Synergix Scanner Service Manual PDF

Transmittal Page
Product Title Part Number
Synergix Scan System Service Manual 701P37410
Status Date
SUPERSEDES December 2001
This service manual replaces 701P36546.

Synergix Scan System

Synergix Scan System SCANNER COMPONENTS
Service Log
IMAGE PROCESSING PWB

DRIVE SHAFT, FRONT
CATCH INTERLOCK
USER INTERFACE
DRIVE SHATF, REAR
PIVOT CLUTCH
OTHERS (SPECIFY)
CABLES/HARNESSES
FIRMWARE UPGRADE
MOTOR CONTROL PWB

MYLAR STRIPS
PLATEN GLASS
IMAGE MODULE
SCANNER MAIN PWB

MOTOR
SENSOR
DC POWER SUPPLY
BELTS
POWER CORD
LAMP
LAMP BALLAST PWB
Serial # :
Install Date:
Account Information:
Reason for
Date Service Meter CSE #
Call:
PLEASE PRINT
PLEASE PRINT
PLEASE PRINT
PLEASE PRINT
PLEASE PRINT
PLEASE PRINT
PLEASE PRINT
Action Codes : X = check / perform R = replace U = upgrade firmware C = clean

Reason for Call : DT = Doc Transpt IQ = Image Quality CM = Commumications Ret = Retrofit Oth = Other
THE DOCUMENT COMPANY
XEROX

Service Manual
CAUTION
Certain components in the Synergix Scan System
are susceptible to damage from electrostatic dis-
charge. Observe all ESD procedures to avoid com-
ponent damage.
701P37410
DECEMBER 2001
NOTICE
While every care has been taken in the preparation of this manual, no liabil-
ity will be accepted by Xerox Corporation arising out of any inaccuracies or
omissions.
NOTICE
All service documentation is supplied to Xerox external customers for infor-
mational 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 mod-
ules, components or parts of such equipment may affect the warranty
offered by Xerox with respect to such equipment. You should consult the
applicable warranty for its terms regarding customer or third party provided
service. If the customer services such equipment, modules, components or
parts thereof, the customer releases Xerox from any and all liability for the
customer actions, and the customer agrees to indemnify, defend and hold
Xerox harmless from any third party claims which arise directly or indirectly
from such service.
Prepared by:
Xerox Corporation
800 Phillips Road
Bldg. 845-17S
Webster, New York 14580-9791
USA
© 2001 by Xerox Corporation. All rights reserved.

Xerox®, XES®, AccXES®, and The Document Company®
are registered trademarks of Xerox Corporation.
Xerox product names mentioned in this publication are trademarks of the
XEROX CORPORATION.
Revision Control List
Product Title Part Number Date
Synergix Scan System Service Manual 701P37410 12/2001
Page No. Rev.

1-5 10/2001
1-6 10/2001
4-14 10/2001
4-69 10/2001
4-70 10/2001
4-75 10/2001
5-1-5-16 10/2001
6-3 10/2001
6-4 10/2001
6-6 10/2001
6-16 10/2001
6-21 10/2001
6-23 10/2001
6-28 10/2001
6-38 10/2001
6-51 10/2001
6-53 10/2001
7-15 10/2001
Introduction
About This Manual .......................................................................................................... iii
Organization.................................................................................................................... iii
How To Use This Manual................................................................................................ iv
Multinational Configuration Differences .......................................................................... v
Repair Analysis Procedures (RAPs) ............................................................................... v
Repair / Adjustment Procedures ..................................................................................... vi
Reference Symbology..................................................................................................... vii
Introduction
Synergix Scan System 1
Introduction
2 Synergix Scan System
About This Manual Organization
This manual is a part of a documentation system for an associated controlling system for the The manual is divided into eight sections:
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 Section 1. Service Call Procedures
the binder because it is the entry point for service on the system. This section contains the following information:
This manual contains Service Call Procedures, Diagnostic Procedures, Status Indicator Repair
Call Flow Procedure
Analysis Procedures, Repair and Adjustment Procedures, Parts Lists and General Procedures
The Call Flow Procedure is a list of the procedures to follow on each service call.
or Information.
Initial Actions / Systems Checks

This information will help a Service Representative repair and maintain this device.
The Initial Actions identify how to collect the information necessary and how to verify, classify
and proceed with the service call.
Message Display Entry Chart

This chart contains a list of Messages, their Cause, the corresponding Clearance Procedure,
and the Go to reference.
Maintenance Procedures
The Maintenance Procedures lists the items that have to be serviced based on the type of call
to be performed.
Final Action
The purpose of this procedure is to record the media feet count and to make a record in the
machine log book of the service activities that were performed. Final Action is designed to test
the image quality under stress and repair any image quality problems
Section 2. Repair Analysis Procedures (RAPs)

This section contains the Repair Analysis Procedures (RAPs) that are necessary to repair the
faults other than the image quality defects. When using a RAP, stop the repairs when the fault
is isolated and repaired, and check the device for correct operation. Do not perform the remain-
ing steps in the RAP. If the device still malfunctions, begin from the top of the RAP to isolate
these faults.
Section 3. Image Quality RAPs

This section contains a listing of image quality defects and samples to assist in classifying the
defects. When the defect has been classified, a checklist is then used to repair the cause of the
defect. The checklists are arranged in the sequence of most probable to least probable cause
with the corresponding corrective action for each cause.
Section 4. Repair / Adjustment Procedures

This section contains the repairs and adjustments for the unit.
Section 5. Parts List

This section contains the detailed Parts Lists for the unit.
Introduction
Synergix Scan System iii
Section 6. General Procedures How To Use This Manual
This section contains the Diagnostic Procedures, Product Specifications, Supplemental Tools Always begin with the Service Call Procedures, Section 1. Perform the Initial Actions to identify
and Supplies, Generic RAPs, Installation and Removal procedures, and other information. and classify the problem.
Section 7. Wiring Data Then, proceed to one of the following sections of the manual to correct the problem.
This section contains the Block Schematic Diagrams.
Section 2 contains the Status Indicator RAPs. Use these RAPS if the unit is not operational,
such as when a Status Code is displayed, or there is an improper indication or “blank” display,
etc.
Section 3 is used to troubleshoot Image Quality problems. If you are not sure of the type of
image quality defect that is occurring, use the contents page in Section 3 to find a defect that
the best represents the type of defect that is on the copy.
When using Section 2 or Section 3, you may be directed to Section 4 to perform repair or
adjustment procedures, or to Section 5, Parts List.
Next, perform the Normal Call procedures.
After performing Normal Call procedure, perform Final Actions to ensure that the unit meets
the copy specifications.
Introduction
iv Synergix Scan System
Multinational Configuration Differences Repair Analysis Procedures (RAPs)
This manual contains information that applies to USO/NACO (USA), EO (European Opera- A RAP is either a table of faults and possible solutions, or a series of steps designed to lead
tions), XCL Canada and XLA/AO (Latin America). you to the cause of a problem. In each step, you will perform an action or observe an occur-
rence. 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 evalu-
ate the unit for proper performance. If a further defect is observed, go to the appropriate RAP
and perform the steps it contains until the additional fault is located and repaired.
Introduction
Synergix Scan System v
Repair / Adjustment Procedures
The repair procedures provide detailed steps on how to remove and replace components. The
adjustment procedures provide detailed steps on how to check and adjust components. Some
units have been modified by various design changes. Each change or modification is labeled
with a Tag/ MOD (modification) number. The Tag/ MOD numbers are identified in the Change
Tag/ MOD Index in Section 6 of this Service Manual.
When a modification affects how a particular procedure is performed, the procedure or steps
are identified with either a W/ Tag/ MOD or a W/ O Tag/ MOD statement. Each procedure or
step that is affected by a modification is identified with the statement, W/ Tag/ MOD, followed
by the modification number. The W/ in the statement indicates that this step must be per-
formed on units that are assembled with that specific modification.
When the procedure or steps are not affected by a particular modification, they are identified
with the statement, W/ O Tag/ MOD, followed by the modification number. The W/ O in the
statement indicates that this step must be performed on units assembled without that specific
modification.
Introduction
vi Synergix Scan System
Reference Symbology (Figure 1): The following symbols are used in this document:
Figure 1 Reference Symbology (1 of 2)
Introduction
Synergix Scan System vii
(Figure 2): Reference Symbology, cont’d.
Figure 2 Refrerence Symbology (2 of 2)
Introduction
viii Synergix Scan System
1 Service Call Procedures
Introduction ..................................................................................................................... 1-3
Call Flow Procedure........................................................................................................ 1-4
Scanner Fault Code Entry Chart ..................................................................................... 1-5
Maintenance Procedures ................................................................................................ 1-13
Call Back ......................................................................................................................... 1-13
Final Action ..................................................................................................................... 1-14
Service Call Procedures

1-1
1-2
Introduction Maintenance Procedures
The Synergix Scanning System functions as an Information Input Terminal (IIT), working in This procedure contains the tasks that are performed after the main cause for the service call
conjunction with an AccXES controller. The Controller takes the image signal from the Scan- has been corrected. The tasks identified in the procedure are performed at the interval indi-
ner and processes it into a form understandable by the Printer. Some image processing is cated. The interval may be after a specified number of feet, for example, 10K. The interval may
done inside the Scanner, while other such processing is done by the Controller. also be specified as a Normal Call (NC).
The Scanner Control Panel acts as the User Interface (UI). It is connected to the Main PWB in Normal Call activities are designed to be performed on all service calls. The specific interval
the Scanner. Some messages displayed on the Scanner Control Panel come directly from the and Normal Call activities include cleaning and replacing parts that require more frequent ser-
Main PWB, while others arrive through the connection to the Controller. vice and inspections The maintenance Procedure activities are designed to restore the device
to an initially clean and functional condition.
The Service Call Procedures, Section 1, are designed to assist the Service Representative to
identify faults, perform the necessary corrective action, and perform the correct Maintenance Final Action
Procedures. The Service Call Procedures are designed to be used with the Interceptor Service The purpose of this procedure is to record the media feet count and to make a record in the
Manual and are the entry level for all service calls. 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
The service manual for the product is the entry point for the fault isolation process at the sys- 82E5980 or 499T286 is made and compared with the image copy quality specifications located
tems level. Begin the service call with the Systems Level Call Flow Diagram within the Service in Section 3 of the manual.
Call Procedures, Section 1. The Call Flow Diagram will help you isolate the problem down to
the system module. The diagram may direct you to a section in the Interceptor service manual
or direct you to other service manuals to continue identify and repair the problem.
In the case of a standalone host computer / Interceptor configuration, the CSE must isolate the
fault to the Interceptor Scanner and then go to
in the Interceptor Service Manual.
Call Flow Procedure

This procedure outlines the major activities that are performed when a service call is made.
The Initial Actions System Checks assist the Customer Service Representative through the
customer interface and help to identify the problem. The procedure also directs the CSE to ver-
ify, 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 appropri-
ate 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.

1-3 Introduction
Call Flow Procedure
Procedure
Perform the following:
1. Ask the operator to describe the problem.
2. Review the logbook for previous service on the Scanner.
3. If a message or fault code is displayed on the screen of the Scanner Control Panel indi-
cating 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 Back-
procedure.
7. Go to Final Action.

Call Flow Procedure 1-4
Scanner Fault Code Entry Chart Fault codes other than POST fault codes are displayed in the fault log. To view the log, go to
the diagnostic test (Scanner Faults (Ordered)).
Scanner Fault Codes, except Power On Self Test (POST) codes, are shown on the Scanner
Control Panel. (POST) codes are displayed on the 7-segment display on the rear of the Scan-
Some fault codes in the LL series are also displayed on the Scanner Control Panel. Additional
ner. Each POST code is normally displayed briefly while the test is performed; if a test fails,
information may be found in the fault log. When switching on the Scanner and looking for fault
the code remains displayed, and no further POST tests are performed.
code displays, it is essential to follow the complete to switch on the Controller only after the
POST code display stops advancing or after P is displayed; otherwise, the expected codes
If the Power On Self Test stops at 5 or later, diagnostics will operate and error codes can be
may not be displayed.
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
(Table 1) shows Scanner fault messages, the probable cause, what to do to clear the fault,
applicable error code is displayed on the Control Panel Display. Diagnostics may then be
and a reference to consult if the problem still exists.
entered and operated. E
Table 1 Message Display Entry Chart

FAULT CODE COMPONENT
DISPLAYED FAULT DESCRIPTION DESIGNATOR CLEARANCE PROCEDURE IF THE PROBLEM STILL EXISTS BSD REF PL REF
POST all seg- Scanner Main PWB boot fault U10 Check that U10 is correctly seated. Replace the Scanner Main PWB. 1.4
ments lit
POST no seg- 1. Power supply fault: 5.0 volts or 3.3 1. Perform GP 8 power off/on cycle. 1. Troubleshoot the Power Supply PS1 1.4, 1.5 1.4
ments lit volts. and cables. Go to GP 5 Generic PWB
2. Scanner Main PWB boot fault Checkout, Section 6. 1.4
2. Replace the Scanner Main PWB
POST 0 Scanner Main PWB - RAM Perform GP 8 power off/power on cycle. Replace the Scanner Main PWB 1.4
Check that U10 on the Main PWB is cor-
rectly seated.+
POST 1 Scanner Main PWB - Boot Flash U10, Main PWB Perform GP 8 power off/power on cycle. Check that integrated circuit U10 is 1.4
Checksum incorrect correctly seated.
Replace the Scanner Main PWB
POST 2 Scanner Main PWB - serial controller Perform GP 8 power off/power on cycle Replace the Scanner Main PWB 1.4
(SCC) fault
POST 3 Scanner Main PWB - IEEE-1394 com- U18 Check that the IEEE 1394 communica- Replace the Scanner Main PWB 1.4
munications fault tions cable to the Controller is not
inserted reversed. Perform a power off/
power on cycle.
POST 4 Application checksum invalid - Scan- Upload the current firmware to the Replace the Scanner Main PWB 1.4
ner Main PWB. NOTE: When Post 4 Scanner.
fails, POST code U is displayed after a
few seconds.
POST 5 The Checksum in the Non Volatile RAM U28 Reset the NVR to default settings using Replace NVR IC U28 on the Main 1.4
(NVR) is invalid -- Scanner Main PWB GP 14 Scanner Diagnostic access using PWB. Perform the Clearance Proce-
a Laptop. If necessary refer to "If the dure again.
Problem still Exists". If the problem still exists, replace the
Scanner Main PWB
Then perform the clearance procedure
again.

1-5 Scanner Fault Code Entry Chart
POST 6 Video code checksum invalid -- Scan- Upload the current firmware to the Replace the Scanner Main PWB 1.4
ner Main PWB Scanner again.
1. Partial download of Scanner firm-
ware.
2. Scanner Main PWB failed.
POST 7 24 VDC Power Supply - no output PS1 1. Open wire on J406 on the Scanner Go to Section 2, RAP 1.1 DC Power. 1.4
Main PWB
2. Defective Power Supply PS1
3. Internal fault in Scanner Main PWB
POST 8 Lamp Test failed Lamp, Lamp Bal- Go to Section 2, RAP LL96. 1.2,
last PWB, Main
PWB
POST 9 Motor test failed MOT2, Motor Con- Perform GP 8 System Power Up Proce-
trol PWB, dure.
POST A 1. Video cables from J 414, J 415, or Check that cables are seated. Check Replace the Main PWB [REP 3.1 Main
J 416 on the Main PWB open or that there is no short circuit to ground at PWB].
shorted to ground, the connectors on the Image Module
2. Main PWB internal fault end. If LL91, LL92, or LL93 is dis- Replace the Image Module [REP 9.2
played, go to that entry in this table. Image Module].
3. Image Module internal fault.
POST B 1. Image Processor PWB not seated. Perform a System Power Up Cycle GP 1. Remove and reseat the Image
2. Malfunction in Image Processor 8 System Power Up Procedure Processor PWB.
PWB. 2. Replace the Image Processor
3. Main PWB internal fault. PWB.
3. Replace the Main PWB [REP 3.1
Main PWB].
POST C 1. Image Processor PWB not seated. Perform a System Power Up Cycle GP 1. Remove and reseat the Image
2. Image Processor PWB - internal 8 System Power Up Procedure. Processor PWB.
fault. 2. Replace the Image Processor
3. Main PWB internal fault. PWB.
Main PWB].

Scanner Fault Code Entry Chart 1-6
POST D 1. Fault in video cables from A1J Perform GP 8 System Power Up Proce- 1. Check that video cables from A1J
414, A1J 415, or A1J 416. dure 414, A1J 415, or A1J 416 are cor-
2. Image Processor PWB - internal rectly seated and have no short
fault. circuit to ground at the Image
Module end.
3. Main PWB - internal fault
2. Switch off the system. Reseat the
4. Image Module - internal fault.
Image Processor PWB. Switch on
the system [GP 8 System Power
Up Procedure].
Main PWB].
4. Replace the Image Module [REP
9.2 Image Module].
POST E No communications with the Scanner Scanner Control Ensure continuity of connections Replace the Scanner Control Panel. 2.1
Control Panel Panel, Scanner between Scanner Main PWB and Scan- Replace the Scanner Main PWB [REP
Main PWB ner Control Panel. 3.1 Main PWB].
POST U 1. Scanner receiving firmware update. 1. None 1. Wait for the update to complete. 1. Send the update again. If not suc- 14.1
cessful, replace the Scanner Main PWB
[REP 3.1 Main PWB].
2. If POST code 4 was displayed for a 2. Scanner Main 2. Switch off the Scanner. Switch on the 2. Resend the current firmware update
few seconds immediately before POST PWB Scanner, and allow the POST to run again. If still not successful, replace the
U, then there is an incorrect checksum again. Scanner Main PWB [REP 3.1 Main
at the end of the POST tests. PWB].
POST P POST tests completed; awaiting com- IEEE 1394 cable, Ensure that the cable is seated at both Check for a fault in the Controller. 14.1
munications with Controller Scanner Main ends. Ensure that the Scanner dis- Replace the Scanner Main PWB [REP
PWB played P before switching on the Con- 3.1 Main PWB].
troller.
POST P. POST tests completed; communica- none If still no operation, perform a complete
tions established. 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.
A1 - 00 Paper jam at Edge Present Sensor. Q4 Remove document; check that the feed Enter diagnostic mode; perform the 4.1 PL 1.2A
MEDIA JAM path is clear. Sensors Input test to check operation.
Check that the document drive operates Clean Sensor Q4. Check the wires.
in the forward direction. If not, go to Replace Sensor Q4.
section 2, [RAP OF-1 Document Trans-
portation].

A1 - 01 Paper jam at Registration Sensor. Q3 Remove document; check that the feed Enter diagnostic mode; perform the 4.1 PL 1.2A
Check that the document drive operates Clean Sensor Q3. Check the wires.
in the forward direction. If not, go to sec- Replace Sensor Q3.
tion 2, [RAP OF-1 Document Transpor-
tation].
A1 - 02 Paper jam at Exit Sensor. Q2 Remove document; check that the feed Enter diagnostic mode; perform the 4.1 PL 1.2A
Clean Sensor Q2. Check the wires.
Replace Sensor Q2.
A1 - 04 Calibration Extrusion failed to sense Q1 Switch off the System. Switch on the Enter diagnostic mode; perform the 6.3 PL 1.2B
home position. system. Sensors input test test to check opera-
tion. Clean Sensor Q1. Check the wir-
ing. Replace Sensor Q1 (PL 1.2B).
A1 - 05 Calibration Extrusion failed on move. MOT2 Switch off the System. Switch on the If the motor does not operate, enter the 6.3 PL 1.2B
Root cause: LL-30. System and ensure that POST 9 com- diagnostics mode and perform the Cali-
Also possible: open interlock switch. pletes. If not, check the power cable to bration Motor test while checking for
the Motor Control PWB and the commu- motor operation. Check the Motor Con-
nications cable to the Motor Control trol PWB and the wires to the Motor.
PWB, Check the motor for open circuits.
Check that 24 VDC is available on the If the test fails, the Scanner Main PWB
Motor Control PWB. may have a fault.
A2 - 00 Interlock open Q10 Ensure that the Upper Document Trans- Go to the BSD and troubleshoot the 6.4 1.1
port is fully down. Q10 sensor circuit (BSD 6.4).
LL - 10 Exposure Lamp Failure - lamp bright- Q11 Clean Illumination Sensor Q11 (PL 1.3). Go to the Scanner Diagnostics. Per- 6.1 1.3
(displayed in ness could not be adjusted to at least If the Lamp Sensor Q11 was removed form the Lamp test. Observe the Illumi-
Fault Log Only. 70% of new lamp brightness. or adjusted, perform ADJ 6.1 Exposure nation Sensor value. It should be
Root cause: LL- Lamp Initialization. greater than 10 when the Lamp is on,
47 or LL-49.) and less than 5 when the Lamp is off.
If not, check the sensor wires. If the
wires are good, replace Q11. If the sen-
sor 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].

LL - 11 Exposure Lamp Failure - lamp is too Lamp, Q11 1. Clean Illumination Sensor Q11 . Enter the diagnostic mode and perform 6.1 1.3
dark. the Lamp test. The SENSOR value var-
ies from 0 (dark) - 256 (extremely
NOTE: when the Lamp has less than bright). If the Lamp is lit, but the SEN-
70% of brightness when new. SOR value is zero or nearly so, trouble-
shoot the sensor and sensor wiring. If
these are correct, replace the Lamp
[REP 6.4 Exposure Lamp]. If the prob-
lem still exists,
replace the Scanner Main PWB [REP
3.1 Main PWB].
LL - 12 Exposure Lamp Failure - Illumination Q11 Check that the Lamp is lit. Enter the diagnostic mode and perform 6.1 1.3
Sensor Q11 failed. the Lamp test. The SENSOR value var-
ies from 0 (dark) - 256 (bright). If the
Lamp is lit, but the SENSOR value is
zero or nearly so, troubleshoot the sen-
sor and sensor wiring. If these are cor-
rect, 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].
LL - 30 Motor Driver Failure - Read response Remove any document from document Enter the diagnostics and perform 4.1 1.4
[fault log only] time out. feed path. motor communications test. Trouble-
Check the Scanner Faults (Ordered) for shoot the motor and motor control cir-
an A1-xx code. Perform the actions in cuitry.
this table for the A1-xx code.
LL - 31 Motor Driver Failure - Unexpected Remove media from document feed Enter the diagnostics and perform 4.1 1.4
reset. path. motor communications test. Trouble-
shoot the motor and motor control cir-
cuitry.
LL - 32 Motor Driver Failure. The Calibration Remove media from document feed Enter the diagnostics and perform the 4.1 1.4
Extrusion has a motion problem. path. Perform GP 8 System Power Up Document Drive Motor test. Check that
Procedure. all the tests are successful. If not, trou-
bleshoot the Calibration Motor circuits
and the Motor Control PWB A3 (PL 1.4).
LL - 33 Motor Driver Failure - Calibration Extru- Open Upper Transport; remove media; Try scanning the thick document with 6.3 1.4
sion unknown state. The Calibration close transport. the Thick Document Lever raised one
Extrusion has been moved during the more position.
scan of the document.
LL - 34 Motor Driver Failure - Calibration Extru- MOT2, Motor Con- Check that Calibration Extrusion can be Go to BSD 6.3 and troubleshoot the DC 6.3 PL 1.2B
sion overcurrent. trol PWB manually rotated. If not, repair the Drive circuit from A3P 308.
cause. Check Motor M2 (Calibration Motor) for
Perform GP 8 System Power Up Proce- open circuits or short circuits.
dure.

LL - 39 Motor Driver Failure -Simultaneous
write.
LL - 40 Calibration Failure - Set integration time 1. Clean Calibration Target Strip and Check that the lamp is installed with 6.3
failure. (uniformly darker image) Platen Glass. correct orientation.
2. Ensure that there is no contamination
NOTE: LL-40 displayed only momen- on Selfoc Lens.
tarily on Scanner Control Panel.
LL - 41 Dark Calibration Failure -Range adjust Check that the Upper document Trans- Enter the Scanner Diagnostics. Per- 6.2
failure on Channel 1. (Lighter streaking port is closed. Observe the lamp for 2 form the Scan Bar Calibration Test. If
in process direction) minutes and check that it switches the test fails for any segment of the
briefly off, then on during dark calibra- Image Module (Scan Bar), switch off
NOTE: LL-41 displayed only momen-
tion. the Scanner. Switch the video cables
tarily on Scanner Control Panel. 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. Oth-
erwise, replace the Scanner Main PWB
[REP 3.1 Main PWB].
LL - 42 Dark Calibration Failure - Range adjust Check that the Upper document Trans- Switch off the Scanner. Switch the 6.2
failure on Channel 2. (Lighter streaking port is closed. Observe the lamp for 2 video cables between channel 1 and
in process direction) minutes and check that it switches channel 2. Switch on the Scanner. If
briefly off, then on during dark calibra- the fault occurs on a different channel,
NOTE: LL-42 displayed only momen- tion. a cable, or the Image Module, have a
tarily on Scanner Control Panel. fault. Otherwise, replace the Scanner
Main PWB [REP 3.1 Main PWB].
LL - 43 Dark Calibration Failure -Range adjust Check that the Upper document Trans- Switch off the Scanner. Switch the 6.2
failure on Channel 3. (Lighter streaking port is closed. Observe the lamp for 2 video cables between channel 3 and
in process direction) minutes and check that it switches channel 2. Switch on the Scanner. If
briefly off, then on during dark calibra- the fault occurs on a different channel,
NOTE: LL-43 displayed only momen- tion. a cable, or the Image Module, has a
tarily on Scanner Control Panel. fault. Otherwise, replace the Scanner
LL - 44 Dark Calibration Failure - Offset adjust SelfFoc Lens Clean these parts. Perform GP 8 Sys- Switch off the Scanner. Switch the 6.2
failure on Channel 1. (Lighter streaking Platen Glass tem Power Up Procedure. video cables between channel 1 and
in process direction) Target Calibration channel 2. Switch on the Scanner. If
Strip the fault occurs on a different channel,
NOTE: LL-44 displayed only momen- a cable, or the Image Moduler, has a
tarily on Scanner Control Panel. Old Lamp fault. Otherwise, replace the Scanner
NOTE: LL-45 displayed only momen- a cable, or the Image Module, has a
fault. Otherwise, replace the Scanner

NOTE: LL-46 displayed only momen- a cable, or the Image Module, has a
fault. Otherwise, replace the Scanner
LL - 47 Gain calibration failure on Channel 1. Examine the Calibration Target Strip, Go to the Scanner Diagnostics and do 6.2
(Dark streaks). the SelfFoc Lens, and the Platen Glass the Full System Test. Troubleshoot any
for dirt or contamination; clean if failures. Do the Scan Bar Calibration
NOTE: LL-47 displayed only momen- required. Use the Calibration Motor test Test. Troubleshoot any failures. If the
tarily on Scanner Control Panel. in Scanner Diagnostics to rotate the problem still exists,
Calibration Extrusion and gain access to replace the Scanner Main PWB [REP
the target strip. 3.1 Main PWB]. If the problem still
Replace the Lamp [REP 6.4 Exposure exists, replace the Image Module [REP
Lamp], particularly if the lamp has dis- 9.2 Image Module].
coloration at the ends.
LL - 48 Gain calibration failure on Channel 2. Examine the Calibration Target Strip, Go to the Scanner Diagnostics and do 6.2
(Dark streaks). the Selfoc Lens, and the Platen Glass the Full System Test. Troubleshoot any
NOTE: LL-48 displayed only momen- required. Use the Calibration Motor test Test. Troubleshoot any failures. If the
exists, replace the Image Module [REP
9.2 Image Module].
LL - 49 Gain calibration failure on Channel 3. Examine the Calibration Target Strip, Go to the Scanner Diagnostics and do
(Dark streaks). the Selfoc Lens, and the Platen Glass the Full System Test. Troubleshoot any
NOTE: LL-49 displayed only momen-
required. Use the Calibration Motor test Test. Troubleshoot any failures. If the
Replace the Lamp [REP 6.4 Exposure exists, replace the Image Module [REP
Lamp], particularly if the lamp has dis- 9.2 Image Module].
coloration at the ends.
LL - 80 Miscellaneous Failure - Invalid scan Print a Configuration Sheet to check if Thick document sensor actuated inter-
parameters. 4 i.p.s. scan speed the feature key is installed. mittently. Check that the Thick Docu-
requested, but 4 i.p.s. feature key not ment Lever is firmly down.
installed.
LL - 81 Miscellaneous Failure -Fault detected Perform GP 8 System Power Up Proce- View the Scanner Faults (Ordered) log
during Power up. dure. to check for other errors that occurred.
Check this table for applicable proce-
dures.

LL - 82 Miscellaneous Failure -Scan engine Check IEEE 1394 communications
task event time out. cable. If disconnected, reconnect. Per-
form GP 8 System Power Up Proce-
dure.
LL - 83 Image processing error. Image Processing Scan the document again. Switch off the system. Reseat the 1.4
PWB Image Processor PWB. Perform GP 8
System Power Up Procedure. Scan the
document again. If the problem still
exists, replace the Image Processor
PWB.
LL - 90 POST Failure - SCVM POST failure. Main PWB. Hardware fault on Main PWB. Replace the Main PWB [REP 3.1 Main
PWB].
LL - 91 POST Failure - Image Bar 1 failure. Cable fault, Main Check that A1P/J 414 is seated. Go to RAP LL91, LL92, LL93.
PWB, Image Bar
Assembly
LL - 92 POST Failure - Image Bar 2 failure. Cable fault, Main Check that A1P/J 415 is seated. Go RAP LL91, LL92, LL93.
PWB, Image Bar
Assembly
LL - 93 POST Failure - Image Bar 3 failure. Cable fault, Main Check that A1P/J 416 is seated. Go to RAP LL91, LL92, LL93.
PWB, Image Bar
Assembly
LL - 94 POST Failure - PMI POST failure. Image Processor Remove and reseat the Image Proces- Replace the Image Processor PWB. If
PWB sor PWB. the problem still exists, replace the
LL - 95 POST Failure - Video POST failure. Main PWB Hardware fault. Replace the Main
PWB.
LL - 96 POST Failure - Motor Driver POST Go to POST 7 in this table. Go to RAP LL96.
failed.

Maintenance Procedures Call Back
Perform the Tasks at the Interval indicated in the table. Perform NC (Normal Call) tasks on 1. Follow the Call Flow Diagram and resolve the problem that caused the Call Back.
every call. The task with specific intervals should be done only at the interval indicated. 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 Docu-
ment 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 Print/Image Quality
the process direction go to ADJ 4.1 Docu-
ment Drive Motor Speed (DS system only).
NC Clean the Calibration Target Strip, using Print/Image Quality
8R27 Film Remover
NC Check the Platen Glass for scratches or Print/Image Quality
chips. If found, and image quality is affected,
replace the Platen Glass.
NC Go to ADJ 8.2 Lead Edge / Trail Edge Adjust- Print/Image Quality
ment (DS system only). Calibrate Document
Registration. Check the document registra-
tion and adjust if necessary.

1-13 Maintenance Procedures, Call Back
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.

Final Action 1-14
2 Status Indicator RAPS
RAP 1.1 DC Power ......................................................................................................... 2-3
RAP LL91, LL92, LL93.................................................................................................... 2-5
RAP LL96........................................................................................................................ 2-6
RAP OF-1 Document Transportation .............................................................................. 2-8
Status Indicator RAPS

Synergix Scan System 2-1
2-2 Synergix Scan System
A
RAP 1.1 DC Power
This RAP is used to isolate faults in the DC Power Generation and Distribution Chain. Table 1
NOTE: The power supply PS1 contains switching power supplies for all but the 5 VDC Standby A1 P404 Volts DC
signal. A1P404-14 must be grounded to obtain +3.3, +5, and +12 VDC output. A1P405-2 Pin Reading
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. 1, 2, 11 +3.2 to +3.4
+5 VDC Standby is always available.
4, 6, 19, +4.9 to +5.1
Initial Actions 20
Insure that the Power Cord is connected to Power Supply PS1 and to the correct source of AC
power. 10 +11.9 to +12.1
Procedure The voltages are present and correct.

Switch off the System. Y N
Open the Electronics Drawer (REP 4.2 Electronics Drawer). Replace Power Supply PS1.
Switch on the Scanner.
Examine LED CR7 (+5 VDC STBY), on the A1 Main PWB (Figure 1. Main PWB). The LED is Check Connector A1P 404 for bent pins or faulty continuity. Repair any problems found.
on.
NOTE: Overcurrent on any of the three supplies, +3.3, +5, and +12, will cause all three to
Y N
shut down.
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 If the problem still exists, use BSDs 1.2 - 1.5 to troubleshoot each voltage signal for short
Y N or open circuits.
Disconnect A1P 404. +5 VDC is present.
Y N Examine LED CR2 (+24 V) located on Main PWB A1. The LED is on.
Replace Power Supply PS1. Y N
Connect the (+) lead to A1P 405 pin 2. The signal is low.
Troubleshoot the distribution of the +5 VDC standby signal, using the BSDs. Y N
Check A1P 405 pin 2 for continuity. If correct, replace the Main PWB.
Connector P404 is seated correctly and has continuity.
Y N Switch off the Scanner. Disconnect Connector A1P 405. Connect A1P 405 pin 2 to A1P
Repair any defective pin. If the problem still exists, replace Power Supply PS1. 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.
Examine LEDs CR9 (+12 V), CR10 (+5 V), and CR8 (+3.3V). The LEDs are all on. Table 2
Y N
Connect the (+) lead of the DMM to A1P 404-14 (BSD 1.2, J5). The signal is low. A1P 405 Volts DC
Y N Pin Reading
1 +23 to +25
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 4 +23 to +25
[Table 1] and measure each voltage.
The voltages are correct.

Y N
Replace Power Supply PS-1.
A B C
Synergix Scan System 2-3 RAP 1.1 DC Power
B C
Check Connector A1P 405 for bent pins or lack of continuity. Repair any problems found.
If the problem still exists, use BSD 1.2 to troubleshoot the 24 VDC signal for short cir-
cuits.
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
Check the ribbon cables for a short circuit to the chassis at the connectors entering the
Image Bar Assembly. If a short circuit is found, correct the problem. If no short circuit is
found, replace the Image Bar Assembly. Figure 1 Main PWB
Disconnect the cable from the IEEE-1394 connector on the rear of the Electronics Drawer.
Connect the (+) Lead to Pin 3 (upper right when looking into the connector) of the IEEE-1394
connector. 3.3 VDC is present.
Y N
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 (PL 1.3).
The DC Power generation circuits are operating correctly.

RAP 1.1 DC Power 2-4 Synergix Scan System
RAP LL91, LL92, LL93
This RAP isolates faults that can cause the calibration test of the Image Module to fail. Such a
failure causes an LL91 (Image Bar 1), LL92 (Image Bar 2) or LL93 (Image Bar 3) status code
to be displayed.
Initial Actions
Open the Electronics Drawer [REP 4.2 Electronics Drawer]. Check that the video cables con-
nected 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 Scan-
ner.
The signal goes low when 8 is displayed on the POST 7-segment display, and goes
high when 9 is displayed.
Y N
Replace the Main PWB (A1).
Replace the Lamp Ballast PWB (A5) (PL 1.4).
Go to the [ RAP 1.1 DC Power ]. The DC Power generation and distribution is good.
Y N
Isolate the problem in these circuits, using the RAP 1.1 DC Power procedure and the
BSDs.
Switch off the Scanner. Go to BSD 6.2 and identify the video cable associated with the LL91,
LL92, or LL93 status code displayed. Disconnect the video cable associated with the fault
from the Main PWB. Disconnect another adjacent video cable. Connect the first video cable to
the second cable’s connector on the Main PWB. Connect the second cable to the first cable’s
connector. Switch on the Scanner. After the POST code on the 7-segment display has
advanced to A, switch on the Controller. The LL status code has changed to a different
code in the LL-91-93 range.
Y N
Replace the video cable associated with the LL9x code. If the problem still exists, replace the
Image Module Assembly. (REP 9.2)

Synergix Scan System 2-5 RAP LL91, LL92, LL93
A B
RAP LL96 Y N
Examine LED CR2 (24 V) (BSD 1.2, G2) on the Main PWB A1.
This RAP isolates faults that can cause the Calibration Extrusion not to rotate to the Home The LED is on.
Position or to fail to be detected as having arrived at the Home Position. 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
Perform GP 8 System Power Up Procedure. If LL96 is still displayed, perform the following
Repair Analysis Procedure. wires have continuity, and +24 VDC is present between A3P 300-1 and
A3P 300-6.
Y N
Procedure Repair the wires.
Examine the 7-segment LED on the Rear Panel of the Electronics Drawer. POST code P. is
displayed. Replace the Motor Control PWB A3 (PL 1.4).
Y N
POST code 5 is displayed. Examine CR2 (12 V) on the Motor Control PWB A3. The LED is on.
Y N Y N
POST code 9 is displayed. Examine LED CR9 (12 V) on the Main PWB A1. The LED is on.
Y N Y N
Check fuse A5F1 on the Lamp Ballast PWB (BSD 1.2, P2). The Fuse is open. Go to RAP 1.1 DC Power.
Y N
Enter the Diagnostics and go to the Lamp Test (Section 6) and check that Go to BSD 1.3 and troubleshoot the wires from A1P/J 406 to A3P/J 300. 12
the Exposure Lamp LP1 operates. The Lamp operates. VDC is present between A3P 300-4 and A3P 300-6.
Y N Y N
Check that the Exposure Lamp is firmly seated in its connectors and Repair the wires.
is installed with the clear window facing forward and slightly up. The
Lamp is correctly installed. Replace the Motor Control PWB A3 (PL 1.4).
Y N
Reinstall the Exposure Lamp and the Lamp Jacket correctly. Examine CR3 (5 V) on Motor Control PWB A3. The LED is on.
Y N
Check wires from A5J 22 and A5J 21 between Lamp and Lamp Bal- Examine CR10 (5 V) on the Main PWB A1. The LED is on.
last PWB (BSD 6.1, F2, H2) for continuity. The wires have conti- Y N
nuity and the connectors are seated. Go to RAP 1.1 DC Power.
Y N
Correct the condition. 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
Replace Exposure Lamp LP1. Then perform ADJ 6.1 Exposure 300-6.
Lamp Initialization. Y N
Repair the wires.
Go to BSD 6.1 and check the wires to Illumination Sensor Q11. The
wires and connectors have continuity. Replace the Motor Control PWB A3 (PL 1.4).
Y N
Repair the wires. Enter the diagnostics and go to the Calibration Motor test. Operate the test.
The Calibration Extrusion rotates.
Replace Sensor Q11 (PL 1.3). Then perform ADJ 6.1 Exposure Lamp Y N
Initialization.
Enter the diagnostics, Component Tests, [ Loopback Communications ] test.
Replace Lamp Ballast PWB A3 (PL 1.4). Operate the test The test is successful.
Y N
Replace the Main PWB A1.
Examine LED CR1 (24V) on the Motor Control PWB A3 (PL 1.4).
The LED is on.
A B A B C D
RAP LL96 2-6 Synergix Scan System
A B C D
Switch off the System. Remove the Loopback Connector from A1j 408. Per-
form the Power On Procedure [GP 8]. Go to BSD 6.3 and check the wires between
A1P 408 and A3P301. The wires are good.
Y N
Repair the wires.
Check the wires from A3P 305 to Motor MOT2 (PL 1.2B). The wires are good.
Y N
Repair the wires.
Check the gears for damage. Replace damaged parts. If Calibration Motor
MOT2 does not rotate when the Calibration Motor test is run, replace Motor
MOT2 (PL 1.2B).
Go to BSD 6.3 and check the voltage on J 400-14 and J 400-16. The voltage goes
low when the window in the Encoder Disk is aligned with the sensor, and high
otherwise.
Y N
The wires between A1P 400-14, -15, and -16, and Sensor Q11 have conti-
nuity.
Y N
Repair the wires.
Replace Illumination Sensor Q11 (PL 1.3). Perform ADJ 6.1 Exposure Lamp
Initialization.
Replace the Main PWB A1.
Enter the diagnostics. Perform the Reset NVR Defaults test (section 6). Perform GP 8
System Power Up Procedure. If POST code 5 is still displayed, replace NVR integrated
circuit U28 on the Main PWB A1. Perform the earlier steps in this paragraph again. If the
problem still exists, replace the Main PWB [REP 3.1 Main PWB].
Go to RAP 1.1 DC Power.

Synergix Scan System 2-7 RAP LL96
RAP OF-1 Document Transportation Initial Actions
This RAP describes corrective actions for faults that prevent correct transportation of inserted Ensure that the customer inserts documents such that the document is centered in the docu-
documents. ment 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
BSD
Problem Probable Cause Corrective Action Reference
The Control Panel Display indicates READY 1. Edge Presence Sensor Q4. 1. Enter the scanner diagnostics. Choose Scanner Control Panel 4.1
but there is no response when a document is from the Component Tests. Actuate Sensor Q4. If the sensor
inserted. Document Drive Motor MOT1 does does not operate, remove the top cover and clean the sensor with
NOT operate. a lint-free cloth. If the problem still exists, go to the BSD and trou-
bleshoot the fault in the sensor circuit (BSD 4.1).
2. Motor Control PWB A3 or Document

2. Enter the diagnostics and choose Component Tests, Document
Drive Motor.
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).
Frequent auto width detection failures 1. Document Right Side Sensor Q6 or 1. Enter the scanner diagnostics. Choose Scanner Control Panel 1. 6.4
Left Side Sensor Q5 are dirty or from the Component Tests. Actuate Sensor Q5 and Q6. If a sen-
faulty. sor does not operate, remove the top cover and clean the sensor
with a lint-free cloth. If the problem still exists, go to the BSD and
troubleshoot the fault in the sensor circuit (BSD 6.4).
2. 6.3
2. Platen Roll is dirty. 2. Clean the Platen Roll, using a lint-free cloth and Film Remover.
(N4)
Document is accepted when inserted, but Edge Registered Sensor Q3 Enter the scanner diagnostics. Choose Scanner Control Panel from 4.1 (R1)
doesn’t stage properly. MEDIA JAM is dis- the Component Tests. Actuate Sensor Q3. If the sensor does not
played. operate, remove the top cover and clean the sensor with a lint-free
cloth. If the problem still exists, go to the BSD and troubleshoot the
fault in the sensor circuit (BSD 4.1).
Display indicates READY; document is Drive belts. Examine the drive belts for damage. Ensure that the belt tension is 4.1 (T5)
inserted. Doc. Drive Motor MOT1 operates, correct. If not, go to Section 4, Adjustments, and perform ADJ 8.1
but the document is not transported. Main Drive Belt / Document Drive Belt Tension.

RAP OF-1 2-8 Synergix Scan System
3 Image Quality RAPS
IQ-1 Image Quality RAP.................................................................................................. 3-3
Image Quality RAPS

Image Quality RAPS
IQ-1 Image Quality RAP Additionally, many problems are caused by dirt on the Calibration Target Strip. Clean this part
with a lint-free cloth and Film Remover 8R27 (Isopropyl Alcohol).
The Image Quality RAP contains a table with descriptions of Image quality problems, probable
causes, and corrective actions. Procedure
Refer to [Table 1].
Initial Actions
Many image quality problems are caused by dirt on the Platen Glass, the SelFoc lens, or the
Platen Roll. Inspect these parts carefully. Clean the glass and the lens with Lens and Mirror
Cleaner 43P 81 and a lint-free cloth. Clean the Platen Roll using a lint-free cloth with Film
Remover 8R27 or isopropyl alcohol.
Table 1
BSD
Problem Probable Cause Corrective Action Reference
Lines on copies in process Chipped or worn Platen Glass Replace the Platen Glass.
direction.
Compressed zones in image, 1. Dirt on Document Drive Rolls. 1. Clean the rolls with Film Remover 8R27. 4.1
perpendicular to process direc- 2. If thick document, Document Thickness 2. Ensure that the customer uses the minimum adjustment of the
tion Lever and associated mechanism Document Thickness Lever to scan thick documents without drag. 6.4
White streaks, process direction Dirty Calibration Target Strip Clean the Calibration Target Strip using Film Remover 8R27. Perform 6.3
a power off - power on cycle [GP 8].
Skewed image 1. Dirt on Document Drive Rolls. 1. Clean the rolls with Film Remover 8R27. 4.1
Image out of focus Interference with complete closure of the Upper 1. Ensure that the Platen Roll in the Upper Document Transport 4.1
Document Transport. moves up and down freely.
2. Ensure that the plastic clamps that hold down the Platen Glass
are correctly seated.
Image Quality RAPS

Synergix Scan System 3-3 IQ-1
Image Quality RAPS
IQ-1 3-4 Synergix Scan System
4. Repairs and Adjustments
Repairs
REP 1.1 Power Supply.................................................................................................... 4-3
REP 3.1 Main PWB......................................................................................................... 4-5
REP 3.2 Image Processing PWB.................................................................................... 4-8
REP 4.2 Electronics Drawer........................................................................................... 4-10
REP 6.2 Platen Glass ..................................................................................................... 4-14
REP 6.3 Video Cables 1, 2, 3 ......................................................................................... 4-15
REP 6.4 Exposure Lamp................................................................................................. 4-18
REP 8.1 Front Drive Shaft Assembly .............................................................................. 4-20
REP 8.2 Rear Drive Shaft Assembly............................................................................... 4-26
REP 8.4 Upper Document Transport .............................................................................. 4-35
REP 8.5 Platen Roll / Calibration Extrusion .................................................................... 4-42
REP 8.6 Upper Document Transport Latches and Interlock Switch ............................... 4-58
REP 9.2 Image Module ................................................................................................... 4-61
REP 9.3 Thick Document Shaft ...................................................................................... 4-64
REP 14.1 Scanner End Covers....................................................................................... 4-68
REP 14.2 Scanner Back Cover ....................................................................................... 4-68
REP 14.3 Upper Document Transport Cover.................................................................. 4-69
REP 14.4 Scanner Feed-In Shelf.................................................................................... 4-70
Adjustments
ADJ 4.1 Document Drive Motor Speed (DS system only).............................................. 4-73
ADJ 6.1 Exposure Lamp Initialization ............................................................................. 4-75
ADJ 8.1 Main Drive Belt / Document Drive Belt Tension ................................................ 4-76
ADJ 8.2 Lead Edge / Trail Edge Adjustment (DS system only) ..................................... 4-78
Repairs and Adjustments

4-1
4-2
REP 1.1 Power Supply 3. (Figure 2): Disconnect the two Power Supply connectors that attach to the Main PWB:
• A1P9 (20 pin connector) from J404 on the Main PWB
Parts List on PL 1.4
• A1P10 (6 pin connector) from J405 on the Main PWB
Removal
WARNING 2
Switch off the Scanner power and disconnect the power cord. Remove the two 5.5mm Mount Screws
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 Elec-
tronics Drawer.
Figure 1 Installing the Static Band and Ground Strap

4-3 REP 1.1
6. (Figure 3): Remove the four slot-head screws that mount the Power Supply to the wall of Replacement
the Electronics Drawer.
1. The replacement or reinstallation of the Main PWB is the reverse of the Removal proce-
dure.
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 4-4
REP 3.1 Main PWB CAUTION
The Image Processing PWB is located on the left side of the Electronics Drawer (as viewed
Parts List on PL 1.4 from the rear of the Scanner). It is secured to the Main PWB by 5 screws. The Image Process-
Removal ing PWB also attaches to the Main PWB by means of three integral connectors. Exercise cau-
WARNING tion when removing this PWB from the Main PWB as these connectors can be damaged if
handled incorrectly.
Switch off the Scanner power and disconnect the power cord.
3. (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

4-5 REP 3.1
(Figure 3): Standing at the rear of the Scanner, dislocate the spring from the left drawer Slide 4. (Figure 4): Disconnect the following connectors from the Scanner Main PWB.
and gently guide the left side of the Electronics Drawer out an additional 12 mm. This will pro-
vide additional room to disconnect the three ribbon cables on the Image Processing PWB.
NOTE: When guiding the Electronics Drawer back into the Scanner (at the completion of J414 J415 J416 J400
this REP) it will be necessary to pull out the retaining spring again slightly as the drawer is
guided back into the Scanner frame.
J403
J413
J404
J405
J408 J407 J406
Figure 4 Disconnecting the Main PWB Connectors
1 2
Gently pull retaining Guide left side of Elec-
spring outward about tronics Drawer out about
5 mm 12 mm
Figure 3 Disconnecting the Slide Spring

REP 3.1 4-6
5. (Figure 5): Remove the seven mount screws and carefully lift the Main PWB from the Replacement
Electronics Drawer.
1. The replacement or reinstallation of the Main PWB is the reverse of the Removal proce-
dure.
3. If the Main PWB has been replaced, any installed feature keys must be re-installed again.
A new feature key file must be created, using the new hardware address of the replace-
ment Main PWB. Print a configuration sheet to obtain the hardware address of the Scan-
ner. 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.
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.

4-7 REP 3.1
REP 3.2 Image Processing PWB CAUTION
The Image Processing PWB is located on the left side of the Electronics Drawer (as viewed
Parts List on PL 1.4 from the rear of the Scanner). It is secured to the Main PWB by 5 screws. The Image Process-
Removal ing PWB also attaches to the Main PWB by means of three integral connectors. Exercise cau-
WARNING tion when removing this PWB from the Main PWB as these connectors can be damaged if
handled incorrectly.
3. (Figure 2): Remove the Image Processing PWB from the Main PWB.
1
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

REP 3.2 4-8
Replacement
1. The replacement or reinstallation of the Image Processing PWB is the reverse of the
Removal procedure.

4-9 REP 3.2
REP 4.2 Electronics Drawer 3. (Figure 2): Remove the Catch Tray from the Scanner.

1
Removal Remove the retaining screw at either end of the
WARNING Catch Tray Mounting Bracket
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 4-10
4. (Figure 3): Remove two screws at the back of the Scanner and pull out the Electronics 5. (Figure 4): Remove the four screws on the Electronics Drawer Top Cover and remove the
Drawer. cover.
1 1
Remove the two Remove the four screws from the
screws Electronics Drawer Top Cover
3 2
Pull out the Electronics Let the ground strap hang free
Drawer 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 Electron-
ics 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.

4-11 REP 4.2
6. (Figure 5): Install a Static Band to your wrist and attach the ground wire to an unpainted 7. (Figure 6): Standing at the rear of the Scanner, dislocate the springs from the left and
area of the Scanner chassis securely. 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 Process-
ing 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.
1 2
Gently pull retaining Guide left side of Elec-
spring outward about tronics Drawer out about
5 mm 12 mm
Figure 6 Disconnecting the Slide Spring

REP 4.2 4-12
8. (Figure 7): Disconnect the following connectors from the Scanner Electronics Drawer. Replacement
1. The replacement of the Scanner Electronics Drawer is the reverse of the Removal proce-
J414 J415 J416 dure.
J305 J500
A0P100 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.

4-13 REP 4.2
REP 6.2 Platen Glass WARNING
Parts List on 1.1 The Exposure Lamp may be hot. Allow the Lamp to cool before removal.
2. (Figure 2): Remove the Platen Glass.
Removal
WARNING
1. (Figure 1): Lift the Upper Document Transport.
2
Lift off the
Lift the Upper Document Transport Glass Clip
(one each
side)
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 4-14
REP 6.3 Video Cables 1, 2, 3
1 Parts List on PL 1.1
Reinstall this edge of the Platen Glass
towards the operator, sharp edge
Platen Glass Removal
down 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.
2 1
Pull the Platen Glass forward Remove one screw from
until it stops up against the Feed Scanner End Cover the inside of the End Cover
In Shelf
Figure 3 Correct Positioning of Platen Glass
CAUTION
In the following step, ensure that the Platen Glass is positioned squarely between the bevels of
the Glass Clips prior to tightening the clips down.
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

4-15 REP 6.2, REP 6.3
4. Remove the Feed-In shelf (REP 14.4 Scanner Feed-In Shelf). 5. (Figure 2): Lower the Video Cable Housing (PL 1.1) down from the underside of the
Image Module. Let it rest upon the lower Scanner Frame.
NOTE: The Video Cable Housing is a folded sheet steel platform that supports the three
Video Cables beneath the Image Module.
1
Disengage the Video Cable Housing by bending the three folded
tabs outward slightly, and lowering the platform
Rear of Scanner
Figure 2 Lowering the Video Cable Housing

REP 6.3 4-16
6. (Figure 3): Remove the Video Cables from the Scanner. Replacement
1. Reinstall the Video Cables on their connectors.
1 2. (Figure 4): Reinstall the Video Cables on the Video Cable Housing in the correct order. A
Any of the three Video Cables can now simplified drawing is provided below to aid in this step.
be disconnected at this point
3
Pull the rear edge of the
Video Cable Housing
upwards and snap it into
Rear of
locked position on the rear
Scanner
edge of the Image Module
2
Engage the hooked
front edge of the VCM
Video Cable 1 Video Cable 2 Video Cable 3 on to the front edge of
the Image Module 1
Video Cable Housing Replace Video Cables in
Front of Video Cable 1 correct order and string
Scanner the cables out the front
Figure 3 Removing the Video Cables of the VCM
Figure 4 Replacing the Video Cable Housing
3. Reinstall the Scanner Feed-In Shelf.

4. Reinstall the Platen Glass Clips. Ensure that the Platen Glass is clean and positioned
squarely between the bevels of the Glass Clips prior to tightening the clips down.
5. Reinstall the Scanner End Covers.
6. Close the Scanner Cover.
7. Perform REP 4.2 Electronics Drawer to reinstall the Electronics Drawer.
8. Return the Scanner to normal operation.

4-17 REP 6.3
REP 6.4 Exposure Lamp WARNING
Parts List on PL 1.3 The Exposure Lamp may be hot. Allow the Lamp to cool before removal.
Removal
WARNING
2
Lift off the
Lift the Upper Document Transport Glass Clip
(one each
side)
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.
3. Rotate the Exposure Lamp and lift it out of the Scanner.
Figure 1 Lifting the Upper Document Transport 4. Remove the black Lamp Jacket from the Exposure Lamp.

REP 6.4 4-18
Replacement CAUTION
If the fluorescent lamp has been replaced, perform all the steps in this procedure in order
NOTE: When reinstalling the Lamp Jacket on the Fluorescent Lamp ensure that the Lamp
to reset the NVR (Non-Volatile Random Access Memory) settings for the new lamp. Fail-
Jacket does not cover the light window on that lamp. The edge of the Lamp Jacket should be ure to heed this caution could result in image quality problems.
about 2mm from the edge of the lamp’s light window.
9. If the fluorescent lamp has been replaced, go to ADJ 6.1 Exposure Lamp Initialization to
1. Reinstall the Lamp Jacket on the Fluorescent Lamp. complete this replacement. If the fluorescent lamp has only been reinstalled, continue on
2. Reinstall the Fluorescent Lamp in the Scanner. with this procedure.
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 11. Return the Scanner to normal operation.
upward and towards the front of the Scanner.
4. Clean the Platen Glass with Glass Cleaner.
5. (Figure 3): Correctly position the Platen Glass in the Scanner.
1
Reinstall this edge of the Platen Glass
Platen Glass
towards the operator, sharp edge
down
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 sec-
onds. Power on the system in the following order: Scanner, Controller (if accessible),
Printer.

4-19 REP 6.4
REP 8.1 Front Drive Shaft Assembly CAUTION
Use caution when removing/reinstalling the screws on the Feed In Shelf. The screws are self-
Parts List on PL 1.3 tapping and can be cross threaded if caution is not exercised.
Removal 3. (Figure 2): Remove the Right and Left End Covers by removing the two retaining screws
WARNING on each End Cover.
1. Lift the Upper Document Transport.
2
Lift off the
Right and Left
Glass Clips
1
Remove one screw from the
inside of the End Cover
3 2
Remove one screw
Lift out the Platen
from the back of the
Glass
1 Scanner frame
Remove the screw (right and
left sides)
Figure 1 Removing the Platen Glass 4. Remove the Feed In Shelf (REP 14.4 Scanner Feed-In Shelf).
CAUTION
Take care when loosening or tightening the screws that retain the Bearing Clamps. The screws
are self-tapping, and are threaded into an aluminum casting. There is a possibility of stripping
the screws if they are misaligned or overtightened.
NOTE: Note the following when removing or reinstalling the Front Drive Shaft Assembly Bear-
ing Clamps:
• The Bearing End Clamps at the outer edges of the Front Drive Shaft Assembly are
retained by two screws each.
• The two inner Bearing Clamps are retained by only one screw.
• The left inner Bearing Clamp also contains a ground strap.
5. (Figure 3): Locate and remove the Bearing Clamps on the Front Drive Shaft Assembly.

REP 8.1 4-20
6. (Figure 4): Remove the small O-Ring Drive Belt from the left side of the Front Drive Shaft
Assembly.
Bearing Clamps (4)

O-Ring Drive Belt
Ground Strap
Figure 3 Location of Bearing Clamps on Front Drive Shaft Assembly

Figure 4 Removing the Small O-Ring Drive Belt

4-21 REP 8.1
7. (Figure 5): Remove the Document Drive Belt from the right side of the Scanner.
3
Remove the Document Drive Belt
2
Remove the screw,
Extension Spring,
and Tension Pulley
1
Remove the screw
Figure 5 Removing the Document Drive Belt

REP 8.1 4-22
8. (Figure 6): Remove the Belt Guard from the right side of the Scanner. Replacement
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
1 the Bearing Clamps
Carefully slide the Belt 3. (Figure 7): Reposition and tighten down the two Bearing Clamps on the right side of the
Guard up and around the Front Drive Shaft Assembly. Ensure that the two tabs on each bearing fully engage the
pulleys slots in the Bearing Clamp prior to tightening down the clamp.
Screws mount to Frame
Bearing
Clamps
Figure 6 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. Inner Bearing Clamp Bearing End Clamp
Configuration Configuration
10. If the Front Drive Shaft Assembly is being replaced, remove the E-ring and pulley from the
old Front Drive Shaft Assembly.
Figure 7 Correct Installation of Inner and Outer Bearing Clamps

4-23 REP 8.1
4. (Figure 8): Reinstall the O-ring Drive Belt and Bearing Clamps. 6. (Figure 9): Reinstall the right side components.
1
Reinstall the O-ring Drive Belt over the
Drive Pulley and the Drive Shaft Pulley 4
Reinstall the Document
Drive Belt
2
Reinstall the
two left side
Bearing Clamps
1
Reinstall the 5
screw Fully tighten screw
3
Reinstall the
spring
2
Loosely reinstall
the Tension Pulley
and screw
Figure 8 Installing the Left Side Belt and Bearing Clamps
5. Slide the Belt Guard back into position on the right side of the Scanner.
Figure 9 Reinstalling the Right Side Components
7. Reinstall the Feed In Shelf.

8. Reinstall the Left and Right End Covers.
CAUTION
9. (Figure 10): Clean and reinstall the Platen Glass.

REP 8.1 4-24
2
Reinstall the
Right and Left
Glass Clips
1
Place the Platen 3
Glass as shown, Reinstall the
biasing it slightly for- screw (right and
ward. left sides)
Figure 10 Reinstalling the Platen Glass


4-25 REP 8.1
REP 8.2 Rear Drive Shaft Assembly 2. (Figure 2): Remove the Right and Left End Covers by removing the two retaining screws
on each End Cover.
Removal
WARNING
Lift the Upper

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

REP 8.2 4-26
3. (Figure 3): Remove the Platen Glass. 5. (Figure 4): Remove the Left Slide Bracket and Left Pivot Bracket.
4
Remove the Left
Pivot Clutch
Assembly 1
Remove two K-
2 clips and one
Lift off the washer
Glass Clip
(one each
side)
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
6. Disconnect the two ground straps, located behind the Right and Left Pivot Clutch Assem-
blies, by removing the screws.

4-27 REP 8.2
7. (Figure 5): Remove the following components on the right side of the Scanner. 8. (Figure 6): Remove the Belt Guard from the right side of the Scanner.
1
Carefully slide the Belt
Guard up and around the
pulleys
Belt Guard
1
Remove the
3 screw, spring and
Remove the Tension Pulley
mount
screw Figure 6 Removing the Belt Guard
2
Remove the belt
Figure 5 Removing the Right Side Components

REP 8.2 4-28
NOTE: In the following illustration the two large pulleys on the right side have been omit- 10. (Figure 8): Remove the Scanner Back Cover.
ted for clarity. They should remain on the Scanner for the duration of this procedure, how-
ever.
9. (Figure 7): Remove the Right Side Pivot Clutch.
3
Remove the Right
Pivot Clutch and
2 Bracket
Remove the Remove the five screws
Bearing
Clamp
1
Remove the two
mount screws Figure 8 Removing the Scanner Back Cover
Figure 7 Removing the Right Pivot Clutch

4-29 REP 8.2
11. (Figure 9): Slide out the Electronics Drawer from the back of the Scanner. 12. (Figure 10): Lift and reposition the Upper Document Transport for access to the Rear
Drive Shaft Assembly.
1
Route the group of cables out around the right side of the
Rear Drive Shaft. Do not disconnect any of the cables.
Slide the Electronics

Drawer out from the
back of the Scanner
Figure 9 Sliding out the Electronics Drawer
2 3
Move the Upper Document Transport Ensure that the Rear Drive Shaft
forward, so that it rests on the Feed In Assembly can be accessed
Shelf
Figure 10 Repositioning the Upper Document Transport

REP 8.2 4-30
13. (Figure 11): Remove the Rear Exit Baffle. CAUTION
Take care when loosening or tightening the screws that retain the Bearing Clamps. The screws
1 are self-tapping, and are threaded into an aluminum casting. There is a possibility of stripping
Remove the mount screw at both the screws if they are inadvertently misaligned or overtightened.
ends of the Rear Exit Baffle 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

4-31 REP 8.2
NOTE: One of the inner Bearing Clamps also contains a ground strap. Ensure that this ground Replacement
strap is disconnected prior to removing the Rear Drive Shaft Assembly. 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
1 each Drive Shaft Bearing must fully engage the slots in the Bearing Clamps prior to tightening
Loosen the mount screws (4) down the Bearing clamps
2. (Figure 14): Reposition and tighten down the two Bearing Clamps in the center of the
Rear Drive Shaft Assembly. Ensure that the two tabs on each bearing fully engage the
slots in the Bearing Clamp prior to tightening down the clamp.
Mount screw Bearing Clamp

into frame
2 Bearing
Swing the Bearing Clamps off the
Rear Drive Shaft Assembly, but do
not remove them Figure 14 Correct Installation of Bearing Clamp
Figure 13 Removing the Bearing Clamps 3. 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.

REP 8.2 4-32
4. (Figure 15): Reposition the Upper Document Transport over the Rear Drive Shaft Assem- 7. (Figure 16): Reinstall the Right Bearing Clamp and Right Pivot Clutch.
bly.
3
4 Reinstall the Right Pivot
1 Depress the pawl to Clutch and Bracket with
Route the cables back to the engage the Right Pivot the two mount screws
inside of the Rear Drive Shaft Clutch
2
Reinstall the
Bearing Clamp
on the Bearing
2
Reposition the Upper Docu- 1
ment Transport back over the Reinstall the
Image Module Bearing on
the Rear
Drive Shaft
Figure 16 Reinstalling the Right Bearing Clamp and Right Pivot Clutch
Figure 15 Repositioning the Upper Document Transport
8. Reinstall the Belt Guard on the right side of the Scanner.
5. Slide the Electronics Drawer back into the Scanner. 9. Reinstall the pulleys and belt on the right side of the Scanner.
6. Reinstall the Scanner Back Cover.
CAUTION
each Drive Shaft Bearing must fully engage the slots in the Bearing Clamps prior to tightening
down the Bearing clamps

4-33 REP 8.2
10. (Figure 17): Reinstall the Left Bearing Clamp and Left Pivot Clutch. 11. (Figure 18): Reinstall the Slide Bracket on the left side of the Scanner.
4 2
Depress the pawl to Reinstall the two K-clips
engage the Left Pivot and washer
Clutch
3
Reinstall the Left Pivot
Clutch and Bracket with 1
two mount screws Reinstall the
Slide Bracket
1 2
Reinstall the Reinstall the Bear-
Bearing on ing Clamp over the Figure 18 Reinstalling the Slide Bracket
the Rear Bearing
Drive Shaft 12. Open the Upper Document Transport.
Figure 17 Reinstalling the Left Bearing Clamp and Left Pivot Clutch CAUTION
In the following step, ensure that the Platen Glass is clean, and that it is positioned squarely
between the bevels of the Glass Clips prior to tightening the clips down.
13. Reinstall the Platen Glass and the Right and Left Glass Clips.
14. Reinstall the Right and Left End Covers.

REP 8.2 4-34
REP 8.4 Upper Document Transport 3. (Figure 2): Remove the Right and Left End Covers by removing the two retaining screws
on each End Cover.
Parts List on PL 1.2A, 1.2B
Removal
WARNING
1. Lift the Upper Document Transport.
2 1
Lift off the Remove one
Right and Left screw from the
Glass Clips inside of the End
Cover
2
Remove one
screw from
the back of the
Scanner frame
3
Lift out the Platen
Glass
1 Figure 2 Removing the Right and Left End Covers
Remove the screw (right and
left sides)
4. Remove the Feed In Shelf (REP 14.4 Scanner Feed-In Shelf).

4-35 REP 8.4
5. (Figure 3): Disconnect the Illumination Sensor and feed the wires down through the
channel.
1
Disconnect the Illumination
Sensor
2
Feed the wires down
through the channel and
out the back of the Scanner
Figure 3 Disconnecting the Illumination Sensor (Q11P1)

REP 8.4 4-36
6. (Figure 4): Remove the Left Slide Bracket and Left Pivot Clutch Assembly. 8. (Figure 5): Remove the Document Drive Belt.
4
Remove the Left
Pivot Clutch 1
Assembly Remove two K-clips
and one washer
3
Remove the belt
3 2
Remove two Remove the Slide
screws Bracket
1
2 Remove the screw,
Remove the Extension Spring
Figure 4 Removing the Left Slide Bracket and Left Pivot Clutch Assembly mount and Tension Pulley
screw
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.)

4-37 REP 8.4
9. (Figure 6): Remove the Belt Guard by lifting it off the Front and Rear Drive Shafts. 10. (Figure 7): Remove the Right Pivot Clutch Assembly.
2
Remove the Right
3 Pivot Clutch
Remove the Assembly
Bearing
1 Clamp
Carefully slide the
Belt Guard up and
around the pulleys
1
Remove the two
mount screws
Figure 6 Removing the Belt Guard Figure 7 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.

REP 8.4 4-38
11. (Figure 8): Remove the Scanner Back Cover. 13. (Figure 9): Disconnect the Upper Document Transport connectors and ground strap from
the Electronics Drawer.
2 1
Disconnect Disconnect
P305 A0P100
Figure 8 Removing the Scanner Back Cover
12. Slide out the Electronics Drawer from the back of the Scanner.
Figure 9 Disconnecting the Upper Document Transport Connectors and Ground Strap
14. Ensure that the connectors previously disconnected can pass freely through the Scanner.
15. Remove the Upper Document Transport from the Scanner and place it on a clean, flat
surface.

4-39 REP 8.4
Replacement 7. (Figure 11): Reinstall the right side components.
1. Place the Upper Document Transport back on the Scanner, making sure that the connec-
tors 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.
4
3. Close the Electronics Drawer. Reinstall the Drive
4. Reinstall the Scanner Back Cover (five screws). Belt
5. (Figure 10): Reinstall the Right Pivot Clutch Assembly.
2
Reinstall the 1
Right Pivot Reinstall the
Clutch screw
3 Assembly
Reinstall the
two mount
screws 3
Reinstall the
spring
2
Reinstall the
Tension Pulley
and screw
1
Reinstall the Figure 11 Reinstalling the Right Side Components
Bearing Clamp
8. Reconnect the ground strap near the Left Pivot Clutch Assembly.
Figure 10 Reinstalling the Right Pivot Clutch Assembly
6. Reinstall the Belt Guard on the Front and Rear Drive Shafts.

REP 8.4 4-40
9. (Figure 12): Reinstall the Left Slide Bracket and the Left Pivot Clutch Assembly.
1
Reinstall the Left
Pivot Clutch
Assembly
4
Reinstall the
washer and two K-
clips
3
2 Reinstall the
Reinstall the Slide Bracket
two screws
Figure 12 Reinstalling the Left Slide Bracket and Left Pivot Clutch Assembly


4-41 REP 8.4
REP 8.5 Platen Roll / Calibration Extrusion 3. (Figure 2): Prepare to remove the Upper Document Transport Cover.
Parts List on PL 1.2A

Removal 2
WARNING Pivot the Document
Thickness Lever to its
Switch off the Scanner power and disconnect the power cord. highest position
NOTE: Perform steps 1 through 21 to remove the Platen Roll. To remove the Calibration Extru-
sion for replacement, perform steps 1 through 22.
1. (Figure 1): Remove the Scanner Control Panel from the Scanner. Upper Document
Transport Cover
1
Loosen the center screw
1
Remove the screws (three per side)
Figure 2 Preparing to Remove the Upper Document Transport Cover
4. Lower the Upper Document Transport (UDT) and lift the UDT cover off the Scanner, start-
ing 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.
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.

REP 8.5 4-42
6. (Figure 3): Remove the Right and Left End Covers by removing the two retaining screws 7. (Figure 4): Prepare to remove the Right Side Belt Guard.
on each End Cover.
3
Remove the belt
1
Remove one screw
from the inside of the
End Cover
2
Remove one screw
from the back of the 1
Scanner frame Remove the
2 screw, Extension
Remove the Spring and Ten-
mount sion Pulley
screw
Figure 4 Preparing to Remove the Right Side Belt Guard


4-43 REP 8.5
8. (Figure 5): Remove the Belt Guard by lifting it off the Front and Rear Drive Shafts. 9. (Figure 6): Remove the right side components of the Platen Roll Shaft.
1
Carefully slide the
Belt Guard up and
around the pulleys
1
Remove the K-clip
and the white nylon
bushing
Figure 6 Removing the Right Side Components

10. Lower the Upper Document Transport.

REP 8.5 4-44
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.
4 1
Remove the Left Pivot Clutch Assembly Remove two K-clips and
one washer
2
Remove the E-
ring and bearing
1
Remove the K-clip
3 and white nylon
Remove the two 2 bushing
screws, Bear- Remove the Slide
ing Clamp and Bracket
Bearing
Figure 8 Removing the hardware
Figure 7 Removing the Left Slide Bracket and Left Pivot Clutch Assembly

4-45 REP 8.5
13. (Figure 9): Pull the Left Side Plate off the Scanner. 14. (Figure 10): Remove the left side Platen Roll Shaft components.
Left Side Plate
1
Remove the
K-Clip
3
Remove the
spring washer
2
Remove the
brass bushing
Figure 10 Removing the Left Side Platen Roll Components
Figure 9 Removing the Left Side Plate

REP 8.5 4-46
15. (Figure 11): Remove the right side Platen Roll Shaft components. CAUTION
In the following steps it is important to exercise caution when removing the Calibration
1 Extrusion Assembly, as it can be easily scratched while being removed from the Scanner,
2 negatively affecting print quality.
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 Cardboard or paper
Document Transport. This will help to avoid damage to the glass while the Calibration placed under Upper
Document Transport
Extrusion Assembly is being removed in the following steps.
Figure 12 Dislocating the Cable Ties

4-47 REP 8.5
NOTE: The Calibration Extrusion Assembly will be removed in the following steps. 19. (Figure 14): Prepare to remove the left side End Cap from the Calibration Extrusion
Ensure that this assembly (and its component parts) does not get dirty or scratched, as Assembly.
print quality problems will result.
NOTE: The Left Side End Cap is distinguishable from the Right Side End Cap by the
18. (Figure 13): Remove the Calibration Extrusion Assembly from the Scanner frame by presence of the Rubber Drive Wheel on the left side.
carefully sliding it out the left side of the Scanner. Set it down upon a clean, flat surface.
End Cap Assembly 1

1 Remove the two screws
Carefully slide the Calibration
Extrusion Assembly out of the
Scanner frame
2
Remove the Rubber
Drive Wheel (and
attached sleeve), not-
ing the clockwise
direction of the Drive
Wheel rubber spokes
Scrap Paper
to protect
Platen Glass
Figure 14 Preparing to Remove the Left Side End Cap
20. Remove the Left Side End Cap from the Calibration Extrusion Assembly by sliding it off
Figure 13 Removing the Calibration Extrusion Assembly
the shaft.

REP 8.5 4-48
21. (Figure 15): Remove the Platen Roll from the Calibration Extrusion Assembly by sliding it Replacement
out, and placing it on a clean, flat surface.
CAUTION
NOTE: At this point the Platen Roll has been successfully removed from the Scanner. Be very careful while handling the Platen Roll. Any dirt, dust, or scratches will adversely affect
The step that follows will continue the product disassembly to separate the Right Side scan quality.
End Cap from the Calibration Extrusion. (This only needs to be done in cases where the 1. If the Calibration Extrusion has been replaced, reinstall the Right Side End Cap on the
Calibration Extrusion is in need of replacement.) 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 2. Clean off the Platen Roll and the Calibration Target Strip on the Calibration Extrusion by
plastic shell) 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

4-49 REP 8.5
4. (Figure 17): Reinstall the Left End Cap on the Calibration Extrusion Assembly. 5. (Figure 18): Reinstall the Rubber Drive Wheel and Sleeve onto the Left Side of the Platen
Roll Shaft.
2
Slide Drive Wheel down on the
2 1 Platen Roll Shaft until the Drive
Reinstall the countersunk Reinstall the slot-head Wheel is flush with the Platen
screw on the left side screw directly adjacent to Roll Shaft Rubber Drive
the small slot in the Left Wheel and
Side End Cap Sleeve
Platen Roll
Left End Cap Shaft
1
Figure 17 Reinstalling the Left End Cap
Ensure that the cutouts on the Sleeve line up with the
flat edges of the Platen Roll Shaft
NOTE: In the following steps, ensure that the Rubber Drive Wheel and shaft are rein-
stalled flush with the edge of the Platen Roll Shaft.
Figure 18 Reinstalling the Rubber Drive Wheel and Sleeve

REP 8.5 4-50
CAUTION 8. (Figure 20): Reinstall the following components on the right side of the Platen Roll Shaft.
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.
1
Ensure that the Rubber Drive Wheel (Left Side of Calibration Extrusion Assembly) is
Reinstall the brass bushing
mounted on the left side of the Scanner. 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.

4-51 REP 8.5
9. (Figure 21): Lift the left end of the Platen Roll Shaft. Reinstall the brass bushing on the 11. (Figure 22): Reinstall the shaft hardware onto the Upper Document Transport right side.
end of the shaft and set it back down into the Scanner frame.
2
Reinstall the K-Clip
1
Reinstall the
1 white plastic
Reinstall the brass bushing
bushing and the
spring washer
2
Reinstall the K-
Clip
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.

REP 8.5 4-52
12. (Figure 23): Reinstall the Thick Document Indicator by pushing it back down over its 14. (Figure 24): Push the Left Side Slide Plate back to its furthest position prior to reinstalling
mounting bracket on the Right Side Slide Plate. 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.

4-53 REP 8.5
15. (Figure 25): Reinstall the Left Side Plate back onto the Scanner left side. 16. (Figure 26): Align the left side of the Thick Document Shaft to the Left Side Plate prior to
reinstalling the bushings.
1 2
Guide the two shafts into the Guide the Thick Document
slots molded in the Left Slide Shaft into the cutout hole.
Plate Assembly. 1
Set the Thick Document Shaft
the required distance from the
Baffle Edge
2
Ensure that one
tooth of the Thick
Document Shaft
Gear overhangs the
last tooth of the
Left Slide Rail
1 inch
(25.4 mm) Thick Document
Baffle Edge Shaft
Figure 25 Reinstalling the Left Side Plate
Figure 26 Aligning the Left Side of the Thick Document Shaft

REP 8.5 4-54
17. (Figure 27): Complete the Left Side Plate Reinstallation. CAUTION
each Drive Shaft Bearing must fully engage the slots in the Bearing Clamps prior to tightening
down the Bearing clamps
CAUTION
Take care when loosening or tightening the screws that retain the Bearing Clamps. These
screws are self-tapping, and are threaded into an aluminum casting. There is a possibility of
stripping the screws if they are inadvertently misaligned or overtightened.
18. (Figure 28): Reinstall the Left Pivot Clutch Assembly.
1
Reinstall the white
bushing and K-clip
4
Depress the pawl to
engage the Left Pivot
Clutch
2
Reinstall the
white bushing
and E-ring
3
Figure 27 Completing the Left Side Plate Reinstallation Reinstall the Left Pivot
Clutch Assembly with
two (2) mount screws
1 2
Reinstall the Place the Bearing
Bearing on Clamp over the
the Rear Bearing
Drive Shaft
Figure 28 Reinstalling the Left Pivot Clutch Assembly

4-55 REP 8.5
19. (Figure 29): Reinstall the Slide Bracket on the left side of the Scanner. 21. (Figure 30): Reinstall the Scanner right side components.
2 1
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 2

Reinstall the screw,
Extension Spring,
20. Place the Right Belt Guard Plate back into position on the Right Side of the Scanner.
3 and Tension Pulley
Reinstall the screw

REP 8.5 4-56
22. Reinstall the Scanner Right and Left End Covers.
23. Reinstall the Scanner Top Cover cover by performing the following steps:
a. Hold the Scanner Top Cover above the Scanner.
b. Feed the Scanner Control Panel cable up through the cutout hole in the Scanner Top
Cover.
c. (Figure 31): Rotate the Thick Document Adjustment Handle to its highest position.
1
Lift handle to
highest position
Figure 31 Rotating the Thick Document Adjustment Handle
d. Guide the Thick Document Adjustment Handle upward through the slot in the Scan-
ner Top Cover, and work the Top Cover down onto the Scanner.
e. Lower the Thick Document Adjustment Handle once the Top Cover has been cor-
rectly 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.

4-57 REP 8.5
REP 8.6 Upper Document Transport Latches and Interlock 2. Perform REP 14.1 Scanner End Covers .
Switch 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.
Parts List on PL 1.1 The left latch does not include an Interlock Switch.
Removal
3. (Figure 2): Remove the Document Drive Belt from the right side of the Scanner.
WARNING
1. (Figure 1): Lift the Upper Document Transport. 3
Remove the Document Drive Belt
Lift the Upper

Document
Transport
1
Remove the screw 2
Remove the screw, spring,
and Idler Pulley

REP 8.6 4-58
4. (Figure 3): Remove the Belt Guard from the right side of the Scanner. 5. (Figure 4): Remove the Upper Document Transport Latch.
2
Remove the two screws and lift the Latch off the
Scanner
1 3
Note the color and Disconnect the connectors
position of the switch from the Interlock Switch
connectors
Figure 4 Removing the UDT Interlock Switch

4-59 REP 8.6
Replacement 4. Reinstall the Scanner End Covers
1. Reinstall the Upper Document Transport Latch and Interlock Switch. 5. Close the Upper Document Transport.
2. Reinstall the Belt Guard on the right side of the Scanner. 6. Return the Scanner to normal operation.
3. (Figure 5): Reinstall the Document Drive Belt on the right side of the Scanner.
4 3
Reinstall the tension spring and Reinstall the Document
fully tighten the retaining screw Drive Belt
1 2
Reinstall the screw Reinstall the screw and Idler Pul-
ley
Figure 5 Reinstalling the Document Drive Belt

REP 8.6 4-60
REP 9.2 Image Module 3. (Figure 2): On the left side of the Scanner, remove the Stub Shaft Bracket.

1
Removal 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 2
Image Module 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)

4-61 REP 9.2
4. Lift the Image Module up from the machine frame and gently turn it over, resting it tempo- Replacement
rarily on its side.
NOTE: If you are replacing the old Image Module, transfer the following non-spared parts from
5. (Figure 3): Remove the Video Cable Housing from the back of the Image Module. No
tools are required for this task. 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 dam-
aged very easily if pinched by the housing.
2. Reinstall the Video Cable Housing to the underside of the Image Module.
Video Cable Housing 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.
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 4-62
6. (Figure 5): Reinstall the Image Module on the Scanner.
1
Reinstall the
two hex nuts
Figure 5 Reinstalling the Image Module
7. Perform REP 8.4 Upper Document Transport to reinstall the Upper Document Transport
onto the Scanner.
8. Perform ADJ 6.1 Exposure Lamp Initialization Procedure.

4-63 REP 9.2
REP 9.3 Thick Document Shaft 3. (Figure 2): Prepare to remove the Upper Document Transport.
Parts List on PL1.2A, 1.2B

Removal 2
1. (Figure 1): Remove the Scanner Control Panel from the Scanner.
Upper Document
Transport Cover
1
1
4. Feed the Scanner Control Panel harness down through the cutout in the Upper Document
2 Transport Cover and carefully lift the cover off the Scanner.
and disconnect the connector U2P1 5. Lower the Document Thickness Lever.
beneath the console
2. Raise the Upper Document Transport from the Feed In Shelf.

REP 9.3 4-64
6. (Figure 3): Remove the Right and Left End Covers by removing the two retaining screws 7. (Figure 4): Remove the bushing and E-ring from both the right and left sides of the Thick
on each End Cover. Document Shaft.
2
back of the Scanner frame
1
Remove one
screw from the
inside of the End
Cover
1
Remove the Bushing
and E-ring (both sides)
Figure 3 Removing the Right and Left End Covers Figure 4 Removing the Bushing and E-Ring from the Thick Document Shaft
NOTE: It may be necessary to gently press the Right or Left Side Plates slightly aside to
achieve enough clearance for removal of the Thick Document Shaft.
8. Remove the Thick Document Shaft from the Scanner.

4-65 REP 9.3
Replacement 3. (Figure 6): Align the right side of the Thick Document Shaft in the Scanner.
CAUTION
It is imperative that the Thick Document Shaft be reinstalled in the Scanner exactly as
described in this procedure. Image quality problems or document feed problems will result if
the Thick Document Shaft is not reinstalled/replaced as described. 1 2
Raise the Upper Document Align the Thick Document Handle
Transport slightly with the angle of the Right Side
1. (Figure 5): Ensure that the Right and Left Slide Plates are moved as far towards the rear Plate
of the Scanner as possible.
1
Press the Right and Left
Slide Rails as far to the rear
of the Scanner as possible
Baffle Edge
Thick Document 1 inch
Shaft (25.4 mm)
Left Slide Rail
3 4 5
Loosely reinstall the Mount the Thick Docu- Reinstall the right
Figure 5 Moving the Side Plates to the Rear of the Scanner right side bushing, ment Shaft on the Right side Bushing and
enough to allow some Slide Rail the required E-Ring
adjustment of shaft distance from the Baffle
2. Set the Thick Document Shaft loosely back into the Scanner. Move the Right and Left
position Edge
Side Plates as necessary to accomplish this.
Figure 6 Aligning the Right Side of the Thick Document Shaft

REP 9.3 4-66
4. (Figure 7): Align the left side of the Thick Document Shaft in the Scanner. 6. Reinstall the Upper Document Transport Cover by performing the following steps:
a. Hold the Upper Document Transport Cover over the Scanner and feed the Scanner
Control Panel connector A2P1 up through the cutout in the Upper Document Trans-
port Cover.
1 2 b. Reinstall the Upper Document Transport Cover screws (3 screws per side).
Close the Upper Document Set the Thick Document Shaft c. Lower the Document Thickness Lever to its lowest position.
Transport the required distance from the
Baffle Edge 7. (Figure 8): Check the installation and positioning of the Thick Document Shaft. If the dis-
play in the Document Thickness Indicator Window is not correct, remove the Upper Docu-
3 ment Transport Cover and adjust the positioning of the Thick Document Shaft on the
Ensure that one Scanner Slide Rails accordingly.
tooth of the Thick
Document Shaft
Gear overhangs the
last tooth of the Red strip is flush with the top Red strip is not flush with the top
Left Slide Rail of the display area of the display area
1 inch
(25.4 mm) Thick Document
Baffle Edge Shaft
4
Reinstall the left side
Bushing and E-Ring Correct installation of Thick Docu- Incorrect installation of Thick Doc-
ment Shaft on Slide Rails ument Shaft on Slide Rails
Figure 7 Aligning the Left Side of the Thick Document Shaft Figure 8 Checking the Display in the Document Thickness Indicator Window
5. Raise the Document Thickness Lever to its highest position. 8. Reinstall the User Interface.

4-67 REP 9.3
REP 14.1 Scanner End Covers REP 14.2 Scanner Back Cover
Parts List on PL 1.5 Parts List on PL 1.5
Removal Removal
WARNING WARNING
Switch off the Scanner power and disconnect the power cord. Switch off the Scanner power and disconnect the power cord.
NOTE: This procedure is identical for the Right and Left End Covers. 1. (Figure 1): Remove the Scanner Back Cover.
1. (Figure 1): Remove the Right or Left End Cover.
1
Remove one screw from the inside of the End Cover
Figure 1 Removing the Scanner Back Cover
3 2
Lift End Cover off Scanner Remove one screw from the back
of the Scanner frame
Figure 1 Removing the Right or Left End Cover

REP 14.1 , REP 14.2 4-68
REP 14.3 Upper Document Transport Cover 3. (Figure 2): Prepare to remove the Upper Document Transport Cover.
Parts List on PL 1.2A

Removal 2
1. (Figure 1): Remove the Scanner Control Panel from the Scanner.
Upper Document
1 Transport Cover
1
4. Lower the Upper Document Transport (UDT) and lift the UDT cover off the Scanner, start-
2 ing from the rear of the machine, and working towards the front.
and disconnect the connector U2P1 5. Feed the Scanner Control Panel harness down through the cutout in the Upper Document
beneath the console Transport Cover.
Replacement
Reinstall the Scanner Top Cover cover by performing the following steps:
2. Raise the Upper Document Transport from the Feed In Shelf. 1. Hold the Scanner Top Cover above the Scanner.
2. Feed the Scanner Control Panel cable up through the cutout hole in the Scanner Top
Cover.
3. (Figure 3): Rotate the Thick Document Adjustment Handle to its highest position.

4-69 REP 14.3
REP 14.4 Scanner Feed-In Shelf
Removal
Perform the following steps to ,remove the scanner Feed-In shelf
1. Open the Document Handler.

2. Remove the Left and Right Covers (REP 14.1 Scanner End Covers).
1
3. Remove the Left and Right Platen Glass Clips. Remove the(2) shelf retaining screws on
Lift handle to
highest position left and right ends of the Feed-In Shelf (Figure 1).
1
Remove the (2) Platen
Glass Clips by removing
the screws
2
Figure 3 Rotating the Thick Document Adjustment Handle Remove the (2)
retaining screws.
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.
3
Remove the (2)
screws securing the
Latch Bracket and
remove the bracket.
Figure 1 Remove the Platen Glass Clips, retaining screws and Latch Bracket.
4. Remove the Latch Bracket (Figure 1).

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

REP 14.3, REP 14.4 4-70
Figure 2 Shift the shelf left and toward you to remove it.

4-71 REP 14.4
REP 14.4 4-72
ADJ 4.1 Document Drive Motor Speed (DS system only) Check
Purpose 1. Go to GP 13 Creating the System Speed and Lead Edge Detect Test Target. Print out
the test target and continue on with this procedure.
The purpose of this procedure is to ensure that the Scanner Document Drive Motor is rotating
2. After five minutes, measure the line on the printed test target, write this measurement
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. down on the test target, as well as the word “print master”.
3. On the Scanner Control Panel, select Main Menu > Configuration > Copy Options >
NOTE: Perform Document Drive Motor in section six when servicing the XEScan Solution sys- Imaging > Auto Rotate (press Enter to select this option).
tem. 4. On the Scanner Control Panel, select Main Menu > Configuration > Scanner Control >
Auto Width = OFF. Then return to the Copy screen.
NOTE: The Document Drive Motor Speed Test requires that a 36 inch (or equivalent ISO A1
5. On the Printer Control Panel, check to see if a 24 inch (610 mm) roll of paper is loaded in
series size) roll of paper be loaded on the Printer.
the printer. If this is the case, change the value stated for that roll to any number other
NOTE: This Adjustment requires the System Speed and Lead Edge Detect Test Target. This than 24 inches (610 mm). (NOTE: This needs to be done to force a rotation of the test
test target must be downloaded from the laptop computer to the Printer, and then printed out print.)
prior to beginning this procedure. 6. On the Scanner Control Panel, check to see that the above change has been confirmed
by the Scanner:
• Under Media Selection/Source, check the R1, R2, R3, and R1/R3 values for the
This line will be measured for the paper rolls in those drawers. No drawer should have a value of 24 inches (610 mm).
Document Drive Motor Speed Test • 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 lead-
ing.
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 rota-
tion 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
Figure 1 System Speed and Lead Edge Detect Test Target
Drive Motor Speed Adjustment.

4-73 ADJ 4.1
Adjustment 8. Exit the Diagnostics mode and return to the Scanner copy mode.
1. This adjustment is password controlled. To enter the Service Diagnostic Password select NOTE: In the following steps it will be necessary to copy the print master System Speed
Main Menu > Diagnostics > Password. Enter the password (6789) and press Enter. and Lead Edge Detect Test Target to ensure test accuracy.
2. (Figure 2): On the Scanner Control Panel select Main Menu > Diagnostics > Scanner
9. Verify that the Scanner Motor is scanning to the correct speed by making another scan
Diagnostics > Component Tests > Motor Speed > Expected Length. The Motor
and print of the original test target, and again measuring the 610 mm line on the print that
Speed screen will appear.
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 sys-
tem options.
• Scanner Control Panel: Main Menu > Configuration > Copy Options > Imaging.
Return the Auto Rotate function to the customer’s preferred selection (On or OFF).
• Scanner Control Panel: Main Menu > Configuration > Scanner Control > Auto
Width = ON.
• Printer Control Panel: Reset the width of the 24 inch (or equivalent) paper roll.
11. Return the system to normal operation.
Figure 2 Motor Speed Expected Length Screen (Example)
3. On the printed test pattern, measure the line marked “610 mm”.
4. Using the keypad on the Scanner Control Panel, enter the measured value from the previ-
ous 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 4-74
ADJ 6.1 Exposure Lamp Initialization 4. Press the Enter key to confirm the change.
5. Switch off the Scanner, Controller and Printer for about 15 seconds.
Purpose
6. Perform GP 8 System Power Up Proceduree. When the system initializes, it will re-estab-
This procedure is used to initialize the Exposure Lamp in cases where the Illumination Sensor
lish the new fluorescent lamp readings and intensity.
Q11 has been repositioned or replaced, or the Exposure Lamp has been repositioned or
7. Run a copy of Test Target #82E5980 to confirm the correct operation and copy quality of
replaced. Writing a 0 (zero) in location 2 of the NVR forces the Scanner to re-evaluate the lamp
the Scanner.
brightness and store the appropriate values.
Check
1. (Figure 1): On the Scanner Control Panel select Main Menu > Diagnostics > Scanner
Diagnostics > Write NVR. The following screen appears.
Figure 1 Write NVR Screen (Default)
2. Use the Enter key and numeric keypad on the Scanner Control Panel to input the values
listed in Figure 1. When the EXECUTE:NO field is reached, use the NEXT key to toggle
the NO value to YES.
3. (Figure 2): The screen will then look like this:
Figure 2 Modified NVR Screen

4-75 ADJ 6.1
ADJ 8.1 Main Drive Belt / Document Drive Belt Tension 2. (Figure 2): Set the Scanner Main Drive Belt tension.
Purpose
The purpose of this procedure is to enable the Service Representative to correctly adjust the
1
belt tension of both the Scanner Main Drive Belt and Document Drive Belt.
Loosen the four (4) Docu-
ment Drive Motor mount
WARNING 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 Main Drive Belt

Spring
2
Remove one screw
scanner frame
1
Remove one
screw from the
inside of the 2 3
Right End Cover Flex the Main Drive Belt to allow the Tighten the four (4) Docu-
Tension Spring to set the Main Drive ment Drive Motor mount
Belt tension screws.
Figure 1 Removing the Right End Cover

Figure 2 Setting the Scanner Main Drive Belt Tension

ADJ 8.1 4-76
3. (Figure 3): Set the Document Drive Belt tension.
1
Loosen the Document Drive Belt Tension Idler screw
3
Tighten down the
Tension Idler
screw
2
Flex the Document Drive Belt to allow
the Tension Idler spring to set the Doc-
ument Drive Belt tension
Figure 3 Setting the Drive Belt Tension
4. Reinstall the Right End Cover.


4-77 ADJ 8.1
ADJ 8.2 Lead Edge / Trail Edge Adjustment (DS system Check
only) 1. (Figure 2): On the Scanner Control Panel select Main Menu > Diagnostics > Scanner
Diagnostics > Component Tests > Lead Edge/Trail Edge Adjustment. The following
Purpose screen will appear.
The purpose of this procedure is to ensure that the Scanner correctly detects the lead and trail
edges of the scanned document.
NOTE: Pereform Lead Edge/ Trail Edge in section six when servicing the XEScan Solution
system.
1. (Figure 1): This Adjustment requires the System Speed and Lead Edge Detect Test Tar-
get. This test target must be downloaded from the laptop computer to the Printer, and
printed out prior to beginning this procedure.
Go to
Creating the System Speed and Lead Edge Detect Test Target. Print out the Test Target
and continue on with this procedure.
This line will be used for the Lead

Edge / Trail Edge Test Figure 2 Lead Edge / Trail Edge Adjustment Screen
2. 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.
3. (Figure 3): Press the Start button. The following screen will appear.
Figure 1 System Speed and Lead Edge Detect Test Target
2. After creating the test target, ensure that the lead edge is completely darkened by cutting
along the line specified with a pair of scissors. Running a dark felt tip pen along that same
lead edge will further enhance edge clarity.
Figure 3 Lead Edge / Trail Edge In Progress Screen
NOTE: As the Scanner diagnostic software begins a check of the lead edge of the docu-
ment, an audible clicking sound should be heard.

ADJ 8.2 4-78
4. (Figure 4): When the Lead Edge / Trail Edge adjustment has been completed, the test
target will be backed out onto the Scanner Feed In Shelf and the following screen will
appear.
Figure 4 Lead Edge / Trail Edge Adjustment Completed Screen

4-79 ADJ 8.2
ADJ 8.2 4-80
5 Parts List
Overview
Introduction ..................................................................................................................... 5-3
Subsystem Information ................................................................................................... 5-4
Symbology ...................................................................................................................... 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) ........................................................... 5-8
PL 1.2B Upper Document Transport (Part 2 of 2) ........................................................... 5-9
Scanner Module Assembly

PL 1.3 Image Module and Document Feed Rollers ........................................................ 5-10
PL 1.4 Electrical Module ................................................................................................. 5-11
PL 1.5 Lower Document Transport ................................................................................. 5-12
Scanner Stand Assembly

PL 2.1 Scanner Stand ..................................................................................................... 5-13
PL 3.0 Miscellaneous ...................................................................................................... 5-14
Common Hardware
Common Hardware ......................................................................................................... 5-15
Part Number Index .......................................................................................................... 5-15
Parts List
Parts List
Introduction Other Information
Overview Abbreviations
Abbreviations are used in the parts lists and the exploded view illustrations to provide
The Parts List section identifies all part numbers and the corresponding location of all spared
information in a limited amount of space. The following abbreviations are used in this manual:
subsystem components.
Table 1
Organization
Abbreviation Meaning
Parts Lists
Each item number in the part number listing corresponds to an item number in the related A3 297 x 594 Millimetres
illustration. All the parts in a given subsystem of the machine will be located in the same A4 210 x 297 Millimetres
illustration or in a series of associated illustrations. A5 148 x 210 Millimetres
AD Auto Duplex
Electrical Connectors and Fasteners AWG American Wire Gauge
This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used EMI Electro Magnetic Induction
in the machine. A part number listing of the connectors is included.
GB Giga Byte
Common Hardware KB Kilo Byte
The common hardware is listed in alphabetical order by the letter or letters used to identify MB Mega Byte
each item in the part number listing and in the illustrations. Dimensions are in millimetres MM Millimetres
unless otherwise identified. MOD Magneto Optical Drive
NOHAD Noise Ozone Heat Air Dirt
Part Number Index
PL Parts List
This index lists all the spared parts in the machine in numerical order. Each number is followed
P/O Part of
by a reference to the parts list on which the part may be found.
R/E Reduction/Enlargement
REF: Refer to
SCSI Small Computer Systems Interface
W/ With
W/O Without
Table 2
Operating Companies
Abbreviation Meaning
AO Americas Operations
NASG - US North American Solutions Group - US
NASG - North American Solutions Group -
Canada Canada
XE Xerox Europe
Symbology
Symbology used in the Parts List section is identified in the Symbology section.
Service Procedure Referencing

If a part or assembly has an associated repair or adjustment procedure, the procedure number
will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)
Parts List
Synergix Scan System 5-3 Introduction
Subsystem Information
Use of the Term " Assembly"
The term "assembly" will be used for items in the part number listing that include other itemized
parts in the part number listing. When the word "assembly is found in the part number listing,
there will be a corresponding item number on the illustrations followed by a bracket and a
listing of the contents of the assembly.
Brackets
A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The
item number of the assembly or kit precedes the bracket; the item numbers of the piece parts
follow the bracket.
Tag
The notation "W/Tag" in the parts description indicates that the part configuration has been
updated. Check the change Tag index in the General Information section of the Service Data
for the name and purpose of the modification.
In some cases, a part or assembly may be spared in two versions: with the Tag and without the
Tag. In those cases, use whichever part is appropriate for the configuration of the machine on
which the part is to be installed. If the machine does not have a particular Tag and the only
replacement part available is listed as "W/Tag," install the Tag kit or all of the piece parts. The
Change Tag Index tells you which kit or piece parts you need.
Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate
number on the Tag matrix.
Parts List
Subsystem Information 5-4 Synergix Scan System
Symbology A Tag number within a circle having a shaded bar and pointing to an item number shows that
the configuration of the part shown is the configuration before the part was changed by the Tag
A Tag number within a circle pointing to an item number shows that the part has been changed
number within the circle (Figure 2).
by the tag number within the circle (Figure 1). Information on the modification is in the Change
Tag Index.
Figure 2 Without Tag Symbol
Figure 1 With Tag Symbol
Parts List
Synergix Scan System 5-5 Symbology
A tag number within a circle with no apex shows that the entire drawing has been changed by A tag number within a circle with no apex and having a shaded bar shows that the entire
the tag number within the circle (Figure 3). Information on the modification is in the Change Tag drawing was the configuration before being changed by the tag number within the circle (Figure
Index. 4).
Figure 3 Entire Drawing With Tag Symbol Figure 4 Entire Drawing Without Tag Symbol
Parts List
Symbology 5-6 Synergix Scan System
PL 1.1 Scanner Module
Item Part Description
1 892E32360 Control Panel Label (English)
– 892E32370 Control Panel Label (French)
– 892E32380 Control Panel Label (Italian)
– 892E32390 Control Panel Label (German)
– 892E32400 Control Panel Label (Spanish)
– 892E32410 Control Panel Label (Portuguese)
2 101K43451 Scanner Control Panel
– 101K47720 Scanner Control Panel (UI for
XEScan Solutions)
3 – Upper Document Transport
Assembly
4 962K01520 Upper Control Panel Harness
5 090E02231 Platen Glass
6 019E47130 Right Glass Clip
7 019E47110 Left Glass Clip
8 – Image Module Assembly
9 – Video Cable Housing
10 962K12170 Video Cable 3
13 – Electrical Module
14 – Lower Document Transport
15 604K08540 Feed-In Shelf Kit (W/TAG 003)
16 019E47140 Platen Glass Foam
17 – IEEE 1394 Cable (NOTE: Connects
to FireBoard 400 Lynx PWB PN
140N05961 (XEScan Solutions),
and IEEE 1394 PWB PN
160K79060 (DS AccXES
Systems.))
18 – Mounting Bracket (P/O Item 2)
11/01 Parts List

Synergix Scan System 5-7 PL 1.1
PL 1.2A Upper Document Transport
(Part 1 of 2)
1 892E31490 Thickness Label
2 056E04650 Indicator Bezel
3 – Guide (P/O PL1.1 Item 3)
4 802E21320 Top Cover
5 892E16370 Logo Strip Label
6 020K11860 Friction Wheel
7 004E20940 Bumper
8 015K47571 Left Side Plate
9 028E14180 Retainer Housing
10 022E24600 Pinch Roller
11 809E32080 Spring
12 006E76990 Shaft
13 130E05421 Sensor (Q2-Q6)
14 055K32880 Rear Mylar Strip
15 055K32870 Front Mylar Strip
16 022K69631 Platen Roll
17 014K06880 Calibration Spacer (2 Places)
18 – Upper Document Housing (P/O
PL1.1 Item 3)
19 016E06020 Bushing (6mm)
20 016E16100 Bushing
21 021K02581 End Cap
22 020K11880 Calibration Housing
23 – Keeper (P/O PL1.5 Item 15)
24 – Keeper (P/O PL1.5 Item 17)
Parts List 11/01

PL 1.2A 5-8 Synergix Scan System
PL 1.2B Upper Document Transport
(Part 2 of 2)
1 019E51420 Clip
2 – Static Eliminator
– 105E09000 Static Eliminator
3 019E15041 Clip
4 127K40860 Calibration Drive Motor (MOT2)
5 130E09690 Calibration Home Sensor (Q1)
6 892E31480 Indicator Label
7 809E43500 Spring
8 032E19371 Guide
9 047E00540 Ball
10 830E72960 Label Bracket
11 007E69160 Gear (36T)
12 815E00590 Side Slide Plate
13 015K47581 Right Side Plate
14 007E68160 Gear (28T)
15 016E16100 Bushing (10mm)
16 409W02078 Spring
17 007E69500 Pawl
18 – Thick Document Handle
19 806E00170 Thick Document Shaft
11/01 Parts List

Synergix Scan System 5-9 PL 1.2B
PL 1.3 Image Module and Document
Feed Rollers
1 – Rear Exit Baffle (P/O PL1.1 Item 8)
2 802E41621 Left Pivot Clutch
3 809E31970 Bearing End Clamp
4 006K20580 Rear Drive Shaft
5 019E47291 Shaft Ground Clip
6 809E32020 Bearing Mid Clamp
7 802E41611 Right Pivot Clutch
8 – Wave Spring (P/O Item 1)
9 013E18660 Bearing
10 020E38280 Timing Pulley (72T)
11 006K20590 Front Drive Shaft
12 113K02790 Lamp Socket
13 122E02640 Lamp
14 802K38101 Image Module
15 – Illumination Sensor Bracket (P/O
PL1.1 Item 8)
16 130K54470 Illumination Sensor PWB (Q11)
17 006K20600 Stub Shaft
18 005E15090 O-Ring Drive Pulley
19 035E56510 O-Ring
20 – Lamp Jacket (P/O PL1.1 Item 8)
21 – Harness (Lamps to Ballast) (Not
Spared)
Parts List 11/01

PL 1.3 5-10 Synergix Scan System
PL 1.4 Electrical Module
1 – Top Cover (P/O PL1.1 Item 13)
2 162K65261 DC Harness
3 105E14291 LV Power Supply (PS1)
4 160K65760 Image Processing PWB
5 160K65792 Scanner Main PWB (A1) (W/TAG
002)
6 160K72091 Motor Control PWB (A3)
7 – Slide (P/O PL1.1 Item 13)
8 – Electrical Module Housing (P/O
PL1.1 Item 13)
9 – Card Guide (P/O PL1.1 Item 13)
10 104K00053 Lamp Ballast PWB (A5)
11 162K65240 Harness (Ballast to Lamps)
12 117E22800 Power Cord
13 733W05871 NVM Flash (U28)
14 537K67112 E-Prom (U10) (W/TAG 002)
15 162K65271 Main Harness Assembly
11/01 Parts List

PL 1.5 Lower Document Transport
1 – Back Cover (P/O PL1.1 Item 14)
2 802E21311 Left End Cover
3 – Lower Transport Housing (P/O
PL1.1 Item 14)
4 127K40860 Document Drive Motor (MOT1)
5 – Motor Bracket (P/O PL1.1 Item 14)
6 – Foot (Not Spared)
7 409W03143 Spring
8 – Interlock Harness (P/O PL1.1 Item
14)
9 802E21301 Right End Cover
10 023E21040 Main Drive Belt
11 020K09370 Dual Driven Pulley
12 020E38170 Tension Idler
13 409W03211 Spring
14 023E21050 Document Drive Belt
15 003K16870 Interlock Assembly
16 – Interlock Catch (P/O Item 15)
17 003K16860 Interlock Assembly
18 – Interlock Catch (P/O Item 17)
Parts List 11/01

PL 2.1 Scanner Stand
1 – Catch Tray/Organizer (Not Spared)
2 – Catch Tray Support (Not Spared)
3 – Scanner Module Assembly (REF:
PL1.1)
4 – Height Adjustment Bracket (Not
Spared)
5 – Organizer Support (Not Spared)
6 830E76070 Organizer Mounting Clip
7 – Stand (Not Spared)
8 017E02620 Swivel Caster
9 017E02610 Rigid Caster
10 021E09960 End Cap
11/01 Parts List

PL 3.0 Miscellaneous
1 115N00356 Dongle
2 140N05961 Fire Board 400 Lynx PWB
3 017E06010 Copy Stop
4 050E10191 Front Stacker
5 121E01402 Latch Magnet
6 055K32270 Mylar Strip
Parts List 11/01

Common Hardware Part Number Index
A 113W16802 Screw (4-40 x 1/2) Table 1 Part Number Index
B 252W31350 Washer (M10) Part Number Part List
C 354W21052 E-Ring (8MM)
003K16860 PL 1.5
D 158W20459 Screw (M4 x 8)
003K16870 PL 1.5
E 354W21252 E-Ring (10MM)
F 158W30359 Screw, Thread Rolling Torx (M3 x 6) 004E20940 PL 1.2A
G 112W24410 Screw (6-32 x 1/4) 005E15090 PL 1.3
H 220W00350 Nut, Hex, Flanged, Self-locking (M3) 006K20580 PL 1.3
J 201W00355 Nut (M3) 006K20590 PL 1.3
K 354W00555 K-Clip (6MM)
006K20600 PL 1.3
L 112W25155 Screw (M3 x 6)
M 102W13556 Screw, M4 Counter sink 006E76990 PL 1.2A
N 113W10555 Screw, Pan Head (M4 x 12) 007E68160 PL 1.2B
P 265W01050 Spring Washer (M10) 007E69160 PL 1.2B
R 251W16655 Washer (6MM) 007E69500 PL 1.2B
S 158W10459 Screw (M3 x 8)
013E18660 PL 1.3
T 153W27554 Screw (M4)
U 265W00850 Spring Washer (8MM) 014K06880 PL 1.2A
V 220W10650 Nut (M6) 015K47571 PL 1.2A
W 158W40459 Screw (M4 x 8) 015K47581 PL 1.2B
X 158W17552 Screw (M4 x 8) 016E06020 PL 1.2A
Y 354W00855 K-Clip (8MM)
016E16100 PL 1.2A
Z 158W20659 Screw (M4 x 10)
PL 1.2B
017E02610 PL 2.1
017E02620 PL 2.1
017E06010 PL 3.0
019E15041 PL 1.2B
019E47110 PL 1.1
019E47130 PL 1.1
019E47140 PL 1.1
019E47291 PL 1.3
019E51420 PL 1.2B
020K09370 PL 1.5
020K11860 PL 1.2A
020K11880 PL 1.2A
020E38170 PL 1.5
020E38280 PL 1.3
021K02581 PL 1.2A
021E09960 PL 2.1
022E24600 PL 1.2A
022K69631 PL 1.2A
023E21040 PL 1.5
023E21050 PL 1.5
028E14180 PL 1.2A
11/01 Parts List

Synergix Scan System 5-15 Common Hardware, Part Number Index
Table 1 Part Number Index Table 1 Part Number Index
Part Number Part List Part Number Part List
032E19371 PL 1.2B 802E41611 PL 1.3
035E56510 PL 1.3 802E41621 PL 1.3
047E00540 PL 1.2B 806E00170 PL 1.2B
050E10191 PL 3.0 809E31970 PL 1.3
055K32270 PL 3.0 809E32020 PL 1.3
055K32870 PL 1.2A 809E32080 PL 1.2A
055K32880 PL 1.2A 809E43500 PL 1.2B
056E04650 PL 1.2A 815E00590 PL 1.2B
090E02231 PL 1.1 830E72960 PL 1.2B
101K43451 PL 1.1 830E76070 PL 2.1
101K47720 PL 1.1 892E16370 PL 1.2A
104K00053 PL 1.4 892E31480 PL 1.2B
105E09000 PL 1.2B 892E31490 PL 1.2A
105E14291 PL 1.4 892E32360 PL 1.1
113K02790 PL 1.3 892E32370 PL 1.1
115N00356 PL 3.0 892E32380 PL 1.1
117E22800 PL 1.4 892E32390 PL 1.1
121E01402 PL 3.0 892E32400 PL 1.1
122E02640 PL 1.3 892E32410 PL 1.1
127K40860 PL 1.2B 962K01520 PL 1.1
PL 1.5 962K12150 PL 1.1
130E05421 PL 1.2A 962K12160 PL 1.1
130E09690 PL 1.2B 962K12170 PL 1.1
130K54470 PL 1.3
140N05961 PL 3.0
160K65760 PL 1.4
160K65792 PL 1.4
160K72091 PL 1.4
162K65240 PL 1.4
162K65261 PL 1.4
162K65271 PL 1.4
409W02078 PL 1.2B
409W03143 PL 1.5
409W03211 PL 1.5
537K67112 PL 1.4
604K08540 PL 1.1
733W05871 PL 1.4
802E21301 PL 1.5
802E21311 PL 1.5
802E21320 PL 1.2A
802K38101 PL 1.3
Parts List 11/01

Part Number Index 5-16 Synergix Scan System
6 General Procedures
Scanner Installation GP 13 Creating the System Speed and Lead Edge Detect Test Target ......................... 6-50
Digital System Scanner Installation................................................................................. 6-3 GP 14 Scanner Diagnostic access using a laptop .......................................................... 6-51
XEScan Solution Scanner Installation............................................................................. 6-4
Special Tools
Diagnostics Special Tools................................................................................................................... 6-53
Diagnostics...................................................................................................................... 6-7
Using the Diagnostic Software - Key Properties ............................................................. 6-7
Change Tag/ Mod Index
Change Tag/ Mod Index.................................................................................................. 6-55
Main Menu Tree Structures............................................................................................. 6-8
Power On Self Test (POST) Diagnostics ........................................................................ 6-12
Usage Meters.................................................................................................................. 6-12
Clear Scanner Usage...................................................................................................... 6-13
Installation Test Print....................................................................................................... 6-13
Password ........................................................................................................................ 6-14
Scanner Diagnostics
Entering the Scanner Diagnostics ................................................................................... 6-15
Image Path Test .............................................................................................................. 6-16
Scan Bar Calibration Test ............................................................................................... 6-16
Full System Test ............................................................................................................. 6-17
Write NVR ....................................................................................................................... 6-18
Reset NVR Defaults ........................................................................................................ 6-18
Scanner Reliability Meter ................................................................................................ 6-19
Scanner Faults (Ordered) ............................................................................................... 6-19
Scanner Faults (Counts) ................................................................................................. 6-20
Clear Scanner Fault Log ................................................................................................. 6-20
Read Non Volatile Random Access Memory (NVR) ....................................................... 6-21
Component Tests
Motor Speed Test............................................................................................................ 6-24
Lead Edge/ Trail Edge ................................................................................................... 6-24
Sensors ........................................................................................................................... 6-25
Scanner Control Panel .................................................................................................... 6-25
Document Motor (Loopback) Communications ............................................................... 6-27
Document Drive Motor .................................................................................................... 6-28
Lamp ............................................................................................................................... 6-28
Calibration Motor............................................................................................................. 6-29
General Procedures
GP 1 How to Check a Short Circuit ................................................................................. 6-30
GP 2 How to Check an Open Circuit............................................................................... 6-31
GP 3 How to Check a Sensor ......................................................................................... 6-32
GP 4 How to Check a Switch and its Associated Wiring................................................. 6-33
GP 5 Generic PWB Checkout ......................................................................................... 6-34
GP 8 System Power Up Procedure................................................................................. 6-37
GP 9 Enabling/Disabling the DDS Option - 8825 / 8830 Printers ................................... 6-38
GP 10 Enabling/Disabling the DDS Option - 8855 Printer .............................................. 6-38
GP 11 Catch Tray and Organizer Tray ........................................................................... 6-39
GP 12 Compact Catch Bins ............................................................................................ 6-44
General Procedures
6-1
General Procedures
6-2
Digital System Scanner Installation 7. Power up the system. Go to the Procedure GP 8 System Power Up Procedure in this
section.
NOTE: This procedure assumes the following conditions: 8. Perform GP 9 Enabling/Disabling the DDS Option - 8825 / 8830 Printers - 8825/8830
• The Printer and Controller are previously installed. Printers.
• V6.1 software (or greater) has been loaded on the Controller. 9. System initializes successfully, and the Scanner is ready to copy.
• The rigger has assembled the Scanner and placed it upon its stand, or on top of the 8855 10. Make a copy of Test Target #82E5980 and check the overall copy quality.
Printer. (Catch Tray and Organizer Tray not yet installed.) 11. Make a copy of the Installation Test Print and check the print quality. If the print quality
1. Install the Scanner Control Panel and Control Panel labels. needs to be modified, go to Section 3 of this publication.
2. Remove any packing materials, tape, etc. from the outside of the Synergix Scanner. Lift 12. Download/Install any Special Feature Key Options (Refer to special instructions con-
tained within Feature Options kit.)
up the Upper Document Transport and remove the material protecting Platen Glass.
Close the Upper Document Transport. 13. Upon successful installation of the entire system, complete the customer operator training
3. Install the Catch Tray and the Organizer Tray (if required). as specified in the System Participant’s Guide.
4. Install the IEEE1394 PMC Card. Go to the IEEE 1394 PWBA Installation procedure in the 14. Make a copy of all system Configuration Test Prints and store them in the Printer Service
AccXES Controller Service Manual. Log.
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 cor-
rectly.
5. Install the IEEE 1394 PMC Cable from the IEEE 1394 Kit.
1
Position the angled edge of
the IEEE1394 PMC Cable
connector into the angled
edge of the Scanner port
Rear of Scanner
Figure 1 Installing the IEEE1394 PMC Cable
6. Install the power cord from the Scanner Nationalization Kit.
General Procedures
6-3 Digital System Scanner Installation
XEScan Solution Scanner Installation
Follow this procedure to install the XEScan Solution standalone scanner and its system soft-
ware.
Installing the XEScan Solution Control Panel

Perform the following steps to install the control panel on the scanner:
1. Remove the existing large control panel bracket (if necessary).
2. Install the smaller control panel bracket using the supplied screws (Figure 1).
Install the bracket

using the (3) screws.
Ensure that the wire Connect the wire
harness is threaded harness to the
throught the hole in the Control Panel
bracket. connector.
Figure 2 Connect the wire harness to the Control Panel.
4. Secure the Control Panel to the control panel bracket using the screws (Figure 3).
Figure 1 Install the XEScan Solution Control Panel bracket
3. Plug the control panel connector into the bottom of the XEScan Solution Control Panel
(Figure 2).
General Procedures
XEScan Solution Scanner Installation 6-4
NOTE: When the scanner is powered up, the communications LED may fail to progress Installing the XEScan software
to a P. (P-dot). If the display shows an E, this indicates that the scanner firmware does not The XEScan software installation routine will install the XEScan application software, hardlock
support the XEScan Solution smaller control panel. Updating the firmware will resolve this software, and the Synergix Diagnostics application. The installation is typical of most Windows
problem.
application installations.
CAUTION
If the software was previously installed on the host PC, perform the Software Uninstall proce-
dure then this procedure to reinstall the software.
When installing the software, follow the installation defaults as you step through the install wiz-
ard.
Once the XEScan software installation has completed, install the Firteboard 400 drivers. From
the Start menus select [Start:Programs:XES Programs:Install Unibrain Firewire Drivers].
Follow the on screen prompts to install the drivers using the default settings.
Completely power OFF the PC when finished.
Connecting the scanner

Once the software has been installed, connect the Synergix scanner to the host PC.
1. Power off the host PC.
2. Connect one end of the IEEE-1394 cable to to one of the connectors on the Fireboard
400 card.
3. Connect the other end of the cable to one of the IEEE-1394 connectors on the back of the
scanner. Secure the cable using the strain relief on the back of the scanner.
4. Connect the power cable to the receptacle on the back of the scanner. Connect the plug
Figure 3 Secure the Control Panel to the bracket using the (2) screws to a dedicated 15A wall plug.
5. Power on the scanner and observe the communications LED for successful completion of
IEEE-1394 Fireboard 400 installation the POST tests. After a period of time a P. (dot) will be displayed
Perform the following styems to install the Fireboard 400 IEEE-1394 interface card in the host
NOTE: If the scanner does not have the correct firmware version to support the standal-
PC
one scanner control panel, the communications LED will only display an E. Updating the
CAUTION firmeware to the most current version should resolve the problem.
Follow electrostatic discharge (ESD) guidelines when working with the electronic components
of the computer. Before removing the cover, unplug any power cord that is connencted to the Configuring the scanner and software
computer. Always wear an ESD wristband that is connected to an exposed metal section of the 1. Clean the scanner Platen Glass. If necessary, access the scanner hardware help for
computer. instructions.
NOTE: If the host PC is using the Windows NT operating system, disable Plug-n-Play in the 2. Power on the scanner. Ensure that it has completed initialization.
system BIOS 3. Power on the host PC.
4. Download and install the latest firmware from the XES website.
1. Power off the host PC.
5. Start the XEScan software. The Keycode entry screen will appear.
2. Remove all cables and place the PC on a sturdy level surface.
6. Place the keycode print into the scanner and click the Scan Keycode button. As an alter-
3. Remove the slot cover for the PCI slot that will receive the Fireboard 400 card.
native method, you can enter the keycode, found on the document included with the
4. Insert the card into the PCI slot. Ensure that the card is seated properly in the slot. install kit, manually.
5. Secure the card using the screw used to secure the slot cover. 7. Redeem and install any feature keys purchased by the customer.
6. Reinstall the PC cover and re-connect the PC cables. 8. Perform a test scan using the Test Scan/Document Scan routine found in the Synergix
7. Install the Keycode Dongle on the PC parallel connector. Diagnostics application.
8. Power On the PC to ensure it boots properly.
General Procedures
6-5 XEScan Solution Scanner Installation
XEScan Software uninstall procedure
Perform the following steps to properly uninstall the XEScan software:
1. Select [Start:Settings:Control Panel]. Double click the Add/Remove Programs icon.
2. On the Install/Uninstall tab scroll the list and select XES XEScan program. Click the
[Remove] button.
3. Scroll the list again and select the Synergix Diagnostics program. Click the [Remove]
button.
4. Click the Finish button to close the dialog. Close the Control Panels window.
5. Use Explorer or My Computer to navigate to the Program Files folder. Delete the XESys-
tems folder.
6. Close Explorer or My Computer and restart the system.
General Procedures
XEScan Solution Scanner Installation 6-6
Diagnostics Passwords
Introduction There are three passwords associated with the Synergix Digital Solution:
This subsection describes the use of the diagnostics software to isolate faults in the Interceptor
• The System Administration Password (SAP). The default value is zero (0), and should be
Scanner system. The diagnostic software enables access to the diagnostic routines contained
changed by the customer to a value of the customer’s choice. As long as the value of the
in the Scanner.
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
The diagnostic routines are contained either in the firmware for the associated Controller to
makes a connection.
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 To enter this password using the Scanner Control Panel, press the Menu key; select Sys-
tem Administration; press the Enter key; and enter the password. Press the Enter key to
features.
confirm the entry. The System Administrator functions are then available, and remain so
To enter the diagnostics mode for the 88xx Synergix Digital Solution and X2 Tech printer, go until the operator exits the Menu mode and returns to normal operation.
to Entering the Scanner Diagnostics in this section. • The System Administrator’s Override Password (SAOP). The password is 88300. Use
this password when the System Administrator Password has been lost or forgotten.
Entering 88300 automatically resets the System Administrator password to 0 (zero). The
Using the Diagnostic Software - Key Properties customer should then immediately change the password to a value of the customer’s
In order to navigate through the Diagnostics menu, the properties of the buttons located choice.
below the LCD must be understood. The following list gives a brief explanation of the proper-
ties of the control buttons. NOTE: The SAOP is hard coded and cannot be changed; therefore, it must never be dis-
closed to the customer.
NOTE: Some diagnostics, marked with a (*) in, require the entry of the Diagnostic Password. To enter this password, press the Menu key; select System Administration; press the
Refer to Password for information about the Service Diagnostic Password and how to enter it.
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 • The Service Diagnostic Password (SDP). The password is 6789. This password is
located beneath the LCD. Three short chirps is an indication of an invalid selection for that required for access to protected Diagnostic functions.
particular menu item. 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
• 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 key. Select PASSWORD, and press the Enter key. Enter 6789 and press the Enter key to
the Main Menu Tree. While the Scanner Control Panel is displaying a Main Menu tree confirm the entry.
screen, pressing this key is equivalent to repeatedly pressing the EXIT key until the Scan- The SDP remains in force as long as the operator remains inside the DIAGNOSTICS
ner Control Panel returns to the previous READY state. 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 vis-
ible.
• 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 tran-
sition between Ready states. (For example, between Ready-to-Copy and Ready-to-
Scan.) When depressed, the MODE key changes from one state to the next state listed
on the display.
General Procedures
6-7 Diagnostics, Using the Diagnostic Software
Main Menu Tree Structures Configuration Menu
NOTE: The following Menu Tree structure views are shown as they will appear with the Fea-
ture Keys enabled.
Figure 1 Configuration Menu
General Procedures
Main Menu Tree Structures 6-8
Diagnostics Menu
Figure 2 Diagnostics Menu
General Procedures
6-9 Main Menu Tree Structures
System Information Menu
Figure 3 System Information Menu
General Procedures
Main Menu Tree Structures 6-10
System Administration Menu
Figure 4 System Administration Menu
General Procedures
6-11 Main Menu Tree Structures
Power On Self Test (POST) Diagnostics Usage Meters
(Table 1): When the Scanner power is switched on, the Scanner performs the following Power (Figure 1): This screen will display the following menu.
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, The Scanner Area usage is measured in square units (either feet or meters) for all types of
and the code of the test that failed is continuously displayed. The POST tests are shown in the Scanners. The Scanner Usage Meter displayed from this menu is maintained by the AccXES
table below. Controller firmware. A usage meter is also maintained by the internal Interceptor Scanner firm-
ware.
The Media Usage is provided by the Printer and is tracked in both linear and square units as
Table 1 POST Codes defined by the Printer.
Code Description
0 RAM test
1 Checksum Test - Update FLASH ROM
2 Serial Controller (SCC) test
3 GPLynx register - write/read back test
4 Application checksum test
5 NVR (Non-volatile Random Access Mem- Figure 1 Usage Meters Screen

ory) verification test
6 Checksum test - SCVM code
7 24 Volts test
8 Lamp Test
9 Motor communications test
A SCVM Load and functional test
B IP card interface test
C IP card internal test
D Video path test
E Scanner Control Panel Communications
U Flash Update Mode
P Post tests completed, no IEEE 1394 com-

munications with external controller
P. IEEE 1394 communications established

with external controller.
General Procedures
Power On Self Test (POST) Diagnostics, Usage 6-12
Clear Scanner Usage Installation Test Print
This screen permits the CSE to reset the Scanner’s usage meter to zero. This operation is This menu will queue an Installation Test Print for use in the Scanner calibration. This test print
password protected. If the password has not been entered the “INVALID PASSWORD, RE- can only be queued if the diagnostic password has been entered. The Installation Test Print is
ENTER” message is displayed, and the operator must return to the password entry screen and used to evaluate the adjustment of the print density produced by the Printer.
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 dis-
played.
Figure 1 Clear Scanner Usage Screen
Figure 1 Installation Test Print Screen
General Procedures
6-13 Clear Scanner Usage, Installation Test Print
Password
This menu item allows the operator to enter the service diagnostic password. This password
unlocks the protected diagnostic tests.
Enter the password 6789 and press the Enter key.
• If an invalid password is entered, the screen displays

INVALID PASSWORD, RE-ENTER.
• Once entered, the password remains in effect until the operator leaves the Diagnostics
menu and returns to normal operation.
Figure 1 Password Screen
General Procedures
6-14
Entering the Scanner Diagnostics Table 1 List of Diagnostic Tests
Do the following steps to enter the Scanner Diagnostics:

Password
Name of Test Type Description Required?
1. Switch on the Scanner, the Controller, and the Printer, and wait for all of the devices to ini-
tialize.
Special Allows the operator to display the NO
2. Press the Menu key on the Scanner Control Panel. entries contained in the Scanner
3. Press the Next key until DIAGNOSTICS is highlighted on the Scanner Control Panel. internal fault log.
4. (Figure 1): Press the Enter key. The DIAGNOSTICS screen is displayed.
Special Allows the operator to display cumu- NO
lative counts of each fault type from
the Scanner internal fault memory.
Special Causes the contents of the Scanner YES

fault logs to be erased.
Figure 1 Entering Scanner Diagnostics Special Allows the CSE to adjust the speed YES
of the Document Drive Motor in the
5. Press the Next key until SCANNER DIAGNOSTICS is highlighted. Scanner.
6. Press the Enter key. Special Enables the adjustment of the stag- NO
A list of Diagnostics tests is displayed. Press the Next or the Previous key to highlight ing position of the lead edge and the
the desired test, and press the Enter Key to operate that test. correct positioning of the trail edge
Results of the tests are displayed on the scanner control panel. Table 1 List of Diagnostic for documents inserted into the Scan-
Tests shows the available tests. ner.
Table 1 List of Diagnostic Tests Special Displays the current state of each of NO
the optical paper sensors in the Inter-
ceptor Scanner.
Password
Name of Test Type Description Required? Special Allows the user to execute the Docu- NO
ment Motor Communications Loop-
Special Tests communications with the NO
back test.
Image Bars.
Special Allows the user to stop and start the NO
Special Adjusts the pixels of the Scan bar for NO Document Drive Motor
uniform response to a target of stan-
dard reflectivity. Special Allows the user to turn the Fluores- NO
cent Lamp on or off.
Special Runs a series of tests that check for NO
correct operation of the Scanner. Special Allows the user to control the Calibra- NO
tion Motor and to select the Calibra-
Special This password-protected diagnostic YES tion Motor function.
allows the CSE to modify the con-
tents of the non-volatile memory of Special This menu will queue an Installation YES
the Scanner. Test Print for use in the Scanner cali-
bration.
Special Allows the technician to reset the YES
NVR values to the factory default val- Special Displays the contents of the Non-Vol- NO
ues. atile RAM on the Scanner.
Special Allows the operator to view the cur- NO

rent value of the usage meter main-
tained by the Scanner.
General Procedures
6-15 Entering the Scanner Diagnostics
Image Path Test Scan Bar Calibration Test
Diagnostic password required: NO. Diagnostic password required: NO.
This test checks the communications with the three Image Bars. This test checks the response of the light-sensitive elements in the Image Bar (Scan Bar).
The Scanner rotates the Calibration Extrusion until the Calibration Target Strip, a surface of
The test runs the IP Card test and the SCVM test. If the IP Card test is successful, the BOARD known reflectivity, into the view of the Image Bar, and the response of each element is com-
ID field contains a numeric value, and the STATUS field indicates PASSED. pared 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.
Communications with the Image Bars are checked using the SCVM test. Each Image Bar is
separately evaluated; a successful test is indicated by PASSED. Select the SCAN BAR CALIBRATION test from the menu of diagnostic tests (Entering the
Scanner Diagnostics).
(Figure 1): If the Scanner does not respond to either the IP Card test, the SCVM test, or both,
the message NO RESPONSE FROM SCANNER is displayed. (Figure 1): Press the Start button on the Scanner Control Panel.
NOTE: To perform the test again, reselect the Image Path Test from the Scanner Diagnostics
menu.
Figure 1 Scan Bar Calibration
The PRESS START TO BEGIN messages changes to RUNNING. If the test is successful,
PASS is displayed. If not, ERROR CODE and a hexadecimal error code are displayed. (
Figure 1 Image Path Test 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 to Table 1 Message Display Entry Chart, (located in Section 1 of this service man-
ual) for possible causes.
General Procedures
Image Path Test, Scan Bar Calibration Test 6-16
Full System Test
Diagnostic password required: NO.
Table 1 Error Codes for the Scan Bar Calibration Test
This test performs a series of tests, shown in (Table 1), to check that the Scanner is operating
Hex
correctly.
Code Meaning Code Meaning
Select the FULL SYSTEM TEST from the menu of diagnostic tests (Entering the Scanner
01 Dark pixel calibration 06 Dark pixel calibration -
Diagnostics).
- Range adjustment time-out
error (Figure 1): Press the Start key to begin the sequence of tests.
02 Dark pixel calibration 07 Offset calibration - time-
- Range status error out
03 Offset calibration 08 Gain calibration - time-

error out
04 Gain calibration error 09 Set integration failure

- Video too high
05 Gain calibration error

- Video too low.
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 com-
plete, P is displayed if the test passed; F, if the test failed.
Table 1
Test Test
Code Description Code Description
A POST test 5 - NVR Veri- E POST test 9 -- Interface -

fication Image Processing PWB
B POST test 6 - Motor F POST test A - Internal test

communications - Image Processing PWB
C Post test 7 SCVM Code G POST test B - Video path

Checksum
D POST 8 SCVM Load

and Functional test
General Procedures
6-17 Scan Bar Calibration Test, Full System Test
Write NVR Reset NVR Defaults
Diagnostic password required: YES. Diagnostic password required: YES.
This password-protected diagnostic allows the CSE to modify the contents of the non-volatile This password-protected diagnostic allows the technician to reset the NVR (Non-volatile Ran-
memory of the Scanner. dom Access Memory) values to the factory default values. All customized NVR default settings
will be lost when this procedure is performed.
CAUTION
Certain customer-defined NVR values will be lost when this reset procedure is performed.
Therefore, record the existing NVR values on a piece of paper by using the READ NVR func-
tion in the Diagnostics Menu prior to performing this function. The READ NVR location on the
Scanner Control Panel is: Main Menu > Diagnostics > Scanner Diagnostics > Read NVR.
Figure 1 Write NVR Screen
The SIZE field specifies the size of the data value to written to the memory. Valid entries are
1,2, and 4 indicating the number of bytes to be written. The ADDRESS field specifies the start-
ing 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 Figure 1 Reset NVR Defaults Screen
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 The following rules apply to the use of this option:
menu and no operation occurs.
• If the CSE hits EXIT or ENTER without scrolling the contents of the EXECUTE box to
NOTE: The fields on this screen may require hexadecimal digits to be entered. To enter Hex A, read YES, this function has no effect.
B, C, D, E, or F, hold down the (.) key while pressing 0, 1, 2, 3, 4, or 5, respectively. If you enter
• If the CSE selects YES in the EXECUTE box and hits the return key, the Scanner resets
an incorrect digit by mistake, press the EXIT key and begin again.
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 opera-
tor 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 (DS
system only)] test and perform the procedure.
3. Go to the [ADJ 4.1 Document Drive Motor Speed (DS system only)] and perform the
procedure.
General Procedures
Write NVR, Reset NVR Defaults 6-18
Scanner Reliability Meter Scanner Faults (Ordered)
This user-accessible diagnostic allows the operator to view the current value of the usage This user-accessible diagnostic allows the operator to display the entries contained in the
meter maintained by the Scanner. The Scanner usage meter is intended for gathering data Scanner internal fault log. The entries are presented three to a screen. The operator scrolls
about reliability of the scanning mechanism. When a fault is recorded in the Scanner Fault through the list using the NEXT and PREVIOUS keys on the Scanner Control Panel. The oper-
Log, the value of this meter at the time is also included. ator may view all valid log entries in the Scanner fault log from this screen. Empty log entries
are not displayed.
NOTE: This meter measures linear usage only and is not intended for billing purposes.
Press the Next or Previous keys to scroll through the entries.
If there are no fault entries, LAST CLEARED XXXX is displayed, where XXXX is the value of
the Scanner Reliability meter at the time the log was cleared.
Figure 1 Scanner Reliability Meter Screen
• Units of measure are displayed according to the setting configured in the Scanner NV
RAM when the Scanner is installed.
• The meter may be reset by writing to the appropriate locations in NV RAM. Refer to the
Figure 1 Scanner Fault Log (Ordered)
diagnostic, Read Non Volatile Random Access Memory (NVR), for a map of the contents
of the Scanner Non Volatile Memory.
• The first column of the display indicates the log entry number.
• The second column indicates the fault code recorded in the log.
• The third column is the value of the internal Scanner usage meter at the time that the fault
was detected. This value is displayed in decimal format and is the value stored in the
Scanner Reliability Meter at the time of the fault.
General Procedures
6-19 Scanner Reliability Meter, Scanner Faults (Or-
Scanner Faults (Counts) Clear Scanner Fault Log
Diagnostic password required: NO. Diagnostic password required: YES.
This user accessible diagnostic allows the operator to display cumulative counts of each fault This password-protected menu causes the contents of the Scanner fault logs to be erased.
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.
If there are no fault entries, LAST CLEARED XXXX is displayed, where XXXX is the value of
the Scanner Reliability meter at the time the log was cleared.
Figure 1 Clear Scanner Fault Log Screen
• 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 opera-
tor 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.
Figure 1 Scanner Fault Log (Counts)
General Procedures
Scanner Faults (Counts), Clear Scanner Fault Log 6-20
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
0 NVR_VERSION 0000 0000- This defines the current NVR version. It’s used for automatic NVR upgrade dur-
FFFF ing a new firmware load.
2 ILL_SP_PERCENT 00 00-FF Illumination setpoint as a percentage of ILL_INSTALL_READ. Set to zero to
force ILL_INSTALL_READ to be recalculated (when installing a new fluorescent
lamp).
3 ILL_RENULL_THRESH 03 ILL_ ADC counts of drift allowed before renull required.
4 ILL_COLD_WARMUP 1 00-FF Number of minutes required for the lamp to warm up following a cold start.
5 ILL_CONDITION_TIME 3C (60 minutes) 00-FF Number of minutes the fluorescent lamp must be on following install before the
final ILL_INSTALL_READ is taken.
6 ILL_INSTALL_UPTIME 00 00-FF Number of minutes of conditioning time elapsed. When this value equals
ILL_CONDITION_TIME then the final ILL_INSTALL_READ is taken.
7 ILL_INSTALL_READ 00 00 - FF Contains the Lamp Illumination Sensor reading taken when the lamp is installed.
8 ISO_PACKET_SIZE 0800 Number of bytes in isochronous packet.
A SCVM_CAL_ENA_MASK FF 0-FF Calibration Enable Mask. It is used to enable/disable individual calibration opera-
tions. Defaults to all calibrations enabled. Bit assignments are:
• 0x01 - Range Adjust
• 0x02 - Offset Adjust
• 0x04 - Set Integration Time
• 0x08 - Coarse (stationary) Gain Adjust
• 0x10 - Fine (moving) Gain Adjust
NOTE: Bit Set = Enable. Bit Clear = Disable

B SCVM_INTEG_VAL 20 01-F0 SCVM Integration Time
C SCVM_DARK_LO_LIMIT 0002 0000 - SCVM Dark range lower limit.
0FFF
E SCVM_DARK_HI_LIMIT 0100 0000 - SCVM Dark range upper limit.
0FFF
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 - Gain multiplier value used during gain cal override.
0FFF
General Procedures
6-21 Read Non Volatile Random Access Memory (NVR)
14 SCVM_GAIN_SETPOINT 367 0000 - Gain cal setpoint.
03FF
16 SCAN_SPEED 09 00 - 0C Default Scan Speed
• 0 ips: NVR Value = 0
• 0.125 ips: NVR value = 1
• 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 This contains the scan meter for the total length scanned.
-
FFFFFFFF
1D SCAN_METER_MONO 00000000 Scan meter - Monochrome scans only.
-
FFFFFFFF
21 SCAN_METER_COLOR 00000000 Scan meter - Color scans only.
-
FFFFFFFF
25 SCAN_METER_REM 00000000 Scan meter remainder, used to store any partial units (feet, yards, meters)
- scanned.
FFFFFFFF
29 RFLOG_FULL_FLAG 0 0,1 Used to keep track of when the recent fault log is full.
2A RFLOG_NEXT_INSERT 0 0 - 100 Next available location in the recent fault log.
2B FHLOG_CLEAR_METER 00000000 Total scan meter reading when the fault history log was last cleared.
-
FFFFFFFF
2F POWER_SAVER_TIME 3C 00 - FF Power Saver timer in minutes.
30 DIST_AWD 8B 32 - 1C2 Distance in Full Steps count from home to AWD rotation. 8B is 50 degrees.
32 CALIBRATION_TIME 5 5 - 5A How long before Calibration begins (in minutes).
General Procedures
Read Non Volatile Random Access Memory (NVR) 6-22
33 MOV_CAL_SPEED_IX 0 0 - FF Moving the Calibration (Fine Gain Adjustment) is done with the Calibration Extru-
sion.
• 0: rotating at 0.5 ips
• 1: rotating at 0.8 ips
• 2 - FF: stationary
34 PERC_SPEED_ADJ 3E8 384 - 44C Percent of the Nominal Document Speed
3E816 = = 100010 = = 100.0 percent (default)
36 CALZONE_VERSION 2 0-2 0:Ver0:Old Calzone (Not Supported)
1: Ver 1: 1st B1 Home Sensor w/Narrow slot
2: Ver 2: 13.5 degrees different from ver 1 from fixing scratch lens
37 FILTER_TRC_ORDER 0 0-1 0-Filter is done prior to TRC
1-TRC is done prior to Filter
38 HORIZONTAL_SYS_ADJ 0 0-A Represents 0.1% increments in horizontal magnification performed by Pixel
Magic (i.e. 3 = 100.3%, 4 = 100.4%,...). Any value over 0xA is reduced to 0xA
General Procedures
6-23 Read Non Volatile Random Access Memory (NVR)
Motor Speed Test Lead Edge/ Trail Edge
NOTE: When servicing an XEScan Solution system, follow the instructions in the online hard- NOTE: When servicing an XEScan Solution system, follow the instructions in the online hard-
ware help files for this procedure. ware help files for this procedure.
This test is found under the menu item, COMPONENT TESTS. This test is found under the menu item, COMPONENT TESTS.
This password-protected test allows the CSE to adjust the speed of the Document Drive Motor NOTE: This adjustment calculates both the lead edge and the trail edge of the scanned image.
in the Scanner. The speed adjustment corrects the difference between the expected length of
This test enables the adjustment of the staging position of the lead edge and the correct posi-
a measured line in the document and the length of that line in the output image. The measured
tioning of the trail edge for documents inserted into the Scanner.
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
Select the LEAD EDGE/TRAIL EDGE test from the menu of diagnostic tests (Entering the
process speed errors in the Printer.
Scanner Diagnostics).
Select the MOTOR SPEED test from the menu of diagnostic tests (Entering the Scanner Diag-
To perform the test:
nostics). For how to conduct the test, see the adjustment, ADJ 4.1 Document Drive Motor
Speed (DS system only). in Section 4 of this service manual.
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 Tar-
get, be sure to cut off the end as indicated on the target, before using it. Then insert the
target black edge first.
2. Press the START key.
The document is scanned, and new values are stored in Non-Volatile Random Access Memory
(NVR). If the test is successful, the screen displays PASSED. If not, the screen displays
FAILED. If the test fails, perform the test again. If the test still fails, isolate and correct the
Figure 1 Motor Speed Test problem, then try the test again.
Figure 1 Lead Edge/Trail Edge
General Procedures
Motor Speed Test, Lead Edge/ Trail Edge 6-24
Sensors Scanner Control Panel
This test is found under the menu item, COMPONENT TESTS. This diagnostic isolates and tests the operation of the Scanner Control Panel in the following
areas: Liquid Crystal Display, Communications, Control Panel LEDs, Control Panel Keys.
This diagnostic displays the current state of the left and right width sensors, the Edge Present
(INPUT) sensor, the Edge Registered (REGISTERED) sensor, the Exit Sensor, and the Docu- NOTE: If the Scanner Control Panel fails any area of this test, replace it.
ment Thickness Sensor. It is one of the Component Tests.
Procedure
• When a sensor is covered (actuated) its status reads ON.
1. Ensure that the Scanner is powered off and unplugged.
• When a sensor is uncovered (deactuated) its status reads OFF.
2. Loosen the center screw at the rear of the Scanner Control Panel and flip the Control
• The THICK field reads YES when the Thick Document Sensor is activated, and NO when
Panel over, resting it on top of the Scanner.
the sensor is not activated.
3. Loosen the two remaining screws at the rear of the Scanner Control Panel and remove
• The polling is stopped by pressing the EXIT key, also causing the display to return to the
the Mounting Bracket from the Control Panel.
parent menu.
4. (Figure 1): Prepare the Scanner Control Panel PWB for Loopback connector installation.
1
Disconnect A2P1 from the Scanner Control Panel
PWB
Figure 1 Sensors Screen
Figure 1 Preparing the Scanner Control Panel PWB for Loopback Connector
General Procedures
6-25 Sensors, Scanner Control Panel
5. (Figure 2): Attach the Loopback Connector in series to the Scanner Control Panel PWB. 7. (Figure 3): Power the Scanner back on, and observe the Scanner Control Panel.
NOTE: For the purposes of this test, the Control Panel keys directly beneath the LCD dis-
play (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
2 until the EXIT key is pressed.
Attach the other end of the Loopback Connector to the Scanner Con- • Press the Previous key to execute the Communication Loopback Test. When this
trol Panel PWB 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. Subse-
6. Flip the Scanner Control Panel back over and rest it on the Upper Document Transport. quent depressions of the Next button will cause each LED on the Control Panel to
Ensure that the display area of the Control Panel can be observed. 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 key-
board 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.
8. Once the test has been completed, press Exit, power off the Scanner and Remove the
Loopback Connector wire.
9. Reconnect the Scanner Control Panel wires and reinstall the Control Panel to its original
position on the Scanner.
10. Power on the system and return the Scanner to normal operation.
General Procedures
Scanner Control Panel 6-26
Document Motor (Loopback) Communications 3. 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
This user-accessible diagnostic allows the user to execute the Document Motor Communica- Scanner: 9.
tions Loopback test. It is one of the Diagnostic Component Tests. This diagnostic checks the • Additionally, an LL96 fault code will be generated on the Scanner Control Panel.
communications interface to the Motor Control PWB, but does not check the operation of the 4. On the Scanner Control Panel, enter Menu > Diagnostics > Scanner Diagnostics >
Document Drive Motor or the Motor Control PWB. Component Tests > Motor Communications > Enter.
5. When this test screen is entered the third line of the display reads “PRESS START TO
This test isolates the Scanner Main PWB and performs diagnostic tests upon it. If this test fails, BEGIN” and the fourth line is blank.
replace the Scanner Main PWB.
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. 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 Con-
nector on that connector.
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:
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.
9. Reboot the Synergix Scan System and return it to normal operation.
2
Install Loopback Connector
at same location
Figure 1 Installing the Loopback Connector on the Scanner Main PWB
General Procedures
6-27 Document Motor (Loopback) Communications
Document Drive Motor Lamp
This test is found under the menu item, COMPONENT TESTS. This test is found under the menu item, COMPONENT TESTS.
This user-accessible diagnostic allows the user to stop and start the Document Drive Motor, This user-accessible diagnostic allows the user to turn the Lamp on or off. As a result of this
and also to change the direction and speed of that motor. function, a feedback from the Illumination Sensor Q11 is transmitted. The value for the SEN-
SOR field ranges from 0 - 255. A value of 0 or 1 is typical when the Lamp is not illuminated; 50
NOTE: When changing the speed of the Document Drive Motor, enter the speed change prior - 150 is typical when the Lamp is on.
to starting the motor.
To operate:
To operate:
1. Press Next until the desired state of the Lamp (OFF or ON) is displayed.
1. Press the Next key to select SPEED (motor speed).
2. Press the Enter key to switch to the selected lamp state and read the output of the Illumi-
2. Press the Enter key to confirm the choice.
nation Sensor.
3. Press the Next key to set the desired state.
3. Press the Enter key again.
4. Press the Exit key.
4. Press the Next key to select another state of the lamp, if desired.
5. Similarly, set DIRECTION (motor rotation direction) to FORWARD or REVERSE.
5. Repeat steps 2 - 4 as desired.
6. Similarly, set MOTOR (motor state) to ON.
6. Press the Exit key to exit the Lamp test.
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.
Figure 1 Fluorescent Lamp Screen
Figure 1 Document Drive Motor Screen
General Procedures
Document Drive Motor, Lamp 6-28
Calibration Motor
This test is found under the menu item, COMPONENT TESTS.
This user-accessible diagnostic allows the user to control the Calibration Motor and to select
the Calibration Motor function.
• Selections for the MOTOR field are ON or OFF.

• Selections for the FUNCTION field are
1. GO TO WIDTH. The Calibration Extrusion rotates to place the Plate Roll in view of
the Image Bar.
2. GO TO CALIBRATE. The Calibration Extrusion rotates to place the Calibration Tar-
get Strip in view of the Image Bar.
3. GO TO HOME. The Calibration Extrusion rotates to the home position as deter-
mined by the alignment of the hole in the right hub of the extrusion with the Calibra-
tion Home Sensor.
4. FIND HOME. The Calibration Extrusion rotates to the home position as determined
by assignment of the hole in the right hub of the extrusion with the Calibration Home
Sensor.
5. ROTATE. The Calibration Extrusion rotates continuously until the MOTOR OFF
state is selected.
• The operator must set the FUNCTION field followed by setting the MOTOR field to ON to
accomplish the requested operation.
• When a GO TO or FIND selection is made, the selection for MOTOR will be set to OFF by
the AccXES Controller, since the Calibration Motor stops when the destination is reached.
• When ROTATE is selected (in the FUNCTION field) the motor runs continuously until the
operator selects OFF in the MOTOR Field.
• In the event that the Scanner reports failure accessing the Calibration Motor function, the
fourth line of the display will read “FAILURE CODE”, followed by a two-digit hexadecimal
number.
Figure 1 Calibration Motor Screen
General Procedures
6-29 Calibration Motor
GP 1 How to Check a Short Circuit Y N
Disconnect P/JD on the Distribution PWB. Make a check for 0 Ohms between pin 4 on the
This checkout can be used to isolate a short circuit.
harness side of he connector and DC Common (ground). 0Ohms is measured.
Y N
WARNING The short circuit is on the Distribution PWB. INstall a new Distribution PWB, PL X.X.
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
Initial Actions 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.
Reconnect any circuits that you have disconnected.
THe short circuit is between PB-2 and the circuits VV-01 and WW-02. Check the wiring of each
Procedure circuit and if necessary repair the wiring. If the short circuit is found to be on YYY PWB, install
Disconnect P/JB on the Distribution PWB. Make a check for 0 Ohms between pin 2 on the har- a new YYY PWB, PL X.X.
ness side of the connector and 0 V (ground). 0 Ohms is measured.
Figure 1 Circuit Diagram
General Procedures
GP 1 6-30
GP 2 How to Check an Open Circuit Procedure
This checkout can be used to isolate an open circuit. Power is available at P/JA-1 on the Distribution PWB.
Y N
WARNING 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
Disconnect the power cord before disconnecting or reconnecting a P/J, reconnect the
the wiring. If no wiring fault is found, go to the relevant chain 1 RAP and find the fault.
power cord then switch the copier on.
Initial Actions The voltage is correct at P/JB-2 and P/JD-4 on the Distribution PWB.
Reconnect any circuits that you may have disconnected. 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 neces-
sary, repair the wiring.
Figure 1 Circuit Diagram
General Procedures
6-31 GP 2
A B
GP 3 How to Check a Sensor Switch off the copier. There is continuity between P404-1 on the Main PWB and
GND.
This procedure can be used to check two types of sensors used on the copier. Y N
Check the GND input.
TYPE A: Flag Sensors
Disconnect P/J105. Check the wiring and the connector crimps between P/J105, P/J13,
This sensor is actuated by the movement of a mechanical flag, which interrupts the light path and the Main PWB for an open circuit, or a short circuit. If the fault is in the wiring repair
between the source and the sensor.
the wiring. IF the problem is in Main PWB replace the Main PWB, If the wiring and
the Main PWB are both problem free install a new sensor, PL X.X.
• Q56 ADF Exit Sensor
• Q51 ADF Nudger Roller Sensor The circuit is currently working properly. Check for loose connectors, bent pins, or damaged
• Q56 DADF Exit Sensor wires. Replace the sensor (PL X.X) before replacing the Main PWB .
• Q57 DADF Nudger Roller Sensor
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 cir-
cuit diagrams in the RAPs that are affected by the loss of the +5 VDC, + 24 VDC and GND to
the appropriate PWBs.
• Ensure that the sensor is not blocked.
• Clean the sensor surfaces before using this procedure.
Procedure
Sensor Checkout
Connect the meter between P/J404-2 (+) and GND (-). Actuate the sensor, using a sheet of
white paper. The voltage changes from +5 VDC to 0 VDC or 0 VDC to +5 VDC.
Y N
Disconnect P/J404. There is +5 VDC at P402- 2 on the Main PWB.
Y N
There is +5 VDC available P404-3 on the Main PWB.
Y N
Replace the Main PWB . (If the input power source and returns are
shown on the circuit diagram, check the voltage before replacing the Main
PWB. Replace or repair the voltage source.)
Figure 1 Sensor (generic)
Replace the Main PWB
A B
General Procedures
GP 3 6-32
A
GP 4 How to Check a Switch and its Associated Wiring Check the mechanical actuation of the switch. If the switch has an adjustment, perform the
adjustment.
This RAP is an example of the checks required to locate a fault on a switch circuit. The switch
can be either the simple mechanical type or the magnetically operated type.
NOTE: Due to the generic format of this RAP there will be no specific ADJ, PL, or Diagnostic
codes identified.
NOTE: The input power source (+5 VDC, + 24 VDC, and GND) will be shown only on the cir-
cuit 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 Figure 1 Switch (generic)
the Main PWB. Replace or repair the voltage source.)
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 con-
tinuity when the switch is actuated and no continuity when the switch is deactu-
ated.
Y N
Install a new switch, PL X.X.
The Control PWB is not detecting the operation of the switch. Verify the supply voltages to
the Control PWB. Install a new Control PWB, PL X.X.
A
General Procedures
6-33 GP 4
GP 5 Generic PWB Checkout Procedure
This procedure is performed to isolate a failing PWB. The applicable PWBs for this procedure Power on the Scanner. Measure the voltages on the Main PWB.
are the Main PWB, the Image Processing PWB, the Motor Control PWB, and the Lamp Ballast
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 CR9 +12 VDC +/-.5 VDC
Drawer. 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 dam- CR7 +5 VDC standby +/-.25 VDC
aged.
Initial Actions All the voltages measure the proper value (except 24 VDC before the POST LED dis-
1. Extend the rear Electronics Drawer. plays 4).
2. Unfasten the four screws and remove the metal top cover from the Electronics Drawer. 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 mea-
sure the proper value (except 24 VDC before the POST LED displays 4).
Y N
Replace the power supply (REP 1.1).
Power on the Scanner. Measure the voltages on the Main PWB. All the voltages
measure the proper value (except 24 VDC before POST LED displays 4).
Y N
Power on the Scanner. Measure the voltages on the Main PWB. All the volt-
ages 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.

Figure 1 Removing the Electronics Drawer Cover. Replace the disconnected PWB.
Power on the Scanner. Measure the voltages on the Main PWB. All the voltages mea-
NOTE: For a illustration of Plug/Jack locations, go to (Figure 2 Electronics Drawer inte- sure the proper value (except 24 VDC before POST LED displays 4).
rior) and (Figure 3 Location of Test Points on Lower Right Edge of Main PWB). Y N
Check the cabling to the PWB for a short circuit.
3. Disconnect all cables except the power cables for the PWB in question.
• P404 and P405 for the Main PWB. Observe the POST LED. The POST LED increments from 0 to 8 within 60 seconds of
• P407 for the Lamp Ballast PWB. Connect J404 and P405 also. power on.
Y N
• P300 for the Motor Control PWB. Connect J404 and P405 also.
Power on the Scanner. The POST LED increments from 0 to 8 within 50 seconds of
power on.
A
General Procedures
GP 5 6-34
A
Y N Power on the Scanner. Observe the POST LED. The POST LED increments to B.
Elevate the problem to the Hotline. Y N
Power off the Scanner. Connect P407, Lamp Ballast PWB. Power on the Scanner. The Scan- Replace the Image Module [REP 9.2 Image Module].
ner lamp illuminates for one second when the POST LED displays 8.
Y N The POST LED increments to E.
Power off the Scanner. Y N
Check the cables from J407 to the lamp. Power off the Scanner.
Power on the Scanner. The lamp illuminates for one second when the POST LED dis- Check the Image Processing PWB for proper seating. The Image Processing PWB is
plays 8. properly seated.
Y N Y N
Probe the fuse on the Lamp Ballast PWB. +24VDC is present on both sides of Reseat the Image Processing PWB.
the fuse.
Y N Replace the Image Processing PWB [REP 3.2 Image Processing PWB].
Replace the Lamp Ballast PWB. Power off the Scanner.
Power on the Scanner. The lamp illuminates for one second when the Connect P413.
POST LED displays 8. Power on the Scanner. Observe the POST LED. The POST LED increments to P.
Y N Y N
Power off the Scanner. Power off the Scanner.
Replace the lamp [REP 6.4 Exposure Lamp]. Check the DDS Control Panel cable.
Power off the Scanner. Go to Section 1, Final Action.

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].

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 incre-
ments 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.
General Procedures
6-35 GP 5
Motor Control PWB
J413 J414 J415 J416 PJ 400 PJ 401 J403
Main PWB
Lamp Power
Ballast Supply
PWB
J300 Image Processing PWB J408 J407 J406 J405 J404
Figure 2 Electronics Drawer interior
Figure 3 Location of Test Points on Lower Right Edge of Main PWB
General Procedures
GP 5 6-36
GP 8 System Power Up Procedure
NOTE: When servicing an XEScan Solution system, follow the instructions in the online hard-
Printer Power Switch Ground Fault Interrupter
ware help files for this 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 dis-
play at the rear of the Scanner. If any POST fails, the startup process stops and the code of the
test that failed is continuously displayed. If such a failure should occur, go to the Scanner
Fault Code Entry Chart in Section 1 of this service manual.
1. Ensure that the Scanner power is switched off, and that the Printer power switch and
Ground Fault Interrupter (located at the back of the Printer) are also switched off.
NOTE: There are two different configurations of Ground Fault Interrupter (GFI) for the
8825/8830 Printer. They both function in exactly the same way.
• The white On / Off switch located at the back of the Printer only switches the Printer
on or off. The GFI switches off both the Printer and Controller.
• (Figure 1): The older configuration GFI has rectangular buttons for the test and
retest functions.
• (Figure 2): The more recent configuration GFI has a flip mechanism similar to a
light switch for the test and retest functions.
Figure 2 New Configuration Ground Fault Interrupter

Printer Power Switch Ground Fault Interrupter
2. Switch on the Synergix Scanner power. Wait until the “P” is visible on the 7 segment dis-
play 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 indi-
cates 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
General Procedures
6-37 GP 8
GP 9 Enabling/Disabling the DDS Option - 8825 / 8830 GP 10 Enabling/Disabling the DDS Option - 8855 Printer
Printers The purpose of this procedure is to ensure that the Scanner, Controller and 8855 Printer are
The purpose of this procedure is to ensure that the Scanner, Controller and 8825/8830 Printer correctly configured for Digital Document System (DDS) operation.
are correctly configured for Digital Document System (DDS) operation.
1. Launch the Web Browser.
1. Ensure that the system is powered up in the following order: Scanner, Controller (if exter- 2. Enter the IP address of your Controller in the form: http://xxx.xxx.xxx.xxx.
nal to the Printer) and Printer. 3. Click on Session Setup and enter the Printer password.
NOTE: This procedure is conducted from the Printer Control Panel. The Printer Control NOTE: 0 is the default password. However, this may have been changed by the Key
Panel buttons have symbols to represent the following commands. 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 Figure 1 Printer Setup Screen
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 5. Click on the Update Printer button at the bottom of the screen.
Enter button.
6. Printer Updated should be displayed at the top of the screen.
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 6-38
GP 11 Catch Tray and Organizer Tray NOTE: The Catch Tray and the Organizer Tray are identical parts.
WARNING
Switch off the Scanner power and disconnect the power cord. Organizer Support (2) Catch Tray Support (2) Catch Tray / Organizer Tray (2)
1. (table 1) (Figure 1): Compare the items listed in the following table with the items present
in the Catch Tray / Organizer Tray Kit. Ensure that all items are present before beginning
this procedure.
Table 1 Catch Tray / Organizer Parts

Item Description Quantity
1 Organizer Support 2
2 Catch Tray Support 2
3 Catch Tray / Organizer Tray 2
4 Organizer Mounting Clip 4
5 Height Adjustment Bracket 2
6 Catch Tray Mounting Bracket 1
7 T20 x 8mm Screws 14
Organizer Height Adjustment Bracket (2) Catch Tray Mounting

Mounting Bracket
Clips (4)
Figure 1 Catch Tray and Organizer Tray Parts
General Procedures
6-39 GP 11
2. (Figure 2): Install the two Organizer Mounting Clips to the inside of each Scanner column 3. (Figure 3): Install the Height Adjustment Bracket on the back of each Scanner column.
(four Clips total). Note the location of the two installation screws.
NOTE: Install only the lower screw on each Organizer Mounting Clip at this time.
1
2 Insert two mount screws through the
Install only the lower Height Adjustment Bracket, and mount
two screws in the clips the bracket to the Scanner Column
at this time
1
Place the two Clips on
the inside of each Scan-
ner column with the
hooks facing upwards
NOTE: The lower set of NOTE: These

screws are not used in this two outer mount
procedure holes on the
Scanner column
are not used
Figure 3 Installing the Height Adjustment Bracket on each Scanner Column

Figure 2 Installing the Two Organizer Mounting Clips on each Scanner Column
General Procedures
GP 11 6-40
4. (Figure 4): Install an Organizer Support on each column of the Scanner. 5. (Figure 5): Position the Organizer Tray on the Scanner frame as shown.
3
Press the Organizer Support into the Organizer
Mounting Clips until it snaps into place
1
Set the Organizer Tray down on the Scanner frame with Document
Extensions facing to the rear, and downward
2
Position the Orga-
nizer Support as
shown on the
Mounting Clips
Document
1 Extensions
Remove the E-
clips (both sides)
Rear of Scanner
Figure 4 Installing the Organizer Support

Figure 5 Positioning the Organizer Tray
General Procedures
6-41 GP 11
6. (Figure 6): Install the front side of the Organizer Tray on the Scanner. 8. (Figure 7): Mount the Catch Tray Mounting Bracket on the Scanner as shown. Insert and
partially tighten the right side screw only.
2 1
Raise the Organizer Support and Lift the front edge of the Organizer
insert its front post into the tubular Tray off the Scanner frame 1 2 3
mount on Organizer Tray (both sides) Set the Catch Tray Mounting Ensure that the hooks Insert and partially
Bracket on the shelf at the face toward the Scanner tighten right side
back of the Scanner mount screw
Figure 7 Mounting the Catch Tray Mounting Bracket on the Scanner
3 4
Reinstall the E-clips on the ends Install the two upper retaining
of the Organizer Supports screws on each Organizer Mount-
ing 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 Orga-
nizer Supports.
General Procedures
GP 11 6-42
9. (Figure 8): Insert the lead edge of the Catch Tray into the Catch Tray Mount Bracket, and 10. (Figure 9): Insert the Catch Tray Supports into the Catch Tray (both sides).
fasten the Mount Bracket to the Scanner frame.
1
1 2 Insert the longer end of
Pick up the Catch Tray and Place the Catch Tray into the Mount Bracket, the Catch Tray Support
position it over the Organizer making sure that the 3 hooks in the Mount into the mount on the
Tray, facing in the same direc- Bracket are equidistantly spaced along the wires Catch Tray
tion. at the edge of the Catch Tray.
2
Insert the shorter end of the
Catch Tray Support into the
3 Height Adjustment Bracket
Place the left mount screw in posi- Catch Tray
tion and tighten it down. Fully
tighten the right mount screw.
Figure 9 Inserting the Catch Tray Supports

Figure 8 Mounting the Catch Tray to the Scanner Frame
General Procedures
6-43 GP 11
GP 12 Compact Catch Bins
WARNING
Switch off the Scanner power and disconnect the power cord. Mounting Bin Support Screws Rear Bin Mounting
1. Disconnect the power cord and the IEEE 1394 PMC cable from the Scanner. Clips Bracket Bracket
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.
Table 1 Catch Tray / Organizer Parts

Item Description Quantity
1 Rear Bin Mounting Bracket 1
2 Lower Bin 1
3 Upper Bin 1
4 Rear Bin 1
5 Bin Support Bracket 2
6 Document Storage Flaps 2
7 T20 x 8mm Screws 14
8 Mounting Clips 8
Lower Bin Upper Bin Rear Bin

Document Storage Flaps
Figure 1 Compact Catch Bins Parts
General Procedures
GP 12 6-44
3. (Figure 2): Install the four Mounting Clips on the inside of each Scanner leg. 4. (Figure 3): Install the Bin Support Bracket onto the back of each Scanner leg.
NOTE: In the following step, install only the lower mount screws on the Mounting Clips at NOTE: At the present time only the top screw can be mounted through the Bin Support
this time. Bracket into the Scanner frame.
1 2 2
Install the four Mounting Clips Install only the bottom screws in the
1
Place Mounting Bracket on back of Mount the Support Bracket to
with the hooks facing upward Mounting Clips
Scanner leg with the slot at the top the Scanner leg with one screw
edge of the bracket into the top of the bracket
Bin Support Bracket (2)
Figure 2 Installing the Mounting Clips
Figure 3 Installing the Bin Support Brackets
General Procedures
6-45 GP 12
5. (Figure 4): Install the Lower Bin onto the Scanner. 6. (Figure 5): Install the Upper Bin onto the Scanner.
1 2 1
Set the Lower Bin down on the 2
Ensure that the squared por- Holding the Upper Bin
Scanner frame with the curved Insert the “legs” of the Upper Bin into the
tion of the Lower Bin is as shown, guide it into
portion of the bin facing to the upper Mounting Clips on the inside of
folded underneath the position over the Lower
rear of the Scanner each Scanner leg
curved portion Bin
hinges
Mounting Clips
Lower Bin
Rear of Scanner
Rear of Scanner
5 3
Install the top screw on each Lift each side of the Lower
of the lower Mounting Clips Bin frame and insert it into
the lower set of Mounting 3
Clips on the Scanner legs Install the top screw on
each of the four upper
Mounting Clips
Mounting Clip
Figure 5 Installing the Upper Bin
4
Rear of Scanner Leg Ensure that the pressed locator tabs are
positioned forward of the Mounting Clips
Figure 4 Installing the Lower Bin
General Procedures
GP 12 6-46
7. (Figure 6): Standing at the back of the Scanner, lift and fasten the Lower Bin to the Bin 8. (Figure 7): When correctly installed, the shaft at the end of the Lower Bin will be seated in
Support Brackets. 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 Sup-
port Brackets Bin Support Brackets (2)
NOTE: Lower Bin overlaps the Upper

Bin
Figure 6 Fastening the Lower Bin to the Bin Support Brackets Figure 7 Installation of Lower Bin into Bin Support Bracket
General Procedures
6-47 GP 12
9. (Figure 8): Install the Rear Bin Mounting Bracket. 10. (Figure 9): Mount the Rear Bin onto the Scanner.
1 2 1
Position the Rear Bin Mount- Fasten a T20 screw While holding on to the left end of the Rear Bin Mount-
ing Bracket on the Scanner as through the Rear Bin ing Bracket, guide the angled portion of the Rear Bin
shown, with the bracket Mounting Bracket into the over the three hooks on that mounting bracket
hooks facing inward Scanner frame
Rear Bin
2
Fasten a T20 screw into the mount hole on the left side of
Figure 8 Installing the Rear Bin Mounting Bracket the Rear Bin Mounting Bracket
Figure 9 Mounting the Rear Bin onto the Scanner
General Procedures
GP 12 6-48
11. (Figure 10): Install the two Document Storage Flaps on the lower edge of the Rear Bin. 12. (Figure 11): Secure the Rear Bin to the Scanner Frame.
1 1
Guide the outward ends of the Rear Bin Support Bracket
Pull the Rear Bin outward slightly
Bin into the side slots on the Bin Sup-
port Bracket
2
Document Storage Hook the curved edge of the Doc- Figure 11 Securing the Rear Bin to the Scanner Frame
Flap ument Storage Flap onto the
lower edge of the Rear Bin (2 13. Reconnect the power cord and the IEEE 1394 PMC cable to the Scanner.
places) 14. Return the Scanner to normal operation.
Figure 10 Installing the Document Storage Flaps
General Procedures
6-49 GP 12
GP 13 Creating the System Speed and Lead Edge Detect 2. Examine the following TCP/IP settings contained within the Configuration Test Print:
• TCP/IP Enable
Test Target
• TCP/IP IP Address
The purpose of this procedure is to enable the technical representative to generate a test tar-
• TCP/IP Subnet Mask
get that can be used in Document Drive Motor Speed and Lead Edge / Trail Edge adjustments
for the Synergix Scan System. • TCP/IP Default Gateway
3. Power down the Synergix Scan System.
NOTE: This procedure uses a laptop computer hookup to the Controller to generate the test 4. Connect the laptop computer to the Controller with the Network Crossover Cable.
target. You will need the following items for this procedure: 5. Switch on the system power.
• Laptop Computer equipped with an PCM CIA card 6. Verify the Controller 10/100 network Link (green) LED is lit. If the Link LED is not lit, per-
• Crossover cable for connecting the laptop computer to the Controller User Interface on form the following:
the IOT.
a. Switch off the Printer and Controller
1. ( b. Reboot the laptop computer
1. c. Switch on the Controller and Printer
1.): Use the Printer Control Panel to print out a Configuration Test Print. The information 7. Set the laptop computer to use the same TCP/IP parameters as the printer with the
on this test print will be used to determine the network address of the Printer. exception of the IP address. Use an appropriately unique IP address for the laptop com-
puter.
1 NOTE: To examine the current values stored on the laptop computer, perform the follow-
Note the following Printer settings on your test print ing:
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.
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”.
Figure 1 Sample Printer Configuration Test Print 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 6-50
GP 14 Scanner Diagnostic access using a laptop [4] Write an NVM location
[5] Display Usage Meters
Use the following procedure if scanner diagnostics are unavailable due to a malfunction of the
[6] Display Recent Fault Log
user interface panel.
[7] Display Fault History Log
[8] clear Usage Meteers
Prerequisites [9] Clear Recent Fault Logs
The following equipment is required to perform this procedure: [10] Clear Fault History Log
• Standard laptop PC running Windows 95/98/NT or 2000 [11] Reset NVM to defaults
• Standard 9-pin ‘D’ null-modem cable, female at both ends [D] Diagnostic Menu
[?] Help
Procedure
NOTE: When resetting NVM values to the default values, all fault logs, usage meters, and
1. Perform REP 4.2 Electronics Drawer, steps 1-5 to access the scanner main PWB in the
electronics drawer.
machine set-ups (such as lead edge registration, lamp-life, etc) will be reset to default val-
ues. Feature keys should be left intact. On an XEScan Solution system, restore the meter
2. Plug the null-modem connector into J409 on the scanner main control board. counts to the last recorded value to enable proper meter count feedback for the system.
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:
• 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
6. Power on the scanner. When the LED on the rear of the scanner displays “P”, the Hyper-
Terminal 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] NVM settings
[3] Scan functions
[4] Lamp Functions
[5] Document Advance Functions
[6] Image Processing Functions
[7] Calzone Rotation Functions
[8] Feature Key Menu
[M] Main Menu
[?] Help
8. Type 2 to enter the NVM settings menu. The following menu options will apear:
[1] Validate NVM
[2] dump NVM contents
[3] Read NVM locations
General Procedures
6-51 GP 14
General Procedures
GP 14 6-52
Special Tools
The following special tools are required to service the Synergix scanner
Table 1
Tool Part Number
Torx Wrench 600T41300
Loopback Cable Kit 600K89460
General Procedures
6-53 Special Tools
General Procedures
Special Tools 6-54
Change Tag/ Mod Index Classification Codes
All important modifications are identified by a Tag/ MOD number on a matrix label attached to A Tag/ MOD number may be required to identify differences between parts that cannot be
each Scanner inside the Top Cover. 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, firm-
ware, or if mandatory modifications have been installed. Each Tag/ MOD number is given a
classification code to identify the type of a change the Tag/ MOD has made.
M− Mandatory
N− Not installed in the field
O− Optional
R− Repair
S− Situational
TAG: None
CLASS: R
USE: All
Tag Matrix MFG SERIAL NUMBERS: USO: All EO: All
NAME: xxxx xxxxx xxxx xxxx
PURPOSE: xxxx xxxxx xxx xxxx xxxx x
KIT NUMBER: xxxxxxxxxx
REFERENCE:
Figure 1 Location of the Change Tag/MOD Matrix
This section describes all the tags as well as multinational applicability, classification codes,
and permanent or temporary modification information.
General Procedures
6-55 Change Tag/ Mod Index
General Procedures
Change Tag/ Mod Index 6-56
7 Wiring Data
BSD 1.0 Level 1 Interconnection.................................................................................... 7-3
BSD 1.1 ACH Main Power On ........................................................................................ 7-5
BSD 1.2 DC Power Generation (50 and 60 HZ) ............................................................. 7-6
BSD 1.3 (+12 VDC) Power Distribution........................................................................... 7-8
BSD 1.4 (+5 VDC Standby / +5.25 VDC) Power Distribution.......................................... 7-9
BSD 1.5 (+5 VDC / +3.3 VDC) Power Distribution .......................................................... 7-10
BSD 2.1 User Interface ................................................................................................... 7-11
BSD 4.1 Document Scan and Rescan Drive................................................................... 7-12
BSD 6.1 Document Illumination ...................................................................................... 7-14
BSD 6.2 Image Capture .................................................................................................. 7-16
BSD 6.3 Image Calibration Control ................................................................................. 7-18
BSD 6.4 Thick Document / Document Width Sensing .................................................... 7-20
BSD 14.1 Communications ............................................................................................. 7-22
Wiring Data
7-1
Wiring Data
7-2
BSD 1.0 Level 1 Interconnection
Figure 1 Level 1 Interconnection
Wiring Data
7-3 BSD 1.0
PAGE INTENTIONALLY BLANK
Figure 2 Level 1 Interconnection
Wiring Data
BSD 1.0 7-4
BSD 1.1 ACH Main Power On
Figure 1 ACH Main Power On
Wiring Data
7-5 BSD 1.1
BSD 1.2 DC Power Generation (50 and 60 HZ)
Figure 1 DC Power Generation
Wiring Data
BSD 1.2 7-6
Figure 2 DC Power Generation
Wiring Data
7-7 BSD 1.2
BSD 1.3 (+12 VDC) Power Distribution
Figure 1 (+12 VDC) Power Distribution
Wiring Data
BSD 1.3 7-8
BSD 1.4 (+5 VDC Standby / +5.25 VDC) Power Distribution
Figure 1 (+5 VDC Standby / +5.25 VDC) Power Distribution
Wiring Data
7-9 BSD 1.4
BSD 1.5 (+5 VDC / +3.3 VDC) Power Distribution
Figure 1 (+5 VDC / +3.3 VDC) Power Distribution
Wiring Data
BSD 1.5 7-10
BSD 2.1 User Interface
Figure 1 User Interface
Wiring Data
7-11 BSD 2.1
BSD 4.1 Document Scan and Rescan Drive
Figure 1 Document Scan and Rescan Drive
Wiring Data
BSD 4.1 7-12
Figure 2 Document Scan and Rescan Drive
Wiring Data
7-13 BSD 4.1
BSD 6.1 Document Illumination
PAGE INTENTIONALLY BLANK
Figure 1 Document Illumination
Wiring Data
BSD 6.1 7-14
Figure 2 Document Illumination
Wiring Data
7-15 BSD 6.1
BSD 6.2 Image Capture
Figure 1 Image Capture
Wiring Data
BSD 6.2 7-16
Figure 2 Image Capture
Wiring Data
7-17 BSD 6.2
BSD 6.3 Image Calibration Control
Figure 1 Image Calibration Control
Wiring Data
BSD 6.3 7-18
Figure 2 Image Calibration Control
Wiring Data
7-19 BSD 6.3
BSD 6.4 Thick Document / Document Width Sensing
Figure 1 Thick Document / Document Width Sensing
Wiring Data
BSD 6.4 7-20
Figure 2 Thick Document / Document Width Sensing
Wiring Data
7-21 BSD 6.4
BSD 14.1 Communications
Figure 1 Communications
Wiring Data
BSD 14.1 7-22

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Product Title Part Number

Synergix Scan System Service Manual 701P37410

SUPERSEDES December 2001

This service manual replaces 701P36546.

Synergix Scan System

IMAGE PROCESSING PWB

MOTOR CONTROL PWB

SCANNER MAIN PWB

Action Codes : X = check / perform R = replace U = upgrade firmware C = clean

Synergix Scan System

© 2001 by Xerox Corporation. All rights reserved.

Synergix Scan System Service Manual 701P37410 12/2001

Page No. Rev.

Initial Actions / Systems Checks

Message Display Entry Chart

Section 2. Repair Analysis Procedures (RAPs)

Section 3. Image Quality RAPs

Section 4. Repair / Adjustment Procedures

Section 5. Parts List

Next, perform the Normal Call procedures.

Figure 1 Reference Symbology (1 of 2)

Figure 2 Refrerence Symbology (2 of 2)

Service Call Procedures

in the Interceptor Service Manual.

Call Flow Procedure

Initial Actions / System Checks

Message Display Entry Chart

Service Call Procedures

Service Call Procedures

Table 1 Message Display Entry Chart

Service Call Procedures

Service Call Procedures

Service Call Procedures

Service Call Procedures

Service Call Procedures

Service Call Procedures

Service Call Procedures

Service Call Procedures

Service Call Procedures

Service Call Procedures

Status Indicator RAPS

Procedure The voltages are present and correct.

The voltages are correct.

Power Supply PS1 is good.

Test Point VDC Reading

+5A +4.9 to +5.2

-5.2A -4.9 to -5.2

The voltages are correct.

Connect the (+) lead to A1P 403-4. +15 VDC is present.

The DC Power generation circuits are operating correctly.

Status Indicator RAPS

Replace the Lamp Ballast PWB (A5) (PL 1.4).

Status Indicator RAPS

Replace the Main PWB A1.

Go to RAP 1.1 DC Power.

Status Indicator RAPS

2. Motor Control PWB A3 or Document

Status Indicator RAPS

Image Quality RAPS

Image Quality RAPS

Repairs and Adjustments

Figure 2 Disconnecting the Main PWB Connectors