Synergix WF Scan System Service Manual

Transmittal Page
Product
Title
Part Number
Wide Format
Scan System
Service Manual
701P49155
Status
Date
Re-issue
Change Highlights
Updated BSDs.
Updated Parts Lists.
October 2008
THE DOCUMENT COMPANY

XEROX
Wide Format
Scan System
Service Manual
CAUTION
Certain components in the Scan System are susceptible to damage from electrostatic discharge.
Observe all ESD procedures to avoid component
damage.
701P49155
October 2008
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
Global Knowledge & Language Services
800 Phillips Road
Bldg. 218-01A
Webster, New York 14580-9791
USA
2008 XEROX CORPORATION. All rights reserved.
Xerox, AccXES, and The Document Company
are registered trademarks of Xerox Corporation.
Xerox product names mentioned in this publication are trademarks of the
XEROX CORPORATION.
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
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i
Wide Format Scan System
Introduction
Introduction
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ii
Re-issue
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:
This manual contains Service Call Procedures, Diagnostic Procedures, Status Indicator Repair
Analysis Procedures, Repair and Adjustment Procedures, Parts Lists and General Procedures
or Information.
This information will help a Service Representative repair and maintain this device.
Section 1. Service Call Procedures

This section contains the following information:
Call Flow Procedure
The Call Flow Procedure is a list of the procedures to follow on each service call.
Initial Actions / Systems Checks
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.
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iii
Introduction
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
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iv
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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.
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v
Introduction
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
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Reference Symbology
(Figure 1): The following symbols are used in this document:
Figure 1 Reference Symbology (1 of 2)
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vii
Introduction
(Figure 2): Reference Symbology, contd.
Figure 2 Refrerence Symbology (2 of 2)
Introduction
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1 Service Call Procedures

Introduction .....................................................................................................................
Call Flow Procedure........................................................................................................
Scanner Fault Code Entry Chart .....................................................................................
Scanner Other Faults Entry Chart ...................................................................................
Maintenance Procedures ................................................................................................
Call Back .........................................................................................................................
Final Action .....................................................................................................................
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1-4
1-4
1-13
1-14
1-14
1-15
10/2008
1-1
Service Call Procedures
10/2008
1-2
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Introduction
The WIDE FORMAT SCAN 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.
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.
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 SCAN SYSTEM
Service Manual and are the entry level for all service calls.
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.
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 SCAN SYSTEM service
manual or direct you to other service manuals to continue identify and repair the problem.
In the case of a standalone host computer / SCAN SYSTEM configuration, the CSE must isolate the fault to the SCAN SYSTEM Scanner and then go to Section 1 in the SCAN SYSTEM
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.
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).
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1-3
Introduction
Call Flow Procedure
Scanner Fault Code Entry Chart
Procedure
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.
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.
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
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)).
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 allow thepower on sequence to complete before switching on
the Controller only after the POST code display stops advancing or after P is displayed; otherwise, the expected codes may not be displayed.
(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 segments lit
Scanner Main PWB boot fault
POST no segments lit
1. Power supply fault: 5.0 volts or 3.3

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
COMPONENT
DESIGNATOR
U10
U10, Main PWB
CLEARANCE PROCEDURE
IF THE PROBLEM STILL EXISTS
Check that U10 is correctly seated.
Replace the Scanner Main PWB (REP

3.1 Main PWB).
1. Perform a power off/power on cycle.
1. Troubleshoot the Power Supply PS1

and cables. Go to GP 5 Generic PWB
Checkout, Section 6.
2. Replace the Scanner Main PWB
(REP 3.1 Main PWB)
BSD REF
PL REF
PL 1.4
Electrical
Module
BSD 1.4 (+5

VDC Standby
/ +5.25 VDC)
Power Distribution,
BSD 1.5 (+5
VDC / +3.3
VDC) Power
Distribution
PL 1.4
Electrical
Module
PL 1.4
Electrical
Module
Perform a power off/power on cycle.

Check that U10 on the Main PWB is cor- 3.1 Main PWB).
rectly seated.+
PL 1.4
Electrical
Module
Check that integrated circuit U10 is correctly seated.

3.1 Main PWB).
PL 1.4
Electrical
Module

3.1 Main PWB).
PL 1.4
Electrical
Module
Call Flow Procedure, Scanner Fault Code Entry Chart
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1-4
Re-issue

FAULT CODE
DISPLAYED
FAULT DESCRIPTION
POST 3
Scanner Main PWB - IEEE-1394 communications fault
POST 4
COMPONENT
DESIGNATOR
BSD REF
PL REF
Check that the IEEE 1394 communica- Replace the Scanner Main PWB (REP
tions cable to the Controller is not
3.1 Main PWB).
inserted reversed. Perform a power off/
power on cycle.
PL 1.4
Electrical
Module
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.

3.1 Main PWB).
PL 1.4
Electrical
Module
POST 5
The Checksum in the Non Volatile RAM U28

(NVR) is invalid -- Scanner Main PWB
Reset the NVR to default settings using

the diagnostic (Reset NVR Defaults).
Then, if possible, perform ADJ 6.1
Exposure Lamp Initialization, ADJ 8.2
Lead Edge / Trail Edge Adjustment and
ADJ 4.1 Document Drive Motor Speed.
If not possible, 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 (REP 3.1 Main
PWB).
Then perform the clearance procedure
again.
PL 1.4
Electrical
Module
POST 6
Video code checksum invalid -- Scanner Main PWB

1. Partial download of Scanner firmware.
2. Scanner Main PWB failed.
Upload the current firmware to the

Scanner again.

3.1 Main PWB).
PL 1.4
Electrical
Module
POST 7
24 VDC Power Supply - no output
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.
PL 1.4
Electrical
Module
POST 8
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.
1.
Image Processor PWB not seated.
2.
Malfunction in Image Processor

PWB.
3.
Main PWB internal fault.
POST B
Re-issue
U18
CLEARANCE PROCEDURE
PL 1.2A
Upper Document
Transport
(Part 1 of 2)
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.
Replace the Main PWB [REP 3.1 Main

PWB].
Perform a System Power Up Cycle GP

8 System Power Up Procedure
1.
Remove and reseat the Image

Processor PWB.
2.
Replace the Image Processor

PWB.
3.
Replace the Main PWB [REP 3.1

Main PWB].
10/2008
1-5
Replace the Image Module [REP 9.2

Image Module].
PL 1.3A
Image Module and
Document
Feed Rollers (Part 1
of 2)
PL 1.4
Electrical
Module

FAULT CODE
DISPLAYED
POST C
POST D
FAULT DESCRIPTION
1.
Image Processor PWB not seated.
2.
Image Processor PWB - internal

fault.
3.
Main PWB internal fault.
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
Perform a System Power Up Cycle GP
8 System Power Up Procedure.

1.
Remove and reseat the Image

Processor PWB.
2.
Replace the Image Processor

PWB.
3.

Main PWB].
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.

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
3.1 Main PWB].
ner Control Panel.
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.
PL 1.4
Electrical
Module
PL 1.3A
Image Module and
Document
of 2)
BSD 2.1 User PL 1.4

Interface
Electrical
Module
PL 1.4
Electrical
Module
PL 1.4
Electrical
Module
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]
00 - 01
Normal power up routine. This is not a

fault. Appears in fault log only.
PL REF
1. Send the update again. If not sucBSD 14.1

cessful, replace the Scanner Main PWB Communications
[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
BSD REF
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1-6
Check for a fault in the Controller.

Replace the Scanner Main PWB [REP
3.1 Main PWB].
BSD 14.1
Communications
Re-issue

FAULT CODE
DISPLAYED
FAULT DESCRIPTION
COMPONENT
DESIGNATOR
CLEARANCE PROCEDURE
BSD REF
PL REF
A1 - 00
MEDIA JAM
Paper jam at Edge Present Sensor.
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].
Enter diagnostic mode; perform the

Sensors Input test to check operation.
Clean Sensor Q4. Check the wires.
Replace Sensor Q4.
BSD 4.1 Document Scan

and Rescan
Drive
PL 1.2A
Upper Document
Transport
(Part 1 of 2)
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].

Replace Sensor Q3.

and Rescan
Drive
PL 1.2A
Upper Document
Transport
(Part 1 of 2)
A1 - 02
MEDIA JAM
Paper jam at Exit Sensor.
Q2
Remove document; check that the feed Enter diagnostic mode; perform the
path is clear.
Replace Sensor Q2.

and Rescan
Drive
PL 1.2A
Upper Document
Transport
(Part 1 of 2)
A1 - 04
Calibration Extrusion failed to sense

home position.
Q1
Switch off the System. Switch on the

system.

Synergix Scanner Sensors input test
test to check operation. Clean Sensor
Q1. Check the wiring. Replace Sensor
Q1.
BSD 6.3
Image Calibration Control
PL 1.2B
Upper Document
Transport
(Part 2 of 2)
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

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.
BSD 6.3
PL 1.2B
Upper Document
Transport
(Part 2 of 2)
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
Thick Document / Document Width
Sensing
PL 1.1
Scanner
Module
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10/2008
1-7

FAULT CODE
DISPLAYED
FAULT DESCRIPTION
COMPONENT
DESIGNATOR
CLEARANCE PROCEDURE
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.)
Q11
Clean Illumination Sensor Q11.

If the Lamp Sensor Q11 was removed
or adjusted, perform ADJ 6.1 Exposure
Lamp Initialization.
LL - 11
Lamp, Q11
Exposure Lamp Failure - lamp is

too dark.
NOTE: when the Lamp has less

than 70% of brightness when new.
Illumination Sensor connected to

the Interlock connector.
LL - 12
Exposure Lamp Failure - Illumination

Sensor Q11 failed.
LL - 30
[fault log only]
LL - 31
BSD REF
PL REF
Go to the Scanner Diagnostics. PerBSD 6.1 Docform the Lamp test. Observe the Illumi- ument Illumination Sensor value. It should be
nation
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].
PL 1.3A
Image Module and
Document
of 2)
Clean Illumination Sensor Q11.

Enter the diagnostic mode and perform BSD 6.1 DocConnect the Ilumination Connec- the Lamp test. The SENSOR value var- ument Illumination
tor to P/J 403, Red at pin 3; Yellow ies from 0 (dark) - 256 (extremely
bright). If the Lamp is lit, but the SENat pin 4.
SOR value is zero or nearly so, troubleshoot the sensor and sensor wiring. If
these are correct, replace the Lamp
[REP 6.4 Exposure Lampp]. If the
problem still exists,
Replace the Scanner Main PWB REP
3.1 Main PWB].
PL 1.3A
Image Module and
Document
of 2)
Check that the Lamp is lit.
Enter the diagnostic mode and perform BSD 6.1 Docthe Lamp test. The SENSOR value var- ument Illumiies from 0 (dark) - 256 (bright). If the
nation
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].
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.
BSD 4.1 Doc- PL 1.4

ument Scan Electrical
and Rescan Module
Drive
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.
BSD 4.1 Doc- PL 1.4

and Rescan Module
Drive
Q11
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1-8
PL 1.3A
Image Module and
Document
of 2)
Re-issue

FAULT CODE
DISPLAYED
FAULT DESCRIPTION
COMPONENT
DESIGNATOR
CLEARANCE PROCEDURE
BSD REF
PL REF
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

Document Drive Motor test. Check that
all the tests are successful. If not, troubleshoot the Calibration Motor circuits
and the Motor Control PWB A3.
BSD 4.1 Doc- PL 1.4

and Rescan Module
Drive
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.
BSD 6.3
PL 1.4
Electrical
Module
LL - 34
Motor Driver Failure - Calibration Extru- MOT2, Motor Con- Check that Calibration Extrusion can be
manually rotated. If not, repair the
sion overcurrent.
trol PWB
cause.
Perform GP 8 System Power Up Procedure.
Go to BSD 6.3 and troubleshoot the DC

Drive circuit from A3P 308.
Check Motor M2 (Calibration Motor) for
open circuits or short circuits.
BSD 6.3
PL 1.2B
Upper Document
Transport
(Part 2 of 2)
LL - 39
Motor Driver Failure -Simultaneous

write.
LL - 40
Calibration Failure - Set integration time

failure. (uniformly darker image)
NOTE: LL-40 displayed only momentarily on Scanner Control Panel.
LL - 41
Dark Calibration Failure -Range adjust

failure on Channel 1. (Lighter streaking
in process direction)
LL - 42
Dark Calibration Failure - Range adjust

Re-issue
BSD 6.3
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 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. PerBSD 6.2

form the Scan Bar Calibration Test. If Image Capture
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.
PL 1.4
Electrical
Module
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].
PL 1.4
Electrical
Module
10/2008
1-9
BSD 6.2
Image Capture

FAULT CODE
DISPLAYED
LL - 43
FAULT DESCRIPTION
COMPONENT
DESIGNATOR
Dark Calibration Failure -Range adjust

CLEARANCE PROCEDURE
BSD REF
PL REF

a cable, or the Image Module, has a
BSD 6.2
Image Capture
PL 1.4
Electrical
Module
LL - 44
Dark Calibration Failure - Offset adjust SelfFoc Lens

failure on Channel 1. (Lighter streaking Platen Glass
Target Calibration
Strip
Old Lamp
Clean these parts. Perform GP 8 System Power Up Procedure.

a cable, or the Image Moduler, has a
Main PWB [REP 3.1 Main PWB.
BSD 6.2
Image Capture
PL 1.4
Electrical
Module
LL - 45

Target Calibration
Strip

BSD 6.2
Image Capture
PL 1.4
Electrical
Module
LL - 46

Target Calibration
Strip

BSD 6.2
Image Capture
PL 1.4
Electrical
Module
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 BSD 6.2

the Full System Test. Troubleshoot any Image Capfailures. Do the Scan Bar Calibration
ture
Test. Troubleshoot any failures. If the
replace the Scanner Main PWB [REP
3.1 Main PWB]. If the problem still
exists, replace the Image Module [REP
9.2 Image Module].
PL 1.4
Electrical
Module
10/2008
1-10
PL 1.3A
Image Module and
Document
of 2)
Re-issue

FAULT CODE
DISPLAYED
LL - 48
FAULT DESCRIPTION
COMPONENT
DESIGNATOR

(Dark streaks).
LL - 49

(Dark streaks).
CLEARANCE PROCEDURE
BSD REF

the Selfoc Lens, and the Platen Glass
the target strip.

ture
9.2 Image Module].
PL 1.4
Electrical
Module

the Selfoc Lens, and the Platen Glass
the target strip.
Replace the Lamp [REP 6.4 Exposure
Lamp], particularly if the lamp has discoloration at the ends.

ture
REP 9.2 Image Module].
PL 1.4
Electrical
Module
Thick document sensor actuated intermittently. Check that the Thick Document Lever is firmly down.
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.
LL - 82
Miscellaneous Failure -Scan engine

task event time out.
Check IEEE 1394 communications

cable. If disconnected, reconnect. Perform GP 8 System Power Up Procedure.
LL - 83
Image processing error.
Image Processing
PWB
Scan the document again.
Switch off the system. Reseat the

BSD 6.2
Image Processor PWB. Perform GP 8 Image CapSystem Power Up Procedure. Scan the ture
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.
Re-issue
PL REF
10/2008
1-11
PL 1.3A
Image Module and
Document
of 2)
PL 1.3A
Image Module and
Document
of 2)
BSD 1.2 DC
Power Generation (50 and
60 HZ)
PL 1.4
Electrical
Module

FAULT CODE
DISPLAYED
FAULT DESCRIPTION
COMPONENT
DESIGNATOR
CLEARANCE PROCEDURE
BSD REF
LL - 92
Cable fault, Main

PWB, Image Bar
Assembly
Go RAP LL91, LL92, LL93.
BSD 6.2
Image Capture
LL - 93
Cable fault, Main

PWB, Image Bar
Assembly
Go to RAP LL91, LL92, LL93.
BSD 6.2
Image Capture
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
LL - 95
POST Failure - Video POST failure.
Main PWB
Hardware fault. Replace the Main

PWB.
BSD 6.2
Image Capture
LL - 96
POST Failure - Motor Driver POST

failed.
Go to RAP LL96.
BSD 1.2 DC
Power Generation (50 and
60 HZ)
BSD 6.1 Document Illumination
10/2008
1-12
PL REF
PL 1.4
Electrical
Module
PL 1.4
Electrical
Module
Re-issue
Scanner Other Faults Entry Chart
The table below includs faults that may occur with out generating fault codes or messages.
Review the table Problem descriptions to locate a fault that possibly fits the problem being
checked out.
Table 1 OtherFaults Entry Chart
Problem Description
Cause
Solution
Firmware Upgrade does not appear to fix problem
When the firmware is downloaded to the scanner, the scanner does a soft reboot at the end;and comes back to READY.
A test sheet is printed indicating Scanner Frimware: Successful. However, the FPGA (Fully Programmable Gate Array) will
not have been reprogrammed and any changes to the operation will not be enabled until the Scanner is powered off then
on.
After the firmware download is complete, wait until the Scanner returns to READY then perform GP 8 System Power Up
Procedure ensuring the the P. is displayed.
CAUTION
Corrupted NVM
Reset NVR defaults and perform other adjustments. Generally on all Scanners that fail the Scanner diagnostics cannot
be accessed. Therefore, repair can only be accomplished by
two methods:
POST 5 and 6 Error Codes after replacing the Boot ROM or

Main PWB
Do not switch the Scanner off then on until it has finished the
download. Swithing power off then on will damage the system
1.
2.
Replace the U28 NVM chip (PL 1.4 Electrical Module),

(REP 3.1 Main PWB). Ensure the the Pin 1 orientation is
correct when installing U28. Replacing U28 will allow
Scanner diagnostics to be accessed. If not, proceed to
Step 2. Perform the Following:
a.
ADJ 6.1 Exposure Lamp Initialization
b.
ADJ 8.2 Lead Edge / Trail Edge Adjustment
c.
ADJ 4.1 Document Drive Motor Speed
GP 14 Scanner Diagnostic access using a laptop. Enter

the diagnostics (upper case E). Then access the NVM
settings (2) and Reset NVM to defaults (11). This resets
all NVM for the current download. All fault logs, usage
meters and machine setup will be erased. Feature Keys
should be intact.
Power of the Scanner and disconnect the laptop. Switch
on the Scanner and allow the start up sequence to complete. Access the Scanner diagnostics and perform the
following:
a.
b.
c.
Scanner Product Code PKU only: Cannot select PRODUCTIVITY MODE
AccXES firmware is not at version 9.5 or higher
Install the current version of firmware 9.5 or higher.
Discrete width sensor component failure.
Refer to IQ 2 Discrete Document Width Sensors and

troubleshoot the discrete width sensor components.
Scanner Product Code PKU only: Frequent Width Detection Failures
Discrete width sensor component failure.
Refer to IQ 2 Discrete Document Width Sensors and troubleshoot the discrete width sensor components.
50000020 Update Scanner Software message is displayedwhen attempting a Line Mode scan.
Scan System firmware is not at version 3.0.9 or higher.
Install frimware 3.0.9 or most current higher version.
Re-issue
10/2008
1-13
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.
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. Calibrate Document Registration.
Check the document registration and adjust if
necessary.
Maintenance Procedures, Call Back
10/2008
1-14
Re-issue
Final Action
1.
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.
2.
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.
Re-issue
10/2008
1-15
Final Action
Final Action
10/2008
1-16
Re-issue
2 Status Indicator RAPS

RAP 1.1 DC Power .........................................................................................................
RAP LL91, LL92, LL93....................................................................................................
RAP LL96........................................................................................................................
RAP OF-1 Document Transportation ..............................................................................
Re-issue
2-3
2-5
2-6
2-8
10/2008
2-1
Status Indicator RAPS
10/2008
2-2
Re-issue
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.
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
+5 VDC Standby is always available.
Procedure
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 [PL 1.4].
Troubleshoot the distribution of the +5 VDC standby signal, using the BSDs.
The voltages are present and correct.

Y
N
Replace Power Supply PS1 [PL 1.4].
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 [PL 1.4].
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 [PL 1.4].

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 [PL 1.4].
Table 2
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
+23 to +25
+23 to +25
The voltages are correct.

Y
N
Replace Power Supply PS-1 [PL 1.4].
A
Re-issue
B
10/2008
2-3
C
RAP 1.1 DC Power
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 (REP 3.1 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 Module Assembly (REP 9.2 Image Module).
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
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.
The DC Power generation circuits are operating correctly.
RAP 1.1 DC Power
10/2008
2-4
Re-issue
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) (REP 3.1 Main PWB).
Replace the Lamp Ballast PWB (A5) (PL 1.4).
Go to the BSD 1.2 DC Power Generation (50 and 60 HZ). Check that DC voltages are present.
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 Image Capture 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 cables connector on the Main PWB. Connect the second cable to
the first cables 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 (PL 1.1). If the problem still exists,
replace the Image Module Assembly (PL 1.1).
Re-issue
10/2008
2-5
RAP LL91, LL92, LL93
RAP LL96
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 DC Power Generation
(50 and 60 HZ), 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 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.
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
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(PL 1.3A).
Exposure 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
Go to BSD 6.1 Document Illumination and check the wires to Illumination

Sensor Q11. The wires and connectors have continuity.
Y
N
Repair the wires.

Enter the diagnostics and go to the Scan Bar Calibration Test . Operate the test.
The Calibration Extrusion rotates.
Y
N
Replace Sensor Q11 (PL 1.3A). Then perform ADJ 6.1 Exposure Lamp
Initialization.
Enter the diagnostics, Component Tests, [Full System Test] test. Operate the
test. The test runs to completion.
Y
N
Replace the Main PWB A1 (PL 1.4).
Replace Lamp Ballast PWB A3 (PL 1.4).
Examine LED CR1 (24V) on the Motor Control PWB A3.

The LED is on.
A
RAP LL96
A
10/2008
2-6
D
Re-issue
D
Switch off the System. Perform the GP 8 System Power Up Procedure. Go to
BSD 6.3 Image Calibration Control 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. 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 Image Calibration Control 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 1.3A). Perform ADJ 6.1 Exposure Lamp
Initialization.
Replace the Main PWB A1 (PL 1.4).
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].
Re-issue
10/2008
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.

and Rescan Drive
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.

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.
2.
Platen Roll is dirty.
Frequent auto width detection failures
3.
Document is accepted when inserted, but

doesnt stage properly. MEDIA JAM is displayed.
RAP OF-1
Discrete width sensors components

not funtioning, if present
1.
Edge Registered Sensor Q3
2.
Stray light is causing erratic sensor

activation.
2.
Clean the Platen Roll, using a lint-free cloth and Film Remover.
3.
Check the Document Feed-in Shelf for the presents of 10 sensor

holes. If the holes are present, go to IQ 2 Discrete Document
Width Sensors to troubleshoot the problem.
1.

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.
2.
Position the Scanner to avoid light shining on the Feed-in Shelf or

block the light from reaching the Feed-in Shelf
10/2008
2-8
1.
BSD 6.4 Thick Document / Document

Width Sensing
2.
BSD 6.3 Image Calibration Control (N4)
3.
BSD 6.5 Feed-in

Shelf With Discrete
Width Sensors

and Rescan Drive (R1)
Re-issue
Table 1
Problem
Probable Cause
Corrective Action
BSD Reference
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.

and Rescan Drive (T5)
Document Feed Problems
Stray light is affecting the activation of the

sensors (generally the Rear Sensor)
Position the Scanner away from the stray light or block the path of the
light to keep it from shining on the Feed-in Shelf.
Re-issue
10/2008
2-9
RAP OF-1
RAP OF-1
10/2008
2-10
Re-issue
3 Image Quality RAPS

IQ-1 Image Quality RAP..................................................................................................
IQ 2 Discrete Document Width Sensors .........................................................................
Re-issue
3-3
3-5
10/2008
3-1
Image Quality RAPS
Image Quality RAPS
10/2008
3-2
Re-issue
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
Problem
Probable Cause
Corrective Action
Lines on copies in process direction.
Chipped or worn Platen Glass
Replace the Platen Glass (PL 1.1).
Compressed zones in image, per- 1.

pendicular to process direction
2.
Dirt on Document Drive Rolls.
1.
If thick document, Document Thickness

Lever and associated mechanism
2.
BSD Reference
Clean the rolls with Film Remover 8R27.

BSD 4.1 Document
Ensure that the customer uses the minimum adjustment of the Doc- Scan and Rescan
Drive
ument Thickness Lever to scan thick documents without drag.
BSD 6.4 Thick
Document / Document Width Sensing
White/light streaks, process direc- Dirty Calibration Target Strip

tion
Clean the Calibration Target Strip using Film Remover 8R27. Perform a
power off - power on cycle GP 8 System Power Up Procedure.
BSD 6.3 Image

Calibration Control
Skewed image
1. Dirt on Document Drive Rolls.
1. Clean the rolls with Film Remover 8R27.
BSD 4.1 Document

Scan and Rescan
Drive
Image out of focus
Interference with complete closure of the Upper

Document Transport.
1.
2.
Ensure that the Platen Roll in the Upper Document Transport moves BSD 4.1 Document
up and down freely.
Scan and Rescan
Ensure that the plastic clamps that hold down the Platen Glass are Drive
correctly seated.
Discrete Width Sensors Only

Document width sensors not functioning.
(Product Code PKU)
Image is clipped or on wrong

size media.
1.
Check that the serial number begins with PKU.
2.
Open the Upper Document Transport and look for 10 holes in the
Document Feed-in Shelf
3.
Press the Menu button and use the Next/Previous buttons to scroll
to CONFIGURATION > SCANNER CONTROL > MODE and check
that the PRODUCTIVITY mode selection is available and set to the
correct media series for the copy job.
4.
If the holes are present and the PRODUCTIVIY mode is not available, refer to IQ 2 Discrete Document Width Sensors. If not, refer to
Section 3 of the appropriate Printer Service manual to continue
troubleshooting this problem.
User is prompted to enter

document width
Partial Image
Re-issue
Faulty Image Processing PWB
BSD 6.5 Feed-in

Shelf With Discrete
Width Sensors
Ensure that Firmware version 3.01.09 is installed. This firmware version

will not correct the problem on Scanners with the Turbo III key.
Install new Image Processing PWB W/TAG 7 (PL 1.4)
10/2008
3-3
Image Quality RAPS
IQ-1
Table 1
Problem
Probable Cause
Corrective Action
Black or Blank Image

Ghost Image

Large fonts have a halo around

them when copying milky white
film documents
The Bitonal feature may be set to off.
1.
Check that the Scanner firmware is at 3.1.12 or higher. If not

upgrade the firmware.
2.
AccXES firmware version 9.0: Select Scan Mode, Press Mode

Line button, In the Scan Options menu select Binarization.
BSD Reference
AccXES firmware version 9.1 or higher: Select Scan Mode,

Press Mode Line button , Select Bitonal.
Image Quality RAPS
IQ-1
10/2008
3-4
Re-issue
IQ 2 Discrete Document Width Sensors

This RAP is used to troubleshoot image quality problems on Scan Systems (Product Code
PKU) that have the discrete width sensors built into the Document Feed-in shelf (Figure 1). The
image is clipped, the document is printed on larger than required media, or the Width Detection
Failure message is displayed frequently when inserting a document.
Initial Actions
1.
Check that the Feed-in Shelf has the 10 sensor holes. If present, continue in this RAP If
the 10 holes are not present, refer to the appropriate Printer service manual, Section 3 to
troubleshoot the problem.
2.
Ensure that the Operator is centering the document on the Feed-in Shelf and not trying to
center it on the sensors. The sensors are not located symetrcally about the center of the
Feed-in Shelf.
3.
Press the Menu button on the Scan System control panel and use the Next/Previous buttons to scroll to CONFIGURATION > SCANNER CONTROL > MODE and check that the
PRODUCTIVITY mode selection is available and the correct media series is selected for
the copy job. The acceptable media series are: ANSI, ARCH, ISO A, ISO B, JIS B, and
CUSTOM.
4.
Ensure that the correct media roll widths are loaded into the Printer. Press the Media button on the Printer control panel and check that the correct media widths are entered.
5.
Make a copy of a Printer internal test pattern. If the image is good, continue in this RAP. If
not, refer to the appropriate Printer service manual to continue troubleshooting the problem.
6.
At the Scan System, enter the Diagnostic mode, Component Test and run the WIDE
FORMAT SCAN SYSTEM Sensors test to check the Width Sensors.
B
Check that the all the System Modules (Scanner, Printer, Controller) are set to the same
media width and type. Check that the document width is the correct width for the Productivity mode being used.
Press the Menu button and scroll to CONFIGURATION>SCANNER CONTROL> MODE and
set the MODE to AUTOWIDTH/AUTOCENTER. Have the operator run the copy job again. The
problem still exists.
Y
N
Replace the Sensor PWB. If the problem is not corrected, replace the Main PWB (PL 1.4).
Check that the all the System Modules (Scanner, Printer, Controller) are set to the same media
width and type. Check that the document width is the correct width for the PRODUCTIVITY
mode being used.
OVERSIZE DOCUMENT
LEFT SIDE SENSOR
DOCUMENT
FEED-IN
SHELF
OVERSIZE DOCUMENT
RIGHT SIDE SENSOR
Procedure
The width sensors are working correctly.
Y
N
More than one sensor is faulty.
Y
N
Replace the faulty sensor.
DOCUMENT WIDTH
SENSORS (4) RIGHT
DOCUMENT WIDTH
SENSORS (4) LEFT
SENSOR PWB
Refer to BSD 6.5 Feed-in Shelf With Discrete Width Sensors and check for +5 VDC at the
sensors. There is +5 VDC at the Sensors.
Y
N
There is +5VDC at Pin 5 of PJ 2
Y
N
Check the connector and wiring between the Sensor PWB and connector
A1J1-HD. If the wiring and connection are good replace the Low Voltage PS
(PL 1.4).
Figure 1 Feed-in Shelf With Discrete Width Sensors
Replace the Sensor PWB

Press the Menu button and scroll to CONFIGURATION>SCANNER CONTROL> MODE
and set the MODE to AUTOWIDTH/AUTOCENTER. Have the operator run the copy job
again. The problem still exists.
Y
N
Replace the Sensor PWB. If the problem is not corrected, replace the Main PWB (PL
1.4).
A
B
Re-issue
10/2008
3-5
Image Quality RAPS
Image Quality RAPS
10/2008
3-6
Re-issue
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 8.7 Document Feed-in Shelf ...................................................................................
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..................................................................
4-3
4-5
4-8
4-10
4-14
4-15
4-19
4-21
4-27
4-36
4-43
4-59
4-62
4-65
4-68
4-72
4-72
4-73
Adjustments
ADJ 4.1 Document Drive Motor Speed ..........................................................................
ADJ 6.1 Exposure Lamp Initialization .............................................................................
ADJ 8.1 Main Drive Belt / Document Drive Belt Tension ................................................
ADJ 8.2 Lead Edge / Trail Edge Adjustment..................................................................
ADJ 8.3 De-Skew Timeout ..............................................................................................
Re-issue
4-75
4-77
4-78
4-80
4-82
10/2008
4-1
Repairs and Adjustments
10/2008
4-2
Re-issue
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.
10/2008
4-3
Figure 1 Installing the Static Band and Ground Strap
Re-issue
REP 1.1
6.
(Figure 3): Remove the four slot-head screws that mount the Power Supply to the wall of
the Electronics Drawer.
Replacement
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.
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.
REP 1.1
10/2008
4-4
Re-issue
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.

Removal
WARNING
3.
1.
2.
(Figure 2): Remove the Image Processing PWB from the Main PWB.
1
Remove the five screws
2
Carefully lift the
Image Processing
PWB off of the
Main PWB
Image Processing PWB
Main PWB

Integral connectors to Main PWB
Figure 2 Removing the Image Processing PWB
Re-issue
10/2008
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.
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.
(Figure 4): Disconnect the following connectors from the Scanner Main PWB.
J414
J415
J416
J400
J403
J413
J404
J405
J408
J407
J406
Figure 4 Disconnecting the Main PWB Connectors
Gently pull retaining

spring outward about
5 mm
Guide left side of Electronics Drawer out about

12 mm
Figure 3 Disconnecting the Slide Spring
REP 3.1
10/2008
4-6
Re-issue
5.
(Figure 5): Remove the seven mount screws and carefully lift the Main PWB from the
Electronics Drawer.
Replacement
1.
The replacement or reinstallation of the Main PWB is the reverse of the Removal procedure.
2.
3.
If the Main PWB has been replaced, the 4 i.p.s. Scanner Feature Key. must be 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.
10/2008
4-7
NVR Chip
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.
Re-issue
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.

Removal
WARNING
3.
1.
2.
(Figure 2): Remove the Image Processing PWB from the Main PWB.
1
2
Carefully lift the
Image Processing
PWB off of the
Main PWB
Main PWB

Integral connectors to Main PWB
Figure 2 Removing the Image Processing PWB
REP 3.2
10/2008
4-8
Re-issue
Replacement
1.
The replacement or reinstallation of the Image Processing PWB is the reverse of the
Removal procedure.
2.
Re-issue
10/2008
4-9
REP 3.2
REP 4.2 Electronics Drawer
3.

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
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
REP 4.2
10/2008
4-10
Re-issue
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.
Remove the two

screws
Remove the four screws from the

Electronics Drawer Top Cover
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.
Re-issue
10/2008
4-11
REP 4.2
6.
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.
Gently pull retaining

spring outward about
5 mm
Guide left side of Electronics Drawer out about

12 mm
Figure 6 Disconnecting the Slide Spring
REP 4.2
10/2008
4-12
Re-issue
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.
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.
Re-issue
10/2008
4-13
REP 4.2
REP 6.2 Platen Glass
WARNING
The Exposure Lamp may be hot. Allow the Lamp to cool before removal.

Removal
2.
(Figure 2): Remove the Platen Glass.
WARNING
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
1.
Clean the Platen Glass with Glass Cleaner.
2.
(Figure 3): Correctly position the Platen Glass in the Scanner.
Figure 1 Lifting the Upper Document Transport
REP 6.2
10/2008
4-14
Re-issue
REP 6.3 Video Cables 1, 2, 3

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

Removal
Platen Glass
WARNING
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.
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
Re-issue
10/2008
4-15
REP 6.2, REP 6.3
4.
(Figure 2): Prepare to remove the Scanner Feed-In Shelf by performing the following
steps to both the left and right sides of the Scanner.
1
Remove the screw
and Glass Clip
2
Remove the two
Feed-In Shelf
retaining screws
Figure 2 Preparing to Remove the Scanner Feed-In Shelf
REP 6.3
10/2008
4-16
Re-issue
CAUTION
6.
Disconnect the sensor on the right side of the Scanner Feed-In Shelf prior to removing the
Feed-In Shelf.
5.
(Figure 3): Remove the Scanner Feed-In Shelf.
(Figure 4): 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.
Disconnect Q10P1 on the right

side of the Feed-In Shelf
Disengage the Video Cable Housing by bending the three folded

tabs outward slightly, and lowering the platform
2
Slide the Scanner Feed-In Shelf
out and away from the Scanner
Rear of Scanner
Figure 4 Lowering the Video Cable Housing

Figure 3 Removing the Scanner Feed-In Shelf
Re-issue
10/2008
4-17
REP 6.3
7.
Replacement
(Figure 5): Remove the Video Cables from the Scanner.
1.
Reinstall the Video Cables on their connectors.
2.
(Figure 6): 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
Video Cable Housing

Video Cable 1
Front of
Scanner
Figure 5 Removing the Video Cables
Replace Video Cables in

correct order and string
the cables out the front
of the VCM
Figure 6 Replacing the Video Cable Housing
REP 6.3
3.
Reconnect the Feed-In Shelf sensor and 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.
10/2008
4-18
Re-issue
REP 6.4 Exposure Lamp
WARNING
The Exposure Lamp may be hot. Allow the Lamp to cool before removal.
Parts List on PL 1.3A

Removal
2.
WARNING
1.
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)

NOTE: Note the positioning of the Exposure Lamp in the Image Module. The lamp will
need to be reinstalled in the same position.
Re-issue
3.
Rotate the Exposure Lamp and lift it out of the Scanner.
4.
Remove the black Lamp Jacket from the Exposure Lamp.
10/2008
4-19
REP 6.4
Replacement
CAUTION
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 lamps light window.
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.
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.
10. Run a copy of Test Target #82E5980 to confirm the correct operation and copy quality of
the Scanner.
NOTE: When correctly positioned, the clear portion of the fluorescent lamp will face
upward and towards the front of the Scanner.
11. Return the Scanner to normal operation.
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
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.
REP 6.4
10/2008
4-20
Re-issue
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.

Removal
3.
WARNING
on each End Cover.
1.
Lift the Upper Document Transport.
2.
2
Lift off the
Right and Left
Glass Clips
1
Remove one screw from the
inside of the End Cover
Lift out the Platen

Glass
Remove one screw

from the back of the
Scanner frame
1
Remove the screw (right and
left sides)

Re-issue
10/2008
4-21
REP 8.1
CAUTION
CAUTION
Exercise care when removing the Feed In Shelf, as there is a connector on the right side of the
shelf (Q10P1) that can be easily damaged if it is not disconnected prior to removing the Feed
In Shelf from the Scanner.
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.
4.
(Figure 3): Remove the Feed In Shelf.
NOTE: Note the following when removing or reinstalling the Front Drive Shaft Assembly Bearing Clamps:
1
Remove two screws
from each side, and
slide the Feed In Shelf
back about two inches
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.
(Figure 4): Locate and remove the Bearing Clamps on the Front Drive Shaft Assembly.
Bearing Clamps (4)
2
Disconnect connector Q10P 1
from the right
side of the Feed
In Shelf
3
Lift the Feed In Shelf off
the Scanner
Figure 3 Removing the Feed In Shelf
Ground Strap
Figure 4 Location of Bearing Clamps on Front Drive Shaft Assembly
REP 8.1
10/2008
4-22
Re-issue
6.
(Figure 5): Remove the small O-Ring Drive Belt from the left side of the Front Drive Shaft
Assembly.
7.
(Figure 6): Remove the Document Drive Belt from the right side of the Scanner.
O-Ring Drive Belt
3
Remove the Document Drive Belt
2
Remove the screw,
Extension Spring,
and Tension Pulley
Figure 5 Removing the Small O-Ring Drive Belt
Remove the screw
Figure 6 Removing the Document Drive Belt
Re-issue
10/2008
4-23
REP 8.1
8.
Replacement
(Figure 7): 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.
Carefully slide the Belt

Guard up and around the
pulleys
(Figure 8): 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.
Screws mount to Frame
Bearing
Clamps
Figure 7 Removing the Belt Guard
CAUTION
Bearings
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.
REP 8.1
10/2008
4-24
Inner Bearing Clamp

Configuration
Bearing End Clamp

Configuration
Figure 8 Correct Installation of Inner and Outer Bearing Clamps
Re-issue
4.
(Figure 9): Reinstall the O-ring Drive Belt and Bearing Clamps.
6.
(Figure 10): 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 9 Installing the Left Side Belt and Bearing Clamps

5.
Slide the Belt Guard back into position on the right side of the Scanner.
Figure 10 Reinstalling the Right Side Components
Re-issue
10/2008
4-25
REP 8.1
NOTE: When reinstalling the Feed In Shelf, remember to reconnect connector Q10P1
7.
Reinstall the Feed In Shelf, connecting Q10P1 prior to reinstalling the four mount screws.
8.
Reinstall the Left and Right End Covers.

CAUTION
9.
(Figure 11): Clean and reinstall the Platen Glass.
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 11 Reinstalling the Platen Glass

10. Close the Upper Document Transport.
REP 8.1
10/2008
4-26
Re-issue
REP 8.2 Rear Drive Shaft Assembly
2.

Removal
on each End Cover.
WARNING
1.
Lift the Upper

Document
Transport
2
Remove one screw
Scanner frame
1
inside of the End Cover

Re-issue
10/2008
4-27
REP 8.2
3.
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 K-clips
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 4 Removing the Left Slide Bracket and Left Pivot Clutch Assembly
4.

6.
REP 8.2
10/2008
4-28
Disconnect the two ground straps, located behind the Right and Left Pivot Clutch Assemblies, by removing the screws.
Re-issue
7.
(Figure 5): Remove the following components on the right side of the Scanner.
8.
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
2
Remove the belt
Figure 5 Removing the Right Side Components
Re-issue
10/2008
4-29
REP 8.2
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
1
Remove the two
mount screws
Figure 8 Removing the Scanner Back Cover
Figure 7 Removing the Right Pivot Clutch
REP 8.2
10/2008
4-30
Re-issue
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
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
Re-issue
10/2008
4-31
REP 8.2
13. (Figure 11): Remove the Rear Exit Baffle.
1
Remove the mount screw at both
ends of 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.
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
REP 8.2
10/2008
4-32
Re-issue
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
1.
Reinstall the Rear Drive Shaft Assembly on to the Image Module.
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
Loosen the mount screws (4)
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.
Mount screw
into frame
Bearing Clamp
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.
Reinstall the Rear Exit Baffle.
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.
Re-issue
10/2008
4-33
REP 8.2
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
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
REP 8.2
10/2008
4-34
Re-issue
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
Depress the pawl to
engage the Left Pivot
Clutch
2
Reinstall the two K-clips
and washer
3
Reinstall the Left Pivot
Clutch and Bracket with two
mount screws
1
Reinstall the
Slide Bracket
1
Reinstall the Bearing on the Rear Drive
Shaft
Reinstall the Bearing Clamp

over the Bearing
Figure 18 Reinstalling the Slide Bracket

12. Open the Upper Document Transport.
CAUTION
Figure 17 Reinstalling the Left Bearing Clamp and Left Pivot Clutch
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.
Re-issue
10/2008
4-35
REP 8.2
REP 8.4 Upper Document Transport
3.
Parts List on PL 1.2A, PL 1.2B

Removal
on each End Cover.
WARNING
1.
Lift the Upper Document Transport.
2.
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
Remove the screw (right and

left sides)
REP 8.4
10/2008
4-36
Re-issue
CAUTION
5.
Exercise care when removing the Feed In Shelf, as there is a connector on the right side of the
shelf (Q10P1) that can be easily damaged if it is not disconnected prior to removing the Feed
In Shelf from the Scanner.
4.
(Figure 4): Disconnect the Illumination Sensor and feed the wires down through the channel.
(Figure 3): Remove the Feed In Shelf.
1
Remove two screws
from each side, and
slide the Feed In Shelf
back about two inches
1
Disconnect the Illumination
Sensor
Lift the Feed In Shelf off

the Scanner
Feed the wires down

through the channel and
out the back of the Scanner
Disconnect connector Q10P1

from the right
side of the Feed
In Shelf
Figure 3 Removing the Feed In Shelf
Figure 4 Disconnecting the Illumination Sensor (Q11P1)
Re-issue
10/2008
4-37
REP 8.4
6.
(Figure 5): Remove the Left Slide Bracket and Left Pivot Clutch Assembly.
8.
(Figure 6): 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
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
mount
screw
Remove the screw,

Extension Spring
and Tension Pulley
REP 8.4
10/2008
4-38
Re-issue
9.
(Figure 7): Remove the Belt Guard by lifting it off the Front and Rear Drive Shafts.
10. (Figure 8): Remove the Right Pivot Clutch Assembly.
Remove the
Bearing
Clamp
Remove the Right

Pivot Clutch
Assembly
1
Carefully slide the
Belt Guard up and
around the pulleys
1
Remove the two
mount screws
Figure 8 Removing the Right Pivot Clutch Assembly
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.
Re-issue
10/2008
4-39
REP 8.4
11. (Figure 9): Remove the Scanner Back Cover.
13. (Figure 10): Disconnect the Upper Document Transport connectors and ground strap
from the Electronics Drawer.
2
Disconnect
P305
1
Disconnect
A0P100

12. Slide out the Electronics Drawer from the back of the Scanner.
Figure 10 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.
REP 8.4
10/2008
4-40
Re-issue
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 11): Reinstall the Right Pivot Clutch Assembly.
(Figure 12): Reinstall the right side components.
4
Reinstall the Drive
Belt
3
Reinstall the
two mount
screws
Reinstall the
Right Pivot
Clutch
Assembly
Reinstall the
screw
3
Reinstall the
spring
2
Reinstall the
Tension Pulley
and screw
1
Reinstall the
Bearing Clamp
8.
Reconnect the ground strap near the Left Pivot Clutch Assembly.
Figure 11 Reinstalling the Right Pivot Clutch Assembly

6.
Reinstall the Belt Guard on the Front and Rear Drive Shafts.
Re-issue
10/2008
4-41
REP 8.4
9.
(Figure 13): Reinstall the Left Slide Bracket and the Left Pivot Clutch Assembly.

Clutch Assembly
Reinstall the washer and

two K-clips
Reinstall the
two screws
Reinstall the Slide

Bracket
Figure 13 Reinstalling the Left Slide Bracket and Left Pivot Clutch Assembly
10. Reinstall the Right and Left End Covers.
REP 8.4
10/2008
4-42
Re-issue
REP 8.5 Platen Roll / Calibration Extrusion
3.
(Figure 2): Prepare to remove the Upper Document Transport Cover.

Removal
2
Pivot the Document Thickness Lever to its highest
position
WARNING
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
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.
10/2008
4-43
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.
Re-issue
REP 8.5
6.
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
Scanner frame
1
2
Remove the
mount
screw
Figure 4 Preparing to Remove the Right Side Belt Guard
REP 8.5
Remove the
screw, Extension
Spring and Tension Pulley
10/2008
4-44
Re-issue
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

Re-issue
10. Lower the Upper Document Transport.
10/2008
4-45
REP 8.5
11. (Figure 7): Remove the Left Slide Bracket and Left Pivot Clutch Assembly.
12. (Figure 8): Remove the following hardware from the left side of the Scanner.
Remove the Left Pivot Clutch Assembly
Remove two K-clips and

one washer
Remove the E-ring and bearing
3
Remove the two
screws, Bearing
Clamp and
Bearing
Remove the Slide

Bracket
Remove the K-clip and white nylon

bushing
Figure 8 Removing the hardware
REP 8.5
10/2008
4-46
Re-issue
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
Remove the
spring washer
Remove the
K-Clip
2
Remove the
brass bushing
Figure 10 Removing the Left Side Platen Roll Components
Figure 9 Removing the Left Side Plate
Re-issue
10/2008
4-47
REP 8.5
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.
2
Remove the K-Clip
Remove the Thick Document Indicator

Bracket by pulling upwards
17. (Figure 12): Dislocate the two cable ties indicated in the illustration below. This will allow
more room to remove the Calibration Extrusion.
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

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.
Cardboard or paper
placed under Upper
Document Transport
Figure 12 Dislocating the Cable Ties
REP 8.5
10/2008
4-48
Re-issue
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
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
Figure 13 Removing the Calibration Extrusion Assembly
Re-issue
20. Remove the Left Side End Cap from the Calibration Extrusion Assembly by sliding it off
the shaft.
10/2008
4-49
REP 8.5
21. (Figure 15): Remove the Platen Roll from the Calibration Extrusion Assembly by sliding it
out, and placing it on a clean, flat surface.
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.)
Replacement
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: 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
REP 8.5
10/2008
4-50
Re-issue
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
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
Figure 17 Reinstalling the Left End Cap

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

flat edges of the Platen Roll Shaft
Figure 18 Reinstalling the Rubber Drive Wheel and Sleeve
Re-issue
10/2008
4-51
REP 8.5
CAUTION
8.
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.
(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 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.
REP 8.5
10/2008
4-52
Re-issue
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.
Re-issue
10/2008
4-53
REP 8.5
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.
REP 8.5
10/2008
4-54
Re-issue
15. (Figure 25): Reinstall the Left Side Plate back onto the Scanner left side.
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.
2
Ensure that one tooth of the
Thick Document Shaft Gear
overhangs the last tooth of
the Left Slide Rail
Baffle Edge
1
Set the Thick Document Shaft
the required distance from the
Baffle Edge
1 inch
(25.4 mm)
Figure 25 Reinstalling the Left Side Plate
Thick Document
Shaft
Figure 26 Aligning the Left Side of the Thick Document Shaft
Re-issue
10/2008
4-55
REP 8.5
17. (Figure 27): Complete the Left Side Plate Reinstallation.
CAUTION
1
Reinstall the white
bushing and K-clip
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.
4
Depress the pawl to
engage the Left Pivot
Clutch
2
Reinstall the
white bushing
and E-ring
3
Clutch Assembly with
two (2) mount screws
Figure 27 Completing the Left Side Plate Reinstallation
Reinstall the
Bearing on
the Rear
Drive Shaft
Place the Bearing

Clamp over the
Bearing
Figure 28 Reinstalling the Left Pivot Clutch Assembly
REP 8.5
10/2008
4-56
Re-issue
19. (Figure 29): Reinstall the Slide Bracket on the left side of the Scanner.
21. (Figure 30): Reinstall the Scanner right side components.
Reinstall the Drive Belt
Reinstall the two K-clips

and one washer
Slide
Bracket
1
Reinstall the
Slide Bracket
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
Re-issue
10/2008
4-57
REP 8.5
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.
REP 8.5
10/2008
4-58
Re-issue
REP 8.6 Upper Document Transport Latches and Interlock

Switch
Removal
WARNING
2.
Perform REP 14.1 Scanner End Covers 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.
3.
(Figure 2): Remove the Document Drive Belt from the right side of the Scanner.
1.
Remove the Document Drive Belt
Lift the Upper

Document
Transport
1
Remove the screw
2
Remove the screw, spring,
and Idler Pulley
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10/2008
4-59
REP 8.6
4.
5.
(Figure 4): Remove the Upper Document Transport Latch.
2
Remove the two screws and lift the Latch off the
Scanner
1
Note the color and
position of the switch
connectors
Disconnect the connectors

from the Interlock Switch
Figure 4 Removing the UDT Interlock Switch
REP 8.6
10/2008
4-60
Re-issue
Replacement
4.
Reinstall the Scanner End Covers
1.
Reinstall the Upper Document Transport Latch and Interlock Switch.
5.
2.
6.
3.
(Figure 5): Reinstall the Document Drive Belt on the right side of the Scanner.
Reinstall the tension spring and

fully tighten the retaining screw

Drive Belt
Reinstall the screw
Reinstall the screw and Idler Pulley
Figure 5 Reinstalling the Document Drive Belt
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10/2008
4-61
REP 8.6
REP 8.7 Document Feed-in Shelf

Removal
2
Remove the Right and Left Glass
Clips
WARNING
1.
Lift the Upper

Document
Transport
1
Remove the four mounting
screws, two each side
Figure 2 Removing the Feed-in Shelf Mounting Screws

2.
Remove the Scanner End Covers (REP 14.1 Scanner End Covers).
3.
(Figure 2): Prepare to remove the Feed-in Shelf.
REP 8.7
10/2008
4-62
Re-issue
4.
1
Pull up on the and rotate
the Feed-in Shelf to
access connector SPP/J2
2
Disconnect SPP/J2
and remove the
Feed-in Shelf
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10/2008
4-63
REP 8.7
Replacement
4.
Reinstall the Scanner End Covers
1.
Reinstall the Upper Document Transport Latch and Interlock Switch.
5.
2.
6.
3.
(Figure 5): Reinstall the Document Drive Belt on the right side of the Scanner.
Reinstall the tension spring and

fully tighten the retaining screw

Drive Belt
Reinstall the screw
Reinstall the screw and Idler Pulley
Figure 4 Reinstalling the Document Drive Belt
REP 8.7
10/2008
4-64
Re-issue
REP 9.2 Image Module
3.
Parts List on PL 1.3B

Removal
(Figure 2): On the left side of the Scanner, remove the Stub Shaft Bracket.
1
Remove the hex nut
WARNING
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)
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10/2008
4-65
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.
Reconnect the three video cables that run beneath the Image Module.
CAUTION
Exercise caution when reinstalling the Video Cable Housing. The video cables can be damaged very easily if pinched by the housing.
Video Cable 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.
10/2008
4-66
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
REP 9.2
Re-issue
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 Transportto reinstall the Upper Document Transport
onto the Scanner.
8.
Perform ADJ 6.1 Exposure Lamp Initialization Procedure.
9.
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4-67
REP 9.2
REP 9.3 Thick Document Shaft
3.
(Figure 2): Prepare to remove the Upper Document Transport.
Parts List on PL 1.2A, PL 1.2B

Removal
2
position
WARNING
1.
Upper Document
Transport Cover
1
1
2
beneath the console
4.
Transport Cover and carefully lift the cover off the Scanner.
5.
Lower the Document Thickness Lever.

2.
REP 9.3
10/2008
4-68
Re-issue
6.
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
back of the Scanner frame
1
Remove one
screw from the
inside of the End
Cover
1
Remove the E-ring and
Bushing (both sides)
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.
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4-69
Remove the Thick Document Shaft from the Scanner.
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.
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.
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
5
Reinstall the right
side Bushing and
E-Ring
Figure 6 Aligning the Right Side of the Thick Document Shaft
REP 9.3
10/2008
4-70
Re-issue
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.
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.
Raise the Document Thickness Lever to its highest position.
Incorrect installation of Thick Document Shaft on Slide Rails
8.
Reinstall the User Interface.
9.
Reinstall the Right and Left End Covers.
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10/2008
4-71
REP 9.3
REP 14.1 Scanner End Covers
REP 14.2 Scanner Back Cover

Removal

Removal
WARNING
WARNING
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
Lift End Cover off Scanner
Remove one screw from the back

of the Scanner frame
Figure 1 Removing the Right or Left End Cover
REP 14.1 , REP 14.2
10/2008
4-72
Re-issue
REP 14.3 Upper Document Transport Cover
3.
(Figure 2): Prepare to remove the Upper Document Transport Cover.

Removal
2
position
WARNING
1.
Upper Document
Transport Cover
1
1
2
beneath the console
2.
Re-issue
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.
Transport Cover.
Replacement
Reinstall the Scanner Top Cover cover by performing the following steps:
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.
10/2008
4-73
REP 14.3
1
Lift handle to
highest position
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.
REP 14.3
10/2008
4-74
Re-issue
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 >
Manual = ON. 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: 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
Figure 1 System Speed and Lead Edge Detect Test Target
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.
Re-issue
10/2008
4-75
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 customers 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.
6.
Press the Start button on the Scanner Control Panel.
7.
(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.
Figure 3 Motor Speed Adjustment Screen (Example)
ADJ 4.1
10/2008
4-76
Re-issue
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.
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.
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
Re-issue
10/2008
4-77
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.
WARNING
1
Loosen the four (4) Document Drive Motor mount
screws
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
scanner frame
1
Remove one
screw from the
inside of the
Right End Cover
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
ADJ 8.1
10/2008
4-78
Re-issue
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.
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10/2008
4-79
ADJ 8.1
Check
Purpose
1.
The purpose of this procedure is to ensure that the Scanner correctly detects the lead and trail
edges of the scanned document.
1.
Diagnostics > Component Tests > Lead Edge/Trail Edge Adjustment. The following
screen will appear.
(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 GP 13 Creating the System Speed and Lead Edge Detect 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.
Figure 1 System Speed and Lead Edge Detect Test Target

2.
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.
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.
ADJ 8.2
10/2008
4-80
Re-issue
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.
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10/2008
4-81
ADJ 8.2
ADJ 8.3 De-Skew Timeout

Purpose
The purpose of this adjustment is to set the time delay for staging a document to be scanned to
allow the document to be inserted straight.
Check
1.
Switch the Scanner off.
2.
Connect the laptopto the Scanner (GP 14 Scanner Diagnostic access using a laptop).
3.
Enter 3 to read the NVM location
4.
Enter 3B to access the de-skew timeout
5.
Enter 1 to read one byte. The de-skew default value is 32 that equals 500 milliseconds.
Adjustment
1.
Switch the Scanner off then on and enter the laptop diagnostics again.
2.
Enter 2 to enter the diagnostics.
3.
Enter 4 to write to the NVM location
4.
Enter 3b for the de-skew timeout location
5.
(Figure 1): Determine the timeout value in milliseconds. The displayed de-skew value is a
hexidecimal number. Multiply the decimal (Dec) equivalent for the Hex number by 10 to
get the millisecond value.
For example: the de-skew default is Hex 32, refer to Figure 1 and get the decimal equivalent value which is 50 and multiplied by 10 equals 500 ms.
6.
Enter the desired Hex number in the 3B location.
Figure 1 Hexidecimal Converstion Table
ADJ 8.3 De-Skew Timeout
10/2008
4-82
Re-issue
5 Parts Lists
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 1.3A Image Module and Document Feed Rollers (Part 1 of 2)..................................
PL 1.3B Image Module (Part 2 of 2)................................................................................
PL 1.4 Electrical Module .................................................................................................
PL 1.5 Lower Document Transport .................................................................................
PL 1.6 Feed-In Shelf (PKU) ............................................................................................
5-10
5-11
5-12
5-13
5-14
Scanner Stand Assembly

PL 2.1 Scanner Stand .....................................................................................................
5-15
PL 3.0 Miscellaneous ......................................................................................................
5-16
Common Hardware
Common Hardware .........................................................................................................
Part Number Index ..........................................................................................................
Re-issue
5-17
5-18
10/2008
5-1
Parts Lists
Parts Lists
10/2008
5-2
Re-issue
Introduction
Table 1
Overview
Abbreviation
The Parts List section identifies all part numbers and the corresponding location of all spared
subsystem components.
R/E
Reduction/Enlargement
REF:
Refer to
SCSI
Small Computer Systems Interface
Organization
W/
With
Parts Lists
W/O
Without
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
Table 2
Operating Companies
Electrical Connectors and Fasteners
Abbreviation
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.
AO
Americas Operations
NASG - US
North American Solutions Group - US
Common Hardware
NASG Canada
North American Solutions Group Canada
XE
Xerox Europe
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 millimeters
unless otherwise identified.
Meaning
Symbology
Part Number Index
Symbology used in the Parts List section is identified in the Symbology section.
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.
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)
Other Information
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:
Table 1
Abbreviation
Meaning
A3
297 x 594 Millimeters
A4
A5
AD
Auto Duplex
AWG
American Wire Gauge
EMI
Electro Magnetic Induction
GB
Giga Byte
KB
Kilo Byte
MB
Mega Byte
MM
Millimeters
MOD
Magneto Optical Drive
NOHAD
Noise Ozone Heat Air Dirt
PL
Parts List
P/O
Part of
Re-issue
10/2008
5-3
Parts Lists
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 Lists
Subsystem Information
10/2008
5-4
Re-issue
Symbology
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.
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).
Figure 2 Without Tag Symbol

Figure 1 With Tag Symbol
Re-issue
10/2008
5-5
Parts Lists
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 Lists
Symbology
10/2008
5-6
Re-issue
PL 1.1 Scanner Module

Item
1
Part
893E37040
892E32360
893E13830
892E95130
892E32370
893E13840
892E32380
893E13850
892E32390
893E13860
892E32400
893E13870
892E32410
893E13880
101K43451
101K47722
101K49340
101K49380
101K49860
3
4
5
6
7
8
9
10
11
12
13
14
15
101K57160
962K01520
962K56150
090E02231
019E47130
019E47110
962K12170
962K56210
962K12160
962K56200
962K12150
962K56190
604K08540
16
17
068K35700
019E47140
117E34860
18
19
20
830E63551
893E37030
21
101E22540
Description
Control Panel Label (PKU) (RoHS)
Control Panel Label (English) (NY5) (Non
RoHS)
Control Panel Label (English) (PKU) (RoHS)
Control Panel Label (English) (MNT) (Non
RoHS)
Control Panel Label (French) (NY5) (Non
RoHS)
Control Panel Label (French) (PKU) (RoHS)
Control Panel Label (Italian) (NY5) (Non
RoHS)
Control Panel Label (Italian) (PKU) (RoHS)
Control Panel Label (German) (Non RoHS)
Control Panel Label (German) (PKU) (RoHS)
Control Panel Label (Spanish) (Non RoHS)
Control Panel Label (Spanish) (PKU) (RoHS)
Control Panel Label (Portuguese) (Non
RoHS)
Control Panel Label (Portuguese) (PKU)
(RoHS)
Scanner Control Panel Assembly (Non
RoHS)
Scanner Control Panel Assembly (UI for XEScan Solutions) (KGC) (Non RoHS)
Scanner Control Panel Assembly (MNT) (Non
RoHS)
Scanner Control Panel Assembly (MNT) (UI
for XEScan Solution) (Non RoHS)
Scanner Control Panel Assembly (PKU) (Non
RoHS)
Scanner Control Panel Assembly (RoHS)
Upper Document Transport Assembly
Upper Control Panel Harness (Non RoHS)
Upper Control Panel Harness (RoHS)
Platen Glass
Right Glass Clip
Left Glass Clip
Image Module Assembly
Video Cable Housing
Video Cable 3 (Non RoHS)
Video Cable 3 (RoHS)
Electrical Module
Lower Document Transport
Feed-In Shelf Kit (Not Spared) (NY5) (W/TAG
003) (RoHS)
Feed-In Shelf Kit (NY5) (W/TAG 003) (Non
RoHS)
Feed-In Shelf (MNT) (Non RoHS)
Platen Glass Foam (RoHS)
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)
Mounting Bracket (Non RoHS)
Mounting Bracket (Not Spared) (RoHS)
Scanner Control Patch Label (Non RoHS)
Scanner Control Patch Label (Not Spared)
(RoHS)
Scanner Control Housing (Non RoHS)
Scanner Control Housing (Not Spared)
(RoHS)
Re-issue
10/2008
5-7
Parts Lists
PL 1.1
PL 1.2A Upper Document Transport

(Part 1 of 2)
Item
Part
Description
1
2
892E31490
056E04650
056E05030
038K14071
038K15640
038K15391
802E21321
802E58950
802E21320
892E16371
892E95110
6
7
8
9
10
11
12
13
14
15
16
17
18
020K11860
004E20940
815K05450
015K47571
028E14180
022E24600
809E32080
809E32081
006E76990
130E05421
130E12090
055K32870
055K32881
022K69631
19
20
21
22
23
24
25
26
016E06020
016E16100
016E16101
021K02581
020K11880
413W00654
014K06880
Thickness Label
Indicator Bezel
Indicator Bezel (MNT) (Non RoHS)
Edge Guide (NY5) (Non RoHS)
Edge Guide (PKU)
Edge Guide (MNT) (Non RoHS)
Top Cover (RoHS)
Top Cover (MNT)
Top Cover (Non RoHS)
Logo Strip Label
Logo Strip Label (MNT) (Non
RoHS)
Friction Wheel
Bumper
Left Side Plate (RoHS)
Left Side Plate (Non RoHS)
Retainer Housing
Pinch Roller
Spring (Non RoHS)
Spring (RoHS)
Shaft
Sensor (Q2-Q6) (Non RoHS)
Sensor (Q2-Q6) (RoHS)
Rear Mylar Strip (PKU)
Front Mylar Strip (PKU)
Platen Roll
Calibration Spacer (P/O Item 26)
Upper Document Housing (P/O
PL1.1 Item 3)
Bushing (6mm)
Bushing (Non RoHS)
Bushing (RoHS)
End Cap
Calibration Housing
Keeper (P/O PL1.5 Item 15)
Keeper (P/O PL1.5 Item 17)
Bearing
Calibration Spacer Assembly (2
Places)
Parts Lists
PL 1.2A
10/2008
5-8
Re-issue
PL 1.2B Upper Document Transport

(Part 2 of 2)
Item
Part
Description
1
2
019E51420
105E23790
105E09000
019E15041
019E15042
127K40860
127K55650
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
130E09690
892E31480
809E43500
032E19371
047E00540
830E72960
849E81780
007E69160
815E00590
815E00591
815K05460
015K47581
007E68160
016E16100
016E16101
409W02078
609W02078
007E69500
003E70520
806E00170
806E00171
Clip
Static Eliminator (RoHS)
Static Eliminator (Non RoHS)
Clip (Non RoHS)
Clip (RoHS)
Calibration Drive Motor (MOT2)
(Non RoHS)
Calibration Drive Motor (MOT2)
(RoHS)
Calibration Home Sensor (Q1)
Indicator Label (PKU)
Spring
Guide
Ball
Label Bracket (PKU) (Non RoHS)
Label Bracket (ABX) (RoHS)
Gear (36T)
Side Slide Plate (Non RoHS)
Side Slide Plate (RoHS)
Right Side Plate (RoHS)
Right Side Plate (Non RoHS)
Gear (28T)
Bushing (10mm) (Non RoHS)
Bushing (10mm) (RoHS)
Spring (Non RoHS)
Spring (RoHS)
Pawl
Thick Document Handle (PKU)
Thick Document Shaft (Non
RoHS)
Thick Document Shaft (RoHS)
Re-issue
10/2008
5-9
Parts Lists
PL 1.2B
PL 1.3A Image Module and Document

Feed Rollers (Part 1 of 2)
Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
802E41622
809E31970
006K20580
006K31510
019E47291
809E32020
802E41612
013E18660
020E38280
006K20590
006K31490
113K02790
113K03350
122E02640
604K18390
604K42290
16
130K54470
130K74630
17
18
19
20
21
006K20600
006K31500
005E15090
035E56510
Rear Exit Baffle (P/O PL1.1 Item 8)

Left Pivot Clutch
Bearing End Clamp
Rear Drive Shaft (Non RoHS)
Rear Drive Shaft (RoHS)
Shaft Ground Clip
Bearing Mid Clamp
Right Pivot Clutch
Wave Spring (P/O Item 1)
Bearing
Timing Pulley (72T)
Front Drive Shaft (Non RoHS)
Front Drive Shaft (RoHS)
Lamp Socket (Non RoHS)
Lamp Socket (RoHS)
Fluorescent Lamp (MNT)
Image Module Kit (Non RoHS)
Image Module Kit (RoHS)
Illumination Sensor Bracket (P/O
PL1.1 Item 8)
Illumination Sensor PWB (Q11)
(Non RoHS)
Illumination Sensor PWB (Q11)
(RoHS)
Stub Shaft (Non RoHS)
Stub Shaft (RoHS)
O-Ring Drive Pulley
O-Ring
Lamp Jacket (P/O PL1.1 Item 8)
Harness (Lamps to Ballast) (Not
Spared)
Parts Lists
PL 1.3A
10/2008
5-10
Re-issue
PL 1.3B Image Module (Part 2 of 2)

Item
Part
Description
962K16850
962K50600
6
7
8
9
10
Interim Cable (Non RoHS)

Interim Cable (RoHS)
Optics Casting (P/O PL1.3A Item
14)
Image Module Back (P/O PL1.3A
Item 14)
Bottom Foam Seal Cover (P/O
PL1.3A Item 14)
Image Module Substrate (P/O
PL1.3A Item 14)
Image Bar (P/O PL1.3A Item 14)
IR Glass (P/O PL1.3A Item 14)
Selfoc Lens (P/O PL1.3A Item 14)
Cable Seal (P/O PL1.3A Item 14)
Relief Strain (P/O PL1.3A Item 14)
Re-issue
10/2008
5-11
Parts Lists
PL 1.3B
PL 1.4 Electrical Module

Item
Part
Description
1
2
162K65262
962K56470
105E18590
105E14293
960K33300
160K65762
960K33310
160K65795
960K33290
160K72091
7
8
9
10
104K00690
104K00053
11
162K65240
12
13
14
962K56460
117E29440
733W05871
833W31031
537K67113
537K67114
15
162K65272
162K65273
Top Cover (P/O PL1.1 Item 13)

DC Harness (Non RoHS)
DC Harness (RoHS)
LV Power Supply (PS1) (RoHS)
LV Power Supply (PS1) (Non
RoHS)
Image Processing PWB (PKU)
(W/TAG 007) (RoHS)
Image Processing PWB (PKU)
(W/TAG 007) (Non RoHS)
Scanner Main PWB (A1) (W/TAG
002, TAG 004, TAG 006) (RoHS)
Scanner Main PWB (A1) (W/TAG
002, TAG 004, TAG 006) (Non
RoHS)
Motor Control PWB (A3) (RoHS)
Motor Control PWB (A3) (Non
RoHS)
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) (RoHS)
Lamp Ballast PWB (A5) (Non
RoHS)
Harness (Ballast to Lamps) (Non
RoHS)
Harness (Ballast to Lamps) (RoHS)
Power Cord (Non RoHS)
Power Cord (Not Spared) (RoHS)
NVM Flash (U28) (Non RoHS)
NVM Flash (U28) (RoHS)
E-Prom (U10) (W/TAG 002, TAG
004) (Non RoHS)
E-Prom (U10) (W/TAG 002, 004)
(RoHS)
Main Harness Assembly (Non
RoHS)
Main Harness Assembly (RoHS)
Parts Lists
PL 1.4
10/2008
5-12
Re-issue
PL 1.5 Lower Document Transport

Item
Part
Description
1
2
802E21311
802E58970
127K40860
5
6
7
609W00187
409W03143
802E21301
802E58960
10
11
12
13
14
15
16
17
18
19
20
023E21040
020K09370
020E38170
409W03211
609W03211
023E21050
003K16870
003K16860
023E23170
023E30980
030K71220
030K71221
Back Cover (P/O PL1.1 Item 14)

Left End Cover
Left End Cover (MNT) (Non RoHS)
Lower Transport Housing (P/O
PL1.1 Item 14)
Document Drive Motor (MOT1)
(RoHS)
Document Drive Motor (MOT1)
(Non RoHS)
Motor Bracket (P/O PL1.1 Item 14)
Foot (Not Spared)
Spring (RoHS)
Spring (Non RoHS)
Interlock Harness (P/O PL1.1 Item
14)
Right End Cover
Right End Cover (MNT) (Non
RoHS)
Main Drive Belt
Dual Driven Pulley
Tension Idler
Spring (Non RoHS)
Spring (RoHS)
Document Drive Belt
Interlock Assembly
Interlock Catch (P/O Item 15)
Interlock Assembly
Interlock Catch (P/O Item 17)
Belt Guard (Non RoHS)
Belt Guard (RoHS)
Idler Bracket (Non RoHS)
Idler Bracket (RoHS)
Re-issue
10/2008
5-13
Parts Lists
PL 1.5
PL 1.6 Feed-In Shelf (PKU)

Item
1
4
5
Part
Description
068K37490
068K48740
962K25880
962K56260
130E05421
130E12090
Shelf (Non RoHS)

Shelf (RoHS)
Sensor Harness (Non RoHS)
Sensor Harness (RoHS)
Sensor (Non RoHS)
Sensor (RoHS)
Feed Shelf PWB (Not Spared)
Wire Saddle (Not Spared)
Parts Lists
PL 1.6
10/2008
5-14
Re-issue
PL 2.1 Scanner Stand

Item
Part
Description
1
2
3
4
5
6
7
10
11
830E73581
830E76070
098S04336
017E02620
017E02621
017E02610
017E02611
021E09960
021E10870
849E18740
12
849E18730
13
604K17060
14
056K02721
056K02720
Catch Tray/Organizer (Not Spared)

Catch Tray Support (Not Spared)
Scanner Module Assembly (REF:
PL1.1)
Height Adjustment Bracket
Organizer Support (Not Spared)
Organizer Mounting Clip
Stand (Non RoHS)
Stand (Not Spared) (RoHS)
Swivel Caster (NY6) (Non RoHS)
Swivel Caster (G505) (Non RoHS)
Swivel Caster (Not Spared) (RoHS)
Rigid Caster (NY6) (Non RoHS)
Rigid Caster (G505) (Non RoHS)
Rigid Caster (Not Spared) (RoHS)
End Cap (NY6)
End Cap (G505) (Non RoHS)
Gusset Bracket (2) (Non RoHS)
Gusset Bracket (Not Spared) (2)
(RoHS)
Gusset Bracket (2) (Non RoHS)
Gusset Bracket (Not Spared) (2)
(RoHS)
Gusset Bracket Kit (NY5) (Non
RoHS)
Gusset Bracket Kit (NY5) (Not
Spared) (RoHS)
UI Display Wall (RoHS)
UI Display Wall (Non RoHS)
Re-issue
10/2008
5-15
Parts Lists
PL 2.1
PL 3.0 Miscellaneous
Item
Part
Description
115N00356
140N05961
3
4
5
6
017E06010
050E10191
121E01402
055K32280
830E77290
Dongle (Non RoHS)

Dongle (Not Spared) (RoHS)
Fire Board 400 Lynx PWB (Non
RoHS)
Fire Board 400 Lynx PWB (Not
Spared) (RoHS)
Copy Stop
Front Stacker
Latch Magnet
Mylar Strip (Non RoHS)
Mylar Strip (Not Spared) (RoHS)
Compact Catch Support Bracket
(PKU)
Parts Lists
PL 3.0
10/2008
5-16
Re-issue
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)
Re-issue
10/2008
5-17
Parts Lists
Common Hardware
Part Number Index
Table 1 Part Number Index

Part Number
Part List
020E38170
PL 1.5
Part Number
Part List
020E38280
PL 1.3A
003K16860
PL 1.5
021K02581
PL 1.2A
003K16870
PL 1.5
021E09960
PL 2.1
003E70520
PL 1.2B
021E10870
PL 2.1
004E20940
PL 1.2A
022E24600
PL 1.2A
005E15090
PL 1.3A
022K69631
PL 1.2A
006K20580
PL 1.3A
023E21040
PL 1.5
006K20590
PL 1.3A
023E21050
PL 1.5
006K20600
PL 1.3A
023E23170
PL 1.5
006K31490
PL 1.3A
023E30980
PL 1.5
006K31500
PL 1.3A
028E14180
PL 1.2A
006K31510
PL 1.3A
030K71220
PL 1.5
006E76990
PL 1.2A
030K71221
PL 1.5
007E68160
PL 1.2B
032E19371
PL 1.2B
007E69160
PL 1.2B
035E56510
PL 1.3A
007E69500
PL 1.2B
038K14071
PL 1.2A
013E18660
PL 1.3A
038K15391
PL 1.2A
014K06880
PL 1.2A
038K15640
PL 1.2A
015K47571
PL 1.2A
047E00540
PL 1.2B
015K47581
PL 1.2B
050E10191
PL 3.0
016E06020
PL 1.2A
055K32280
PL 3.0
016E16100
PL 1.2A
055K32870
PL 1.2A
016E16100
PL 1.2B
055K32881
PL 1.2A
016E16101
PL 1.2A
056K02720
PL 2.1
016E16101
PL 1.2B
056K02721
PL 2.1
017E02610
PL 2.1
056E04650
PL 1.2A
017E02611
PL 2.1
056E05030
PL 1.2A
017E02620
PL 2.1
068K35700
PL 1.1
017E02621
PL 2.1
068K37490
PL 1.6
017E06010
PL 3.0
068K48740
PL 1.6
019E15041
PL 1.2B
090E02231
PL 1.1
019E15042
PL 1.2B
098S04336
PL 2.1
019E47110
PL 1.1
101E22540
PL 1.1
019E47130
PL 1.1
101K43451
PL 1.1
019E47140
PL 1.1
101K47722
PL 1.1
019E47291
PL 1.3A
101K49340
PL 1.1
019E51420
PL 1.2B
101K49380
PL 1.1
020K09370
PL 1.5
101K49860
PL 1.1
020K11860
PL 1.2A
101K57160
PL 1.1
020K11880
PL 1.2A
104K00053
PL 1.4
Parts Lists
Part Number Index
10/2008
5-18
Re-issue
Part Number
Part List
Part Number
Part List
104K00690
PL 1.4
609W00187
PL 1.5
105E09000
PL 1.2B
609W02078
PL 1.2B
105E14293
PL 1.4
609W03211
PL 1.5
105E18590
PL 1.4
733W05871
PL 1.4
105E23790
PL 1.2B
802E21301
PL 1.5
113K02790
PL 1.3A
802E21311
PL 1.5
113K03350
PL 1.3A
802E21320
PL 1.2A
115N00356
PL 3.0
802E21321
PL 1.2A
117E29440
PL 1.4
802E41612
PL 1.3A
117E34860
PL 1.1
802E41622
PL 1.3A
121E01402
PL 3.0
802E58950
PL 1.2A
122E00302
PL 1.3A
802E58960
PL 1.5
122E02640
PL 1.3A
802E58970
PL 1.5
127K40860
PL 1.2B
806E00170
PL 1.2B
127K40860
PL 1.5
806E00171
PL 1.2B
127K55650
PL 1.2B
809E31970
PL 1.3A
130E05421
PL 1.2A
809E32020
PL 1.3A
130E05421
PL 1.6
809E32080
PL 1.2A
130E09690
PL 1.2B
809E32081
PL 1.2A
130E12090
PL 1.2A
809E43500
PL 1.2B
130E12090
PL 1.6
815E00590
PL 1.2B
130K54470
PL 1.3A
815E00591
PL 1.2B
130K74630
PL 1.3A
815K05450
PL 1.2A
140N05961
PL 3.0
815K05460
PL 1.2B
160K65762
PL 1.4
830E63551
PL 1.1
160K65795
PL 1.4
830E72960
PL 1.2B
160K72091
PL 1.4
830E73581
PL 2.1
162K65240
PL 1.4
830E76070
PL 2.1
162K65262
PL 1.4
830E77290
PL 3.0
162K65272
PL 1.4
833W31031
PL 1.4
162K65273
PL 1.4
849E18730
PL 2.1
409W02078
PL 1.2B
849E18740
PL 2.1
409W03143
PL 1.5
849E81780
PL 1.2B
409W03211
PL 1.5
892E16371
PL 1.2A
413W00654
PL 1.2A
892E31480
PL 1.2B
537K67113
PL 1.4
892E31490
PL 1.2A
537K67114
PL 1.4
892E32360
PL 1.1
604K08540
PL 1.1
892E32370
PL 1.1
604K17060
PL 2.1
892E32380
PL 1.1
604K18390
PL 1.3A
892E32390
PL 1.1
604K42290
PL 1.3A
892E32400
PL 1.1
Re-issue
10/2008
5-19
Parts Lists
Part Number Index

Part Number
Part List
892E32410
PL 1.1
892E95110
PL 1.2A
892E95130
PL 1.1
893E13830
PL 1.1
893E13840
PL 1.1
893E13850
PL 1.1
893E13860
PL 1.1
893E13870
PL 1.1
893E13880
PL 1.1
893E37030
PL 1.1
893E37040
PL 1.1
960K33290
PL 1.4
960K33300
PL 1.4
960K33310
PL 1.4
962K01520
PL 1.1
962K12150
PL 1.1
962K12160
PL 1.1
962K12170
PL 1.1
962K16850
PL 1.3B
962K25880
PL 1.6
962K50600
PL 1.3B
962K56150
PL 1.1
962K56190
PL 1.1
962K56200
PL 1.1
962K56210
PL 1.1
962K56260
PL 1.6
962K56460
PL 1.4
962K56470
PL 1.4
Parts Lists
Part Number Index
10/2008
5-20
Re-issue
6 General Procedures
Scanner Installation
Copy System Scanner Installation ..................................................................................
XEScan Solution Scanner Installation.............................................................................
6-3
6-4
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 ........................................................................................................................
6-5
6-5
6-6
6-11
6-11
6-12
6-12
6-12
GP 12 Compact Catch Bins ............................................................................................

GP 13 Creating the System Speed and Lead Edge Detect Test Target .........................
GP 14 Scanner Diagnostic access using a laptop ..........................................................
GP 15 Image Isolation Procedure ...................................................................................
6-44
6-50
6-51
6-52
Special Tools
Special Tools...................................................................................................................
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) .......................................................
6-13
6-14
6-15
6-16
6-16
6-17
6-17
6-18
6-18
6-19
6-20
Component Tests
Motor Speed Test............................................................................................................
Lead Edge/ Trail Edge ...................................................................................................
Sensors Synergix Scanner..............................................................................................
WIDE FORMAT SCAN SYSTEM Sensors......................................................................
Scanner Control Panel ....................................................................................................
Document Motor (Loopback) Communications ...............................................................
Document Drive Motor ....................................................................................................
Lamp ...............................................................................................................................
Calibration Motor.............................................................................................................
6-23
6-23
6-24
6-24
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 ...........................................................................
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6-30
6-31
6-32
6-33
6-34
6-37
6-38
6-38
6-39
10/2008
6-1
General Procedures
General Procedures
10/2008
6-2
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Copy 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:
8.
Perform GP 9 Enabling/Disabling the DDS Option - 8825 / 8830 Printers - 8825/8830

Printers.
System initializes successfully, and the Scanner is ready to copy.
The Printer and Controller are previously installed.
V6.1 software (or greater) has been loaded on the Controller.
9.
The rigger has assembled the Scanner and placed it on its stand, or on top of the 8855/
721P Printer. (Catch Tray and Organizer Tray not yet installed.)
10. Download and install the latest firmware from the XES website.
1.
Install the Scanner Control Panel and Control Panel labels.
12. Go to ADJ 8.2 Lead Edge / Trail Edge Adjustment.
2.
Remove any packing materials, tape, etc. from the outside of the Scanner. Lift up the
Upper Document Transport and remove the material protecting Platen Glass. Close the
Upper Document Transport.
13. Make a copy of Test Target #82E5980 and check the overall copy quality.
3.
Install the Catch Tray and the Organizer Tray (if required).
4.
Install the IEEE1394 PMC Card. Go to the IEEE 1394 PWBA Installation procedure in the
AccXES Controller Service Manual.
15. 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.
11. Go to ADJ 4.1 Document Drive Motor Speed.
14. 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.
16. Press the Menu button and scroll to CONFIGURATION>SCANNER CONTROL>MODE

and check if the PRODUCTIVITY ANSI is present. If present ask the customer which
media series they use most frequently. Then set the PRODUCTIVITY mode to the customers series. Valid media series are: ANSI, ARCH, ISO A, ISO B, JSI B, and CUSTOM.
CUSTOM should be used for copy jobs that have mixed media series.
17. Upon successful installation of the entire system, complete the customer operator training
as specified in the System Participants Guide. Explain the new PRODUCTIVITY mode to
the customer.
18. Make a copy of all system Configuration Test Prints and store them in the Printer Service
Log.
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.
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10/2008
6-3
General Procedures
Copy System Scanner Installation
XEScan Solution Scanner Installation
Connecting the scanner
Follow this procedure to install the XEScan Solution standalone scanner and its system software.
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 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
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.
3.
Plug the control panel connector into the bottom of the XEScan Solution control panel.
4.
Secure the control panel to the control panel bracket using the screw.
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.
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
firmware to the most current version should resolve the problem.
Configuring the scanner and software
IEEE-1394 Fireboard 400 installation

Perform the following to install the Fireboard 400 IEEE-1394 interface card in the host PC
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 connected to the
computer. Always wear an ESD wristband that is connected to an exposed metal section of the
computer.
NOTE: If the host PC is using the Windows NT operating system, disable Plug-n-Play in the
system BIOS
1.
Clean the scanner Platen Glass
2.
Power on the scanner. Ensure that it has completed initialization.
3.
Power on the host PC.
4.
Start the XEScan software. The Keycode entry screen will appear.
5.
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.
6.
Download and install the latest firmware from the XES website.
7.
Redeem and install any feature keys purchased by the customer.
1.
Power off the host PC.
8.
Perform the Lead Edge/ Trail Edge procedure.
2.
Remove all cables and place the PC on a sturdy level surface.
9.
3.
Remove the slot cover for the PCI slot that will receive the Fireboard 400 card.
Perform a test scan using the Test Scan/Document Scan routine found in the Synergix
Diagnostics application.
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.
6.
Reinstall the PC cover and re-connect the PC cables.
7.
Install the Keycode Dongle on the PC parallel connector.
8.
Power On the PC to ensure it boots properly.
Installing the XEScan software

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.
When installing the software, follow the installation defaults as you step through the install wizard.
Once the XEScan software installation has completed, install the Fireboard 400 drivers. From
the Start menus select [Start:Programs:XES PRograms:Install Fireboard drivers]. Follow
the on screen prompts to install the drivers using the default settings.
Completely power OFF the PC when finished.
General Procedures
XEScan Solution Scanner Installation
10/2008
6-4
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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 Scan 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 the diagnostics mode for the 8825, 8830, 8855 Synergix Digital Solution or 510dp
Series WIDE FORMAT COPY SYSTEM, go to Entering the Scanner Diagnostics in this section.
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.
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.
NOTE: Some diagnostics, marked with a (*) in Figure 1, or Figure 2 require the entry of the
Diagnostic Password. Refer to Password for information about the Service Diagnostic Password and how to enter it.
The System Administrators 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 customers
choice.
NOTE: The SAOP is hard coded and cannot be changed; therefore, it must never be disclosed to the customer.
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 customers 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.
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 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.
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.
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10/2008
6-5
General Procedures
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 shows the Configuration Menu up to and including AccXES software version 9.0. Figure 2 shows the Configuration Menu for version 9.1.
Figure 1 Configuration Menu AccXES Software Version 9.0 and Earlier
General Procedures
10/2008
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Figure 2 Configuration Menu AccXES Software Version 9.1
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10/2008
6-7
General Procedures
Diagnostics Menu
Figure 3 Diagnostics Menu
General Procedures
10/2008
6-8
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System Information Menu
Figure 4 System Information Menu
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10/2008
6-9
General Procedures
System Administration Menu
Figure 5 System Administration Menu
General Procedures
10/2008
6-10
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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.
Table 1 POST Codes

Code
Description
RAM test
Checksum Test - Update FLASH ROM
Serial Controller (SCC) test
GPLynx register - write/read back test
Application checksum test
NVR (Non-volatile Random Access Memory) verification test
Checksum test - SCVM code
24 Volts test
Lamp Test
Motor communications test
SCVM Load and functional test
IP card interface test
IP card internal test
Video path test
Scanner Control Panel Communications
Flash Update Mode
Post tests completed, no IEEE 1394 communications with external controller
P.
IEEE 1394 communications established

with external controller.
Re-issue
The Media Usage is provided by the Printer and is tracked in both linear and square units as
defined by the Printer.
Figure 1 Usage Meters Screen
10/2008
6-11
General Procedures
Power On Self Test (POST) Diagnostics, Usage
Clear Scanner Usage
Installation Test Print
This screen permits the CSE to reset the Scanners 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
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
Once entered, the password remains in effect until the operator leaves the Diagnostics
menu and returns to normal operation.
INVALID PASSWORD, RE-ENTER.
Figure 1 Password Screen
General Procedures
Clear Scanner Usage, Installation Test Print,
10/2008
6-12
Re-issue
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.
Figure 1 Entering Scanner Diagnostics

5.
Press the Next key until SCANNER DIAGNOSTICS is highlighted.
6.
Press the Enter key.

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.
Type
Description
Scanner Faults
(Ordered)
Special
Allows the operator to display the

entries contained in the Scanner
internal fault log.
NO
Scanner Faults
(Counts)
Special
Allows the operator to display cumulative counts of each fault type from
the Scanner internal fault memory.
NO
Clear Scanner Fault

Log
Special
Causes the contents of the Scanner

fault logs to be erased.
YES
Motor Speed Test
Special
Allows the CSE to adjust the speed

of the Document Drive Motor in the
Scanner.
YES
Lead Edge/ Trail

Edge
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
Scanner Control
Panel
Special
Displays the current state of each of

the optical paper sensors in the Interceptor Scanner.
NO
Document Motor
(Loopback) Communications
Special
Allows the user to execute the Document Motor Communications Loopback test.
YES
Document Drive
Motor
Special
Allows the user to stop and start the

Document Drive Motor
NO
Lamp
Special
Allows the user to turn the Fluorescent Lamp on or off.
NO
Calibration Motor
Special
Allows the user to control the Calibration Motor and to select the Calibration Motor function.
NO
Installation Test Print
Special
This menu will queue an Installation

Test Print for use in the Scanner calibration.
YES
Sensors Synergix
Scanner
Special
Allows the technician to test the sensors on Scanners with AccXES software version 9.0 or older
NO
Results of the tests are displayed on the scanner control panel. Table 1 List of Diagnostic
Testsshows the available tests.
Password
Required?
Name of Test
Type
Description
Image Path Test
Special
Tests communications with the Image

Bars.
NO
Scan Bar Calibration

Test
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
Full System Test
Write NVR
Reset NVR Defaults
Scanner Reliability
Meter
Special
Special
Special
Special
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Password
Required?
Name of Test
General Procedures
Image Path Test

Password
Required?
Name of Test
Type
Description
WIDE FORMAT
SCAN SYSTEM Sensors
Special
Allows the technician to check the

sensors on Scanners with AccXES
software version 9.1 or newer
NO
Read Non Volatile

Random Access
Memory (NVR)
Special
Displays the contents of the Non-Volatile RAM on the Scanner.
NO
Diagnostic password required: NO.

This test checks the communications with the three Image Bars.
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.
(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.
NOTE: To perform the test again, reselect the Image Path Test from the Scanner Diagnostics
menu.
Figure 1 Image Path Test
General Procedures
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Scan Bar Calibration Test

Table 1 Error Codes for the Scan Bar Calibration Test
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.
Select the SCAN BAR CALIBRATION test from the menu of diagnostic tests (Entering the
Scanner Diagnostics).
Hex
Code
Meaning
Code
Meaning
01
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.
(Figure 1): Press the Start button on the Scanner Control Panel.
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.
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 toTable 1 Message Display Entry Chart, (located in Section 1 of this service manual)
for possible causes.
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10/2008
6-15
General Procedures
Scan Bar Calibration Test
Full System Test
Write NVR
Diagnostic password required: YES.
This test performs a series of tests, shown in (Table 1), to check that the Scanner is operating
correctly.
This password-protected diagnostic allows the CSE to modify the contents of the non-volatile
memory of the Scanner.
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 Write NVR Screen
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
POST test 5 - NVR Verification
POST test 9 -- Interface Image Processing PWB
POST test 6 - Motor

communications
POST test A - Internal test

- Image Processing PWB
Post test 7 SCVM Code

Checksum
POST test B - Video path
POST 8 SCVM Load

and Functional test
General Procedures
Full System Test, Write NVR
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.
10/2008
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Reset NVR Defaults
Scanner Reliability Meter
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.
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.
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.
NOTE: This meter measures linear usage only and is not intended for billing purposes.
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 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.
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] test
and perform the procedure.
3.
Go to the [ADJ 4.1 Document Drive Motor Speed] and perform the procedure.
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10/2008
6-17
General Procedures
Reset NVR Defaults, Scanner Reliability Meter
Scanner Faults (Ordered)
Scanner Faults (Counts)
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.
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.
Press the Next or Previous keys to scroll through the entries.
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.
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 Fault Log (Ordered)
Figure 1 Scanner Fault Log (Counts)
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
Scanner Faults (Ordered), Scanner Faults (Counts)
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Clear Scanner Fault Log

This password-protected menu causes the contents of the Scanner fault logs to be erased.
Figure 1 Clear Scanner Fault Log Screen
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.
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10/2008
6-19
General Procedures
Clear Scanner Fault Log
Read Non Volatile Random Access Memory (NVR)

(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
NVR_VERSION
0000
0000FFFF
This defines the current NVR version. Its used for automatic NVR upgrade during a new firmware load.
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).
ILL_RENULL_THRESH
03
ILL_COLD_WARMUP
00-FF
Number of minutes required for the lamp to warm up following a cold start.
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.
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.
ILL_INSTALL_READ
00
00 - FF
Contains the Lamp Illumination Sensor reading taken when the lamp is installed.
ISO_PACKET_SIZE
0800
SCVM_CAL_ENA_MASK
FF
ILL_ ADC counts of drift allowed before renull required.
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
SCVM_INTEG_VAL
20
01-F0
SCVM Integration Time
SCVM_DARK_LO_LIMIT
0002
0000 0FFF
SCVM Dark range lower limit.
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
General Procedures
Gain multiplier value used during gain cal override.
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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
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.
29
RFLOG_FULL_FLAG
0,1
Used to keep track of when the recent fault log is full.
2A
RFLOG_NEXT_INSERT
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 - 5A
How long before Calibration begins (in minutes).
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General Procedures

Number
33
Name
MOV_CAL_SPEED_IX
Default Value (Hex)

0
Range
0 - FF
Number
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
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
0-1
0-Filter is done prior to TRC

1-TRC is done prior to Filter
38
HORIZONTAL_SYS_ADJ
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
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Motor Speed Test
Lead Edge/ Trail Edge
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.
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. in Section 4 of this service manual.
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).
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.
Figure 1 Motor Speed Test
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 Lead Edge/Trail Edge
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General Procedures
Motor Speed Test, Lead Edge/ Trail Edge
Sensors Synergix Scanner
WIDE FORMAT SCAN SYSTEM Sensors
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.
This diagnostic displays the current state of the width sensors (bottom row of circles, 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 covered (actuated) its circle is filled (black).
When a sensor is uncovered (deactuated) its status reads OFF.
When a sensor is uncovered (de-actuated) its circle is clear (white).
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.
The polling is stopped by pressing the EXIT key, also causing the display to return to the
parent menu.
Width Sensors
Figure 1 Sensors Screen
Figure 1 Sensors Screen
General Procedures
Sensors , WIDE FORMAT SCAN SYSTEM Sensors
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Scanner Control Panel

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.
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 Preparing the Scanner Control Panel PWB for Loopback Connector
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General Procedures
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.
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
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Document Motor (Loopback) Communications
3.
Diagnostic password required: YES

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
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General Procedures
Document Motor (Loopback) Communications
Document Drive Motor
Lamp
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
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Calibration Motor
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

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General Procedures
Calibration Motor
GP 1 How to Check a Short Circuit
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.
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.
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.
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). 0 Ohms 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 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.
Figure 1 Circuit Diagram
General Procedures
GP 1
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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
Reconnect any circuits that you may have disconnected.
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.
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
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6-31
General Procedures
GP 2
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, PL 1.4 . If the wiring and
the Main PWB are both problem free install a new sensor, PL 1.4.
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 1.6 before replacing the Main PWB PL 1.4).
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 (PL 1.4). (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 (PL 1.4).
A
B
General Procedures
GP 3
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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.
A
Check the mechanical actuation of the switch. If the switch has an adjustment, perform the
adjustment.
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
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General Procedures
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
CR10
+5 VDC switched
+/-.25 VDC
When extending the Electronics Drawer, ensure that the wiring to the connectors are not damaged.
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
Replace the power supply. Go to REP?.
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 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.
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.
General Procedures
GP 5
Observe the POST LED. The POST LED increments from 0 to 8 within 60 seconds of
power on.
Y
N
Power on the Scanner. The POST LED increments from 0 to 8 within 50 seconds of
power on.
A
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A
Y
N
Elevate the problem to the Hotline.
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
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
Replace the Lamp Ballast PWB.
Power on the Scanner. The lamp illuminates for one second when the
POST LED displays 8.
Y
N
Replace the lamp [REP 6.4 Exposure Lamp].
Connect P403.
Power on the Scanner.
Observe the POST LED. The POST LED increments to 9 within 60 seconds of power on.
Y
N
Check the illumination sensor [Sensors Synergix Scanner].
Power on the Scanner. Observe the POST LED. The POST LED increments to B.
Y
N
Replace the Image Module [REP 9.2 Image Module].
The POST LED increments to E.
Y
N
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].
Connect P413.
Power on the Scanner. Observe the POST LED. The POST LED increments to P.
Y
N
Check the DDS Control Panel cable.
Go to Section 1, Final Action.

Connect P406 and P408.
Power on the Scanner. The upper document motor runs when the POST LED increments
to 9.
Y
N
Check the upper document motor.
Power on the Scanner. The upper document motor runs when the POST LED increments to 9.
Y
N
Replace the Motor Control PWB.
Connect P400.
Power on the Scanner. Observe the POST LED. The POST LED increments to A.
Y
N
Check the encoder.
Connect the P414, P415, and P416.
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General Procedures
GP 5
Motor Control PWB

J413
J414 J415 J416
PJ 400
PJ 401
Main PWB
J300
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
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GP 8 System Power Up Procedure

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.
Printer Power Switch
Ground Fault Interrupter
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.
Printer Power Switch
Ground Fault Interrupter

Figure 2 New 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 1 Old Configuration Ground Fault Interrupter
Figure 3 Seven-Segment Display Indicating IEEE 1394 Communications
Re-issue
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6-37
General Procedures
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 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.
The purpose of this procedure is to ensure that the Scanner, Controller and 8855 Printer are
correctly configured for Digital Document System (DDS) operation.
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 <System Administration> 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 <Controller Configuration> option is reached. Press the
Enter button.
7.
If the DDS system is enabled, the Control Panel will indicate <DDS = ENABLED>. 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 <DDS = DISABLED> then press the Enter button, and then the
Next button until the selection toggles to the <DDS = ENABLED> 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.
General Procedures
GP 9 , GP 10
Figure 1 Printer Setup Screen

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.
10/2008
6-38
Re-issue
GP 11 Catch Tray and Organizer Tray
NOTE: The Catch Tray and the Organizer Tray are identical parts.
WARNING
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
Organizer Support
Catch Tray Support
Catch Tray / Organizer Tray
Organizer Mounting Clip
Catch Tray Mounting Bracket
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
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10/2008
6-39
General Procedures
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.
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
10/2008
6-40
Re-issue
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
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10/2008
6-41
General Procedures
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
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
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
10/2008
6-42
Re-issue
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).
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
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
Re-issue
Figure 9 Inserting the Catch Tray Supports

10/2008
6-43
General Procedures
GP 11
GP 12 Compact Catch Bins

WARNING
Mounting
Clips
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
Rear Bin Mounting Bracket
Lower Bin
Upper Bin
Rear Bin
Bin Support Bracket
Document Storage Flaps
T20 x 8mm Screws
14
Mounting Clips
Document Storage Flaps
Lower Bin
Upper Bin
Rear Bin
Figure 1 Compact Catch Bins Parts
General Procedures
GP 12
10/2008
6-44
Re-issue
3.
(Figure 2): Install the four Mounting Clips on the inside of each Scanner leg.
4.
NOTE: In the following step, install only the lower mount screws on the Mounting Clips at
this time.
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.
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
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10/2008
6-45
General Procedures
GP 12
5.
(Figure 4): Install the Lower Bin onto the Scanner.
6.
(Figure 5): Install the Upper Bin onto the Scanner.
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
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
10/2008
6-46
Re-issue
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
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10/2008
6-47
General Procedures
GP 12
9.
(Figure 8): Install the Rear Bin Mounting Bracket.
10. (Figure 9): Mount the Rear Bin onto the Scanner.
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
10/2008
6-48
Re-issue
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.
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
Hook the curved edge of the Document Storage Flap onto the
lower edge of the Rear Bin (2
places)
Bin Support Bracket
Figure 11 Securing the Rear Bin to the Scanner Frame

13. Reconnect the power cord and the IEEE 1394 PMC cable to the Scanner.
Figure 10 Installing the Document Storage Flaps
Re-issue
10/2008
6-49
General Procedures
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.
3.
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.
(Figure 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:
TCP/IP Enable
TCP/IP Address
TCP/IP Subnet Mask
TCP/IP Default Gateway
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:
7.
1
Note the following Printer settings on your test print
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.
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.
Figure 1 Sample Printer Configuration Test Print
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.
General Procedures
GP 13
10/2008
6-50
Re-issue
GP 14 Scanner Diagnostic access using a laptop

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.
Plug the other end of the null-modem cable into the laptop serial connector.
4.
Power on the laptop and access the Hyperterminal tool.
5.
Configure Hyperterminal as follows:
6.
[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
NOTE: When resetting NVM values to the default values for the firmware revision level,
all fault logs, usage meters, and machine set-ups (such as lead edge registration, lamplife, etc). Feature keys should be left intact.
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
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 appear:
[1] Validate NVM

[2] dump NVM contents
[3] Read NVM locations
Re-issue
10/2008
6-51
General Procedures
GP 14
GP 15 Image Isolation Procedure

The purpose of this isolation procedure is to troubleshoot image quality problems by isolating
the problem between the Image Module and the PWBs.
1.
Obtain or make a copy that has the defect and identify the lead edge as it exited the
Printer.
2.
Unplug the power cord and firewire from the scanner.
3.
Access the Electronics Drawer (REP 4.2 Electronics Drawer).
4.
Align the copy, with the defect, with the image module as it would have been scanned to
determine the video cable to be swapped.
5.
Change the position of two cables
VIDEO CABLES
Figure 1 Accessing the Video Cables

6.
Connect the Firewire cable and Power Cable, then switch on the Copy System in the correct sequence.
7.
Make a copy of the document. If the defect has changed position the problem is with a
video cable (PL 1.1) or the Image Module (PL 1.3A). If the problem does not change the
problem is one of the PWBs. Refer to (GP 5 Generic PWB Checkout) to troubleshoot the
PWBs.
General Procedures
GP 15
10/2008
6-52
Re-issue
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
Calibration Strip
018E01410
Width Detection Strip
018E01450
Re-issue
10/2008
6-53
General Procedures
Special Tools
General Procedures
Special Tools
10/2008
6-54
Re-issue
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:
CLASS:
USE:
All
MFG SERIAL NUMBERS:
Tag Matrix
NAME:
Loose Plug Fix
PURPOSE:
KIT NUMBER:
162K65621/162K65271
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.
TAG:
CLASS:
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Re-issue
The purpose is to fix scanner reseting itself, unrepeatable random POST failures, scanner fails to come out of power saver mode without a hard recycle,
scanner fails to communicate with the printer.(documents is scaned but not
printed), unusual drive motor noise during initialization
KIT NUMBER:
160K65792
PARTS LIST ON:
PL 1.4
10/2008
6-55
NY5-548913
SCMB Boot Code Version 1.2
General Procedures
TAG:
TAG:
CLASS:
CLASS:
MFG SERIAL NUMBERS:

NAME:
NY5-552369
MFG SERIAL NUMBERS:
Feed-in Tray
PURPOSE:
NAME:
To prevent documents from being damaged by eliminating the interference with

the document glass and feed-in tray.
PURPOSE:
Image Processing PWB upgrade with memory chips. This PWB is required for
Turbo III operation.
KIT NUMBER:
604K8540
KIT NUMBER:
675K11050
PARTS LIST ON:
PL 1.4
PARTS LIST ON:
PL 1.4
TAG:
CLASS:
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
MNT-723684
Image Processing PWB Kit for 721P installs
NY5-553553
New application code and boot flash version 1.4

The purpose is to correct a problem with Scanner firmware updates where the
scanner would lose a communication link in the Update mode resulting in a failure to update.
PARTS LIST ON:
TAG:
CLASS:
PL 1.4
NAME:
PURPOSE:
Material change
PARTS LIST ON:
TAG:
PL 1.4
CLASS:
NAME:
PURPOSE:
Image Processing PWB design change to correct a problem involving reduction

components. This PWB requires Scanner firmware version 3.0.t or higher to
function correctly.
PARTS LIST ON:
PL 1.4
General Procedures
10/2008
6-56
Re-issue
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 6.5 Feed-in Shelf With Discrete Width Sensors......................................................
BSD 14.1 Communications .............................................................................................
Re-issue
7-3
7-4
7-5
7-7
7-8
7-9
7-10
7-11
7-13
7-14
7-16
7-18
7-20
7-23
10/2008
7-1
Wiring Data
Wiring Data
10/2008
7-2
Re-issue
BSD 1.0 Level 1 Interconnection
Re-issue
10/2008
7-3
Wiring Data
BSD 1.0
BSD 1.1 ACH Main Power On
Wiring Data
BSD 1.1
10/2008
7-4
Re-issue
BSD 1.2 DC Power Generation (50 and 60 HZ)
Re-issue
10/2008
7-5
Wiring Data
BSD 1.2
Wiring Data
BSD 1.2
10/2008
7-6
Re-issue
BSD 1.3 (+12 VDC) Power Distribution
Re-issue
10/2008
7-7
Wiring Data
BSD 1.3
BSD 1.4 (+5 VDC Standby / +5.25 VDC) Power Distribution
Wiring Data
BSD 1.4
10/2008
7-8
Re-issue
BSD 1.5 (+5 VDC / +3.3 VDC) Power Distribution
Re-issue
10/2008
7-9
Wiring Data
BSD 1.5
BSD 2.1 User Interface
Wiring Data
BSD 2.1
10/2008
7-10
Re-issue
BSD 4.1 Document Scan and Rescan Drive
Re-issue
10/2008
7-11
Wiring Data
BSD 4.1
Wiring Data
BSD 4.1
10/2008
7-12
Re-issue
BSD 6.1 Document Illumination
Re-issue
10/2008
7-13
Wiring Data
BSD 6.1
BSD 6.2 Image Capture
Wiring Data
BSD 6.2
10/2008
7-14
Re-issue
Re-issue
10/2008
7-15
Wiring Data
BSD 6.2
BSD 6.3 Image Calibration Control
Figure 1 Image Calibration Control
Wiring Data
BSD 6.3
10/2008
7-16
Re-issue
Figure 2 Image Calibration Control
Re-issue
10/2008
7-17
Wiring Data
BSD 6.3
BSD 6.4 Thick Document / Document Width Sensing
Wiring Data
BSD 6.4
10/2008
7-18
Re-issue
Figure 1 Thick Document / Document Width Sensing
Re-issue
10/2008
7-19
Wiring Data
BSD 6.4
BSD 6.5 Feed-in Shelf With Discrete Width Sensors
Wiring Data
BSD 6.5
10/2008
7-20
Re-issue
Re-issue
10/2008
7-21
Wiring Data
BSD 6.5
Wiring Data
BSD 6.5
10/2008
7-22
Re-issue
BSD 14.1 Communications
Re-issue
10/2008
7-23
Wiring Data
BSD 14.1
Wiring Data
BSD 14.1
10/2008
7-24
Re-issue

Synergix WF Scan System Service Manual

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Transmittal Page

THE DOCUMENT COMPANY

Wide Format Scan System

About This Manual

The manual is divided into eight sections:

Section 1. Service Call Procedures

Section 2. Repair Analysis Procedures (RAPs)

Section 3. Image Quality RAPs

Section 4. Repair / Adjustment Procedures

Section 5. Parts List

Section 6. General Procedures

How To Use This Manual

Section 7. Wiring Data

This section contains the Block Schematic Diagrams.

Multinational Configuration Differences

Repair Analysis Procedures (RAPs)

Repair / Adjustment Procedures

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

Figure 1 Reference Symbology (1 of 2)

(Figure 2): Reference Symbology, contd.

Figure 2 Refrerence Symbology (2 of 2)

1 Service Call Procedures

Service Call Procedures

Service Call Procedures

Call Flow Procedure

Initial Actions / System Checks

Message Display Entry Chart

Service Call Procedures

Call Flow Procedure

Scanner Fault Code Entry Chart

Perform the following:

Ask the operator to describe the problem.

Review the logbook for previous service on the Scanner.

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

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

Table 1 Message Display Entry Chart

POST all segments lit

Scanner Main PWB boot fault

POST no segments lit

1. Power supply fault: 5.0 volts or 3.3

Scanner Main PWB - RAM

Scanner Main PWB - Boot Flash

Scanner Main PWB - serial controller

U10, Main PWB

IF THE PROBLEM STILL EXISTS

Check that U10 is correctly seated.

Replace the Scanner Main PWB (REP

1. Perform a power off/power on cycle.

1. Troubleshoot the Power Supply PS1

BSD 1.4 (+5

Perform a power off/power on cycle.

Perform a power off/power on cycle.

Check that integrated circuit U10 is correctly seated.

Perform a power off/power on cycle.

Replace the Scanner Main PWB (REP

Service Call Procedures

Call Flow Procedure, Scanner Fault Code Entry Chart

Table 1 Message Display Entry Chart

Scanner Main PWB - IEEE-1394 communications fault

IF THE PROBLEM STILL EXISTS

Application checksum invalid - Scanner Main PWB. NOTE: When Post 4

Upload the current firmware to the

Replace the Scanner Main PWB (REP

The Checksum in the Non Volatile RAM U28