1. Power off the Scanner. Replace the disconnected PWB. Power on the Scanner. Measure the voltages on the Main PWB. All the voltages measure the proper value (except 24 VDC before POST LED displays 4). Y N Check the cabling to the PWB for a short circuit.

Figure 1 Removing the Electronics Drawer Cover.

NOTE: For a illustration of Plug/Jack locations, go to (Figure 2 Electronics Drawer interior) and (Figure 3 Location of Test Points on Lower Right Edge of Main PWB). 3.

Disconnect all cables except the power cables for the PWB in question. •

P404 and P405 for the Main PWB.

•

P407 for the Lamp Ballast PWB. Connect J404 and P405 also.

•

P300 for the Motor Control PWB. Connect J404 and P405 also.

Observe the POST LED. The POST LED increments from 0 to 8 within 60 seconds of power on. Y N Power off the Scanner. Replace the Main PWB [REP 3.1 Main PWB]. Power on the Scanner. The POST LED increments from 0 to 8 within 50 seconds of power on. A

General Procedures

GP 5

6-34

A Y

N Elevate the problem to the Hotline.

Power on the Scanner. Observe the POST LED. The POST LED increments to B. Y N Power off the Scanner. Replace the Image Module [REP 9.2 Image Module].

Power off the Scanner. Connect P407, Lamp Ballast PWB. Power on the Scanner. The Scanner lamp illuminates for one second when the POST LED displays 8. Y N Power off the Scanner. Check the cables from J407 to the lamp. Power on the Scanner. The lamp illuminates for one second when the POST LED displays 8. Y N Probe the fuse on the Lamp Ballast PWB. +24VDC is present on both sides of the fuse. Y N Power off the Scanner. Replace the Lamp Ballast PWB. Power on the Scanner. The lamp illuminates for one second when the POST LED displays 8. Y N Power off the Scanner. Replace the lamp [REP 6.4 Exposure Lamp].

The POST LED increments to E. Y N Power off the Scanner. Check the Image Processing PWB for proper seating. The Image Processing PWB is properly seated. Y N Reseat the Image Processing PWB. Replace the Image Processing PWB [REP 3.2 Image Processing PWB]. Power off the Scanner. Connect P413. Power on the Scanner. Observe the POST LED. The POST LED increments to P. Y N Power off the Scanner. Check the DDS Control Panel cable.

Power off the Scanner. Connect P403. Power on the Scanner. Observe the POST LED. The POST LED increments to 9 within 60 seconds of power on. Y N Power off the Scanner. Check the illumination sensor [Sensors].

Go to Section 1, Final Action.

Power off the Scanner. Connect P406 and P408. Power on the Scanner. The upper document motor runs when the POST LED increments to 9. Y N Power off the Scanner. Check the upper document motor. Power on the Scanner. The upper document motor runs when the POST LED increments to 9. Y N Power off the Scanner. Replace the Motor Control PWB. Power off the Scanner. Connect P400. Power on the Scanner. Observe the POST LED. The POST LED increments to A. Y N Power off the Scanner. Check the encoder. Power off the Scanner. Connect the P414, P415, and P416. General Procedures 6-35

GP 5

Motor Control PWB J413

J414 J415 J416

PJ 400

PJ 401

Main PWB

J300

Image Processing PWB

J408

J407

J403

Lamp Ballast PWB

J406

J405

Power Supply

J404

Figure 2 Electronics Drawer interior

Figure 3 Location of Test Points on Lower Right Edge of Main PWB

General Procedures

GP 5

6-36

GP 8 System Power Up Procedure NOTE: When servicing an XEScan Solution system, follow the instructions in the online hardware help files for this procedure.

Printer Power Switch

Ground Fault Interrupter

When the Syngergix Scanner power is switched on, the Scanner performs a series of Power On Self Test (POST) routines. The results of these routines are visible on the 7 segment display at the rear of the Scanner. If any POST fails, the startup process stops and the code of the test that failed is continuously displayed. If such a failure should occur, go to the Scanner Fault Code Entry Chart in Section 1 of this service manual. 1.

Ensure that the Scanner power is switched off, and that the Printer power switch and Ground Fault Interrupter (located at the back of the Printer) are also switched off.

NOTE: There are two different configurations of Ground Fault Interrupter (GFI) for the 8825/8830 Printer. They both function in exactly the same way. • The white On / Off switch located at the back of the Printer only switches the Printer on or off. The GFI switches off both the Printer and Controller. • (Figure 1): The older configuration GFI has rectangular buttons for the test and retest functions. • (Figure 2): The more recent configuration GFI has a flip mechanism similar to a light switch for the test and retest functions.

Figure 2 New Configuration Ground Fault Interrupter Printer Power Switch

Ground Fault Interrupter

Figure 1 Old Configuration Ground Fault Interrupter

2.

Switch on the Synergix Scanner power. Wait until the “P” is visible on the 7 segment display at the rear of the Scanner.

3.

Power on the Ground Fault Interrupter at the back of the Printer.

4.

Switch on the Printer Power Switch.

5.

(Figure 3): Notice that the seven-segment display at the rear of the Scanner now indicates a dot after the letter P. This indicates that there are IEEE 1394 communications between the Scanner and the Controller.

Figure 3 Seven-Segment Display Indicating IEEE 1394 Communications

General Procedures 6-37

GP 8

GP 9 Enabling/Disabling the DDS Option - 8825 / 8830 Printers

GP 10 Enabling/Disabling the DDS Option - 8855 Printer The purpose of this procedure is to ensure that the Scanner, Controller and 8855 Printer are correctly configured for Digital Document System (DDS) operation.

The purpose of this procedure is to ensure that the Scanner, Controller and 8825/8830 Printer are correctly configured for Digital Document System (DDS) operation. 1.

Ensure that the system is powered up in the following order: Scanner, Controller (if external to the Printer) and Printer.

1.

Launch the Web Browser.

2.

Enter the IP address of your Controller in the form: http://xxx.xxx.xxx.xxx.

3.

Click on Session Setup and enter the Printer password.

NOTE: This procedure is conducted from the Printer Control Panel. The Printer Control Panel buttons have symbols to represent the following commands.

NOTE: 0 is the default password. However, this may have been changed by the Key Operator. 4.

Go to Printer Defaults > Printer Setup. Click on the box next to DDS Enabled. A check mark should appear to indicate that this selection has taken place.

Online/Offline

Figure 1 Printer Control Panel Buttons 2.

Press the Online/Offline button on the 8825/8830 Printer Control Panel to place the Printer in an Offline condition. Press the Enter button.

3.

Press the Next button on the Printer Control Panel until is reached.

4.

Press the Enter button.

5.

The system software will then prompt the user for the password, which is the number 0. Press the Enter button again, enter zero, and press the Enter button.

6.

Press the Next button until the option is reached. Press the Enter button.

7.

If the DDS system is enabled, the Control Panel will indicate . If this is the case, hit the EXIT key two times and take the Printer out of the Offline mode. If the Control Panel indicates then press the Enter button, and then the Next button until the selection toggles to the state. Then hit the Enter button.

8.

Exit the System Administration menus, and return the Printer Control Panel to the IDLE state.

9.

Perform GP 8 System Power Up Procedure.

Figure 1 Printer Setup Screen

General Procedures

GP 9 , GP 10

6-38

5.

Click on the Update Printer button at the bottom of the screen.

6.

Printer Updated should be displayed at the top of the screen.

GP 11 Catch Tray and Organizer Tray

NOTE: The Catch Tray and the Organizer Tray are identical parts.

WARNING Switch off the Scanner power and disconnect the power cord. 1.

Organizer Support (2)

Catch Tray Support (2)

Catch Tray / Organizer Tray (2)

(table 1) (Figure 1): Compare the items listed in the following table with the items present in the Catch Tray / Organizer Tray Kit. Ensure that all items are present before beginning this procedure. Table 1 Catch Tray / Organizer Parts Item

Description

Quantity

1

Organizer Support

2

Catch Tray Support

2 2

3

Catch Tray / Organizer Tray

2

4

Organizer Mounting Clip

4

5

Height Adjustment Bracket

2

6

Catch Tray Mounting Bracket

1

7

T20 x 8mm Screws

14

Organizer Mounting Clips (4)

Height Adjustment Bracket (2)

Catch Tray Mounting Bracket

Figure 1 Catch Tray and Organizer Tray Parts

General Procedures 6-39

GP 11

2.

(Figure 2): Install the two Organizer Mounting Clips to the inside of each Scanner column (four Clips total).

3.

(Figure 3): Install the Height Adjustment Bracket on the back of each Scanner column. Note the location of the two installation screws.

NOTE: Install only the lower screw on each Organizer Mounting Clip at this time.

1

2

Insert two mount screws through the Height Adjustment Bracket, and mount the bracket to the Scanner Column

Install only the lower two screws in the clips at this time

1 Place the two Clips on the inside of each Scanner column with the hooks facing upwards

NOTE: These two outer mount holes on the Scanner column are not used

NOTE: The lower set of screws are not used in this procedure

Figure 3 Installing the Height Adjustment Bracket on each Scanner Column

Figure 2 Installing the Two Organizer Mounting Clips on each Scanner Column

General Procedures

GP 11

6-40

4.

(Figure 4): Install an Organizer Support on each column of the Scanner.

5.

(Figure 5): Position the Organizer Tray on the Scanner frame as shown.

3 Press the Organizer Support into the Organizer Mounting Clips until it snaps into place

1 Set the Organizer Tray down on the Scanner frame with Document Extensions facing to the rear, and downward

2 Position the Organizer Support as shown on the Mounting Clips

Document Extensions

1 Remove the Eclips (both sides)

Rear of Scanner

Figure 4 Installing the Organizer Support Figure 5 Positioning the Organizer Tray

General Procedures 6-41

GP 11

6.

(Figure 6): Install the front side of the Organizer Tray on the Scanner.

2 Raise the Organizer Support and insert its front post into the tubular mount on Organizer Tray (both sides)

8.

(Figure 7): Mount the Catch Tray Mounting Bracket on the Scanner as shown. Insert and partially tighten the right side screw only.

1 Lift the front edge of the Organizer Tray off the Scanner frame

1

2

3

Set the Catch Tray Mounting Bracket on the shelf at the back of the Scanner

Ensure that the hooks face toward the Scanner

Insert and partially tighten right side mount screw

Figure 7 Mounting the Catch Tray Mounting Bracket on the Scanner

3

4

Reinstall the E-clips on the ends of the Organizer Supports

Install the two upper retaining screws on each Organizer Mounting Clip (on inward side of leg)

Figure 6 Installing the Front Side of the Organizer Tray 7.

Lift the rear edge of the Organizer Tray and allow it to rest on the rear arms of the Organizer Supports.

General Procedures

GP 11

6-42

9.

(Figure 8): Insert the lead edge of the Catch Tray into the Catch Tray Mount Bracket, and fasten the Mount Bracket to the Scanner frame.

10. (Figure 9): Insert the Catch Tray Supports into the Catch Tray (both sides).

1

1

2

Pick up the Catch Tray and position it over the Organizer Tray, facing in the same direction.

Place the Catch Tray into the Mount Bracket, making sure that the 3 hooks in the Mount Bracket are equidistantly spaced along the wires at the edge of the Catch Tray.

Insert the longer end of the Catch Tray Support into the mount on the Catch Tray

2 Insert the shorter end of the Catch Tray Support into the Height Adjustment Bracket

3 Place the left mount screw in position and tighten it down. Fully tighten the right mount screw.

Catch Tray

Figure 8 Mounting the Catch Tray to the Scanner Frame

Figure 9 Inserting the Catch Tray Supports 11. Return the Scanner to normal operation.

General Procedures 6-43

GP 11

GP 12 Compact Catch Bins WARNING Mounting Clips

Switch off the Scanner power and disconnect the power cord. 1.

Disconnect the power cord and the IEEE 1394 PMC cable from the Scanner.

2.

(Table 1) (Figure 1): Compare the items listed in the following table with the items present in the Compact Catch Bins Kit. Ensure that all items are present before beginning this procedure.

Bin Support Bracket

Screws

Rear Bin Mounting Bracket

Table 1 Catch Tray / Organizer Parts Item

Description

Quantity

1

Rear Bin Mounting Bracket

1

2

Lower Bin

1

3

Upper Bin

1

4

Rear Bin

1

5

Bin Support Bracket

2

6

Document Storage Flaps

2

7

T20 x 8mm Screws

14

8

Mounting Clips

8

Document Storage Flaps

Lower Bin

Upper Bin

Figure 1 Compact Catch Bins Parts

General Procedures

GP 12

6-44

Rear Bin

3.

4.

(Figure 2): Install the four Mounting Clips on the inside of each Scanner leg.

NOTE: In the following step, install only the lower mount screws on the Mounting Clips at this time.

1

2

Install the four Mounting Clips with the hooks facing upward

Install only the bottom screws in the Mounting Clips

(Figure 3): Install the Bin Support Bracket onto the back of each Scanner leg.

NOTE: At the present time only the top screw can be mounted through the Bin Support Bracket into the Scanner frame.

1

2

Place Mounting Bracket on back of Scanner leg with the slot at the top edge of the bracket

Mount the Support Bracket to the Scanner leg with one screw into the top of the bracket

Bin Support Bracket (2)

Figure 2 Installing the Mounting Clips Figure 3 Installing the Bin Support Brackets

General Procedures 6-45

GP 12

5.

(Figure 4): Install the Lower Bin onto the Scanner.

6.

(Figure 5): Install the Upper Bin onto the Scanner.

1

2

1

Set the Lower Bin down on the Scanner frame with the curved portion of the bin facing to the rear of the Scanner

Ensure that the squared portion of the Lower Bin is folded underneath the curved portion

Holding the Upper Bin as shown, guide it into position over the Lower Bin

2 Insert the “legs” of the Upper Bin into the upper Mounting Clips on the inside of each Scanner leg

hinges

Mounting Clips

Lower Bin Rear of Scanner Rear of Scanner

5

3

Install the top screw on each of the lower Mounting Clips

Lift each side of the Lower Bin frame and insert it into the lower set of Mounting Clips on the Scanner legs

3 Install the top screw on each of the four upper Mounting Clips

Mounting Clip

Figure 5 Installing the Upper Bin

4 Rear of Scanner Leg

Ensure that the pressed locator tabs are positioned forward of the Mounting Clips Figure 4 Installing the Lower Bin

General Procedures

GP 12

6-46

7.

(Figure 6): Standing at the back of the Scanner, lift and fasten the Lower Bin to the Bin Support Brackets.

8.

(Figure 7): When correctly installed, the shaft at the end of the Lower Bin will be seated in the Bin Support Brackets like this.

1 Lift the Lower Bin and engage the ends of the bin into the top slot of the Bin Support Brackets

Bin Support Brackets (2)

NOTE: Lower Bin overlaps the Upper Bin

Figure 7 Installation of Lower Bin into Bin Support Bracket

Figure 6 Fastening the Lower Bin to the Bin Support Brackets

General Procedures 6-47

GP 12

9.

(Figure 8): Install the Rear Bin Mounting Bracket.

10. (Figure 9): Mount the Rear Bin onto the Scanner.

1

2

1

Position the Rear Bin Mounting Bracket on the Scanner as shown, with the bracket hooks facing inward

Fasten a T20 screw through the Rear Bin Mounting Bracket into the Scanner frame

While holding on to the left end of the Rear Bin Mounting Bracket, guide the angled portion of the Rear Bin over the three hooks on that mounting bracket

Rear Bin

2 Fasten a T20 screw into the mount hole on the left side of the Rear Bin Mounting Bracket

Figure 8 Installing the Rear Bin Mounting Bracket

Figure 9 Mounting the Rear Bin onto the Scanner

General Procedures

GP 12

6-48

11. (Figure 10): Install the two Document Storage Flaps on the lower edge of the Rear Bin.

12. (Figure 11): Secure the Rear Bin to the Scanner Frame.

1

1

Guide the outward ends of the Rear Bin into the side slots on the Bin Support Bracket

Pull the Rear Bin outward slightly

2 Document Storage Flap

Bin Support Bracket

Figure 11 Securing the Rear Bin to the Scanner Frame

Hook the curved edge of the Document Storage Flap onto the lower edge of the Rear Bin (2 places)

13. Reconnect the power cord and the IEEE 1394 PMC cable to the Scanner. 14. Return the Scanner to normal operation.

Figure 10 Installing the Document Storage Flaps

General Procedures 6-49

GP 12

GP 13 Creating the System Speed and Lead Edge Detect Test Target

2.

The purpose of this procedure is to enable the technical representative to generate a test target that can be used in Document Drive Motor Speed and Lead Edge / Trail Edge adjustments for the Synergix Scan System.

NOTE: This procedure uses a laptop computer hookup to the Controller to generate the test target. You will need the following items for this procedure: • Laptop Computer equipped with an PCM CIA card • Crossover cable for connecting the laptop computer to the Controller User Interface on the IOT. 1.

TCP/IP Enable

•

TCP/IP IP Address

•

TCP/IP Subnet Mask

•

TCP/IP Default Gateway

3.

Power down the Synergix Scan System.

4.

Connect the laptop computer to the Controller with the Network Crossover Cable.

5.

Switch on the system power.

6.

Verify the Controller 10/100 network Link (green) LED is lit. If the Link LED is not lit, perform the following:

(

1. 1.): Use the Printer Control Panel to print out a Configuration Test Print. The information on this test print will be used to determine the network address of the Printer.

Examine the following TCP/IP settings contained within the Configuration Test Print: •

7.

a.

Switch off the Printer and Controller

b.

Reboot the laptop computer

c.

Switch on the Controller and Printer

Set the laptop computer to use the same TCP/IP parameters as the printer with the exception of the IP address. Use an appropriately unique IP address for the laptop computer.

NOTE: To examine the current values stored on the laptop computer, perform the following: a. Click the right mouse button on the Network Neighborhood icon b. Select Properties > Protocols > TCP/IP c. Select the Properties field. The current values stored on the laptop computer will be visible.

1 Note the following Printer settings on your test print

8.

After entering the appropriate changes, close out the Network Properties window.

9.

Start the web browser (Netscape 4.0 or Microsoft Internet Explorer 4.0 or higher) on the laptop computer.

10. In the Internet address window, enter the IP Address of the Controller (for example, 13.240.20.38) and press Enter. 11. When the Main Page of the Web PMT displays in the browser, click on Printer Defaults. 12. In the menu on the Printer Defaults page, click on Upload File. 13. Place the service CD in the laptop computer. 14. Use the Browse... button to access the service CD. 15. On the service CD select Scanner Diagnostics > Motor Speed Adjustment > Motor Speed.plt. 16. Select the file and click Open. 17. When the upgrade file displays in the Select The File To Upgrade window, click the upload button. 18. Observe the Web PMT Display for the message “File Uploaded Successfully”. 19. When the System Speed and Lead Edge Detect Test Target exits the Printer, cut along the solid black line to create a print master. Store this print (if possible) for future use.

Figure 1 Sample Printer Configuration Test Print

General Procedures

GP 13

6-50

GP 14 Scanner Diagnostic access using a laptop

[4] Write an NVM location [5] Display Usage Meters [6] Display Recent Fault Log [7] Display Fault History Log [8] clear Usage Meteers [9] Clear Recent Fault Logs [10] Clear Fault History Log [11] Reset NVM to defaults [D] Diagnostic Menu [?] Help

Use the following procedure if scanner diagnostics are unavailable due to a malfunction of the user interface panel.

Prerequisites The following equipment is required to perform this procedure: • •

Standard laptop PC running Windows 95/98/NT or 2000 Standard 9-pin ‘D’ null-modem cable, female at both ends

Procedure 1.

Perform REP 4.2 Electronics Drawer, steps 1-5 to access the scanner main PWB in the electronics drawer.

2.

Plug the null-modem connector into J409 on the scanner main control board.

3. 4.

Plug the other end of the null-modem cable into the laptop serial connector. Power on the laptop and access the Hyperterminal tool.

5.

Configure Hyperterminal as follows:

6.

•

Connect using: COM1 or COM2 (depending on the serial connector you chose to plug the null-modem cable into)

•

Bits per second: 9600

• •

Data Bits: 8 Parity: None

•

Stop Bits: 1

NOTE: When resetting NVM values to the default values, all fault logs, usage meters, and machine set-ups (such as lead edge registration, lamp-life, etc) will be reset to default values. Feature keys should be left intact. On an XEScan Solution system, restore the meter counts to the last recorded value to enable proper meter count feedback for the system.

• Flow Control: None Power on the scanner. When the LED on the rear of the scanner displays “P”, the HyperTerminal window should display:

INTERCEPTOR APPLICATION FIRMWARE VERSION ?.?.? RELEASE DATE: MM DD, YYYY COMPILE DATE AND TIME: MM DD, YYYY HH:MM:SS SYNERGIX SCANNER DIAGNOSTICS MAIN MENU [E] Enter Diagnostics [?] Help 7.

Type a capital E to enter the diagnostics menu. The following menu options will appear

[2] [3] [4] [5] [6] [7] [8] [M] [?]

NVM settings Scan functions Lamp Functions Document Advance Functions Image Processing Functions Calzone Rotation Functions Feature Key Menu Main Menu Help

8.

Type 2 to enter the NVM settings menu. The following menu options will apear:

[1] Validate NVM [2] dump NVM contents [3] Read NVM locations General Procedures 6-51

GP 14

General Procedures

GP 14

6-52

Special Tools The following special tools are required to service the Synergix scanner Table 1 Tool

Part Number

Torx Wrench

600T41300

Loopback Cable Kit

600K89460

General Procedures 6-53

Special Tools

General Procedures

Special Tools

6-54

Change Tag/ Mod Index

Classification Codes

All important modifications are identified by a Tag/ MOD number on a matrix label attached to each Scanner inside the Top Cover.

A Tag/ MOD number may be required to identify differences between parts that cannot be interchanged, or differences in diagnostic, the repairs, installation, or adjustment procedures. A Tag/ MOD number may also be required to identify the presence of optional hardware, firmware, or if mandatory modifications have been installed. Each Tag/ MOD number is given a classification code to identify the type of a change the Tag/ MOD has made. M− Mandatory N− Not installed in the field O− Optional R− Repair S− Situational

TAG:

None

CLASS:

R

USE:

All

MFG SERIAL NUMBERS:

Tag Matrix

NAME:

USO: All EO: All

xxxx xxxxx xxxx xxxx

PURPOSE: KIT NUMBER:

xxxx xxxxx xxx xxxx xxxx x xxxxxxxxxx

REFERENCE: Figure 1 Location of the Change Tag/MOD Matrix This section describes all the tags as well as multinational applicability, classification codes, and permanent or temporary modification information.

General Procedures 6-55

Change Tag/ Mod Index

General Procedures

Change Tag/ Mod Index

6-56

7 Wiring Data BSD 1.0 Level 1 Interconnection.................................................................................... BSD 1.1 ACH Main Power On ........................................................................................ BSD 1.2 DC Power Generation (50 and 60 HZ) ............................................................. BSD 1.3 (+12 VDC) Power Distribution........................................................................... BSD 1.4 (+5 VDC Standby / +5.25 VDC) Power Distribution.......................................... BSD 1.5 (+5 VDC / +3.3 VDC) Power Distribution .......................................................... BSD 2.1 User Interface ................................................................................................... BSD 4.1 Document Scan and Rescan Drive................................................................... BSD 6.1 Document Illumination ...................................................................................... BSD 6.2 Image Capture .................................................................................................. BSD 6.3 Image Calibration Control ................................................................................. BSD 6.4 Thick Document / Document Width Sensing .................................................... BSD 14.1 Communications .............................................................................................

7-3 7-5 7-6 7-8 7-9 7-10 7-11 7-12 7-14 7-16 7-18 7-20 7-22

Wiring Data 7-1

Wiring Data 7-2

BSD 1.0 Level 1 Interconnection

Figure 1 Level 1 Interconnection

Wiring Data 7-3

BSD 1.0

PAGE INTENTIONALLY BLANK

Figure 2 Level 1 Interconnection

Wiring Data

BSD 1.0

7-4

BSD 1.1 ACH Main Power On

Figure 1 ACH Main Power On

Wiring Data 7-5

BSD 1.1

BSD 1.2 DC Power Generation (50 and 60 HZ)

Figure 1 DC Power Generation

Wiring Data

BSD 1.2

7-6

Figure 2 DC Power Generation

Wiring Data 7-7

BSD 1.2

BSD 1.3 (+12 VDC) Power Distribution

Figure 1 (+12 VDC) Power Distribution

Wiring Data

BSD 1.3

7-8

BSD 1.4 (+5 VDC Standby / +5.25 VDC) Power Distribution

Figure 1 (+5 VDC Standby / +5.25 VDC) Power Distribution

Wiring Data 7-9

BSD 1.4

BSD 1.5 (+5 VDC / +3.3 VDC) Power Distribution

Figure 1 (+5 VDC / +3.3 VDC) Power Distribution

Wiring Data

BSD 1.5

7-10

BSD 2.1 User Interface

Figure 1 User Interface

Wiring Data 7-11

BSD 2.1

BSD 4.1 Document Scan and Rescan Drive

Figure 1 Document Scan and Rescan Drive

Wiring Data

BSD 4.1

7-12

Figure 2 Document Scan and Rescan Drive

Wiring Data 7-13

BSD 4.1

BSD 6.1 Document Illumination

PAGE INTENTIONALLY BLANK

Figure 1 Document Illumination

Wiring Data

BSD 6.1

7-14

Figure 2 Document Illumination

Wiring Data 7-15

BSD 6.1

BSD 6.2 Image Capture

Figure 1 Image Capture

Wiring Data

BSD 6.2

7-16

Figure 2 Image Capture

Wiring Data 7-17

BSD 6.2

BSD 6.3 Image Calibration Control

Figure 1 Image Calibration Control

Wiring Data

BSD 6.3

7-18

Figure 2 Image Calibration Control

Wiring Data 7-19

BSD 6.3

BSD 6.4 Thick Document / Document Width Sensing

Figure 1 Thick Document / Document Width Sensing

Wiring Data

BSD 6.4

7-20

Figure 2 Thick Document / Document Width Sensing

Wiring Data 7-21

BSD 6.4

BSD 14.1 Communications

Figure 1 Communications

Wiring Data

BSD 14.1

7-22