Flat Gear and Motor Replacement – iCR 3600

Service- Flat Gear and Motor Replacement

Please read and understand the entire work instruction before beginning any procedures. For any questions,
please contact iCRco Technical Support at techsupport@icrcompany.com.

Warning
iCRco assumes no liability for damage done to the CR unit while following these instructions.
These instructions should be carried out by an iCRco approved technician. If at any point these
instructions become unclear, please contact Technical Support at 1-310-921-9559.

NOTE: In the case of a drive system wear and/or failure:

The rack and pinion gear system used on the 3600 series scanners was designed to provide 10+ year service
with no replacement and no lubrication. The 3600 CR unit was calibrated at the factory, with an Erase Offset
value entered into the settings section of the software, and stored in an EEPROM in the memory of the 3600.

iCRco provides a guide as to which computer to use with the 3600 device.

Some older or slower computers will not be able to communicate at high speed with our device. This creates a
small delay in device response to a computer command.

The Erase Offset value in the settings screen is set to ensure that the end of the cassette is fully erased. If the
computer does not respond properly to a stop command (slower computer), then the offset value may drive
the rack past the end of the pinion gear. This issue does not damage the rack or the pinion if it occurs a few
times.

NOTE: Please listen for a slight clicking noise, or a buzzing sound at the end of a scan. This indicates that the
erase offset is set too high. If you hear such a sound, perform the following steps:

i. Run a scan on the 3600. At the end of the scan, prior to the return, if you hear a knocking, clicking, or
grinding noise, note this.
ii. Once the scan return is complete, go to the Settings page in the software. Enter password “earl” (minus
the quotation marks) to access the settings.
iii. Reduce the Erase Offset by 0.05. Save the settings and exit (Fig i).
iv. Run another scan. If the machine again makes the same noises at the end of the scan, repeat steps ii, iii,
and iv.

NOTE: If the erase offset is set too low, a dark band will appear at the bottom of all images.

NOTE: In a normal, functional unit, noise produced during the scan is very quiet and even. Any clicking,
grinding, or other abnormal noise could indicate an issue with the machine.

TOOLS REQUIRED FOR THIS PROCEDURE:

#2 Philips Head Screwdriver; Eyeglasses Flat Head Screwdriver, 6-32 Socket Wrench
Page 1 of 18 Document# 3600NMGR-04A Rev A February 6, 2012
 ERASE OFFSET
Figure i

1. PRIOR TO MOTOR/GEAR REPLACEMENT: Make sure the CR unit is powered off. Remove the
power cord from the unit. Go to the Settings page, set BOTH PMT Voltages to 0, and click Save
Settings and exit.
2. Remove nine (9) 6-32 x 3/8'' flathead undercut screws from the back cover (Fig 2).

Figure 2

Page 2 of 18 Document# 3600NMGR-04A Rev A February 6, 2012

 Warning
This unit is operated with hazardous voltages which can shock, burn, or cause death. Residual
charge may still be present in the power supply boards. Exercise extreme caution when removing
power plugs from power boards.

3. Remove the internal USB connector from its external connection, the power switch plugs from the main
power supply and the eraser power supply and the external fan power plug (Figs 3a, 3b, 3c).

Figure 3a

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 Figure 3b

Figure 3c

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 4. Remove four (4) 10-32 x 1/2'' truss head screws from the feet (Fig 4).

Figure 4

5. Remove four (4) 6-32 x 3/8'' flathead screws from the front cover (Fig 5).

Figure 5

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 6. Slide the top cover back, then lift the cover off (Fig 6).

Figure 6

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 7. Remove nine (9) 6-32 x 1/4'' screws from the Eraser Cover (Fig 7).

Figure 7

8. Remove the Eraser Cover by gently pulling it away from the machine.
9. Remove eight (8) 10-32 x 1/2''screws from the chassis (Fig 9).

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 Figure 9

Caution
The Technician should be extremely careful when lifting the module out of the shell, as any cables
still attached to the module may be damaged. Double check that all wires (external power, external
USB, external fan) are all disconnected before removing the module from the shell.

10. With two (2) or more people, lift the module out of the outer shell.
11. Using an eyeglasses screwdriver, loosen & remove the motor wires from the Motor Controller Board
(Fig 11).

Note
The screws holding the motor wires to the Motor Controller Board are made to stay in the
plastic housing. Do not try and remove the screws or damage to Motor Controller Board
may occur.

Page 8 of 18 Document# 3600NMGR-04A Rev A February 6, 2012

 Figure 11

12. Remove three (3) 11/32'' nuts from the motor (Fig 12).

Figure 12

13. Carefully pull the Motor away from the unit.

Page 9 of 18 Document# 3600NMGR-04A Rev A February 6, 2012

 14. Slide the Slide Angle with Gear Rack out from the side of the Cassette Tray (Fig 14).

Figure 14

15. Remove two (2) 4-40 x 3/8'' flathead screws from the Gear Rack, and remove the Gear Rack. (Fig 15).

Page 10 of 18 Document# 3600NMGR-04A Rev A February 6, 2012

 REMOVE

REMOVE
Figure 15

16. Fasten the new Gear Rack into place using two (2) 4-40 x 3/8'' flathead screws.
17. Remove two screws holding the motor bracket onto the new motor assembly and loosen the third screw
(Fig 17).

LOOSEN

REMOVE

REMOVE

Figure 17

18. Slide the motor assembly onto the three studs (Fig 18a). Slide the motor bracket around and over the
inner channel angle as shown (Fig 18b). Re-install and tighten the three motor bracket screws.

Page 11 of 18 Document# 3600NMGR-04A Rev A February 6, 2012

Figure 18a

SLIDE MOTOR BRACKET

FLANGE OVER INNER
CHANNEL

Figure 18b

19. Slide the cassette slider back so that the gear rack goes through the motor bracket and interfaces with the
pinion (Fig 19a). If necessary, turn the motor by hand to assist in moving the cassette slider (Fig 19b).
Page 12 of 18 Document# 3600NMGR-04A Rev A February 6, 2012
 SLIDE CASSETTE
SLIDER BACK THROUGH
MOTOR ASSEMBLY

Figure 19a

TURN MOTOR BY HAND

TO HELP IF NECESSARY

Figure 19b

20. Once the gear rack and pinion are meshed, fasten the motor assembly to the module assembly using
three 6-32 lock nuts (Fig 20a & 20b).

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 6-32 LOCK NUTS

Figure 20a

Figure 20b COMPLETED MOTOR ASSEMBLY

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 21. Using an eyeglasses screwdriver, fasten the motor wires back to the Motor Controller Board. Note the
order of the wires in the graphic below. Do not over tighten the screws, as it may cause damage to the
Motor Controller Board (Fig 21).

Figure 21

22. With two (2) or more people, place the module back in the outer shell.
23. Fasten the module to the outer shell using eight (8) 10-32 x 1/2''screws (Fig 23).

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 Figure 23

24. Fasten the Eraser Cover to the unit using nine (9) 6-32 x 1/4'' screws (Fig 24).

Figure 24

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 25. Fasten the front cover using four (4) 6-32 x 3/8'' flathead screws (Fig 25).

Figure 25

26. Fasten the feet to the unit using four (4) 10-32 x 1/2'' truss head screws (Fig 26).

Figure 26

27. Reconnect the internal USB connector, the power switch plugs to the main power supply and the eraser
power supply and the external fan power plug (Fig 27a, 27b, 27c).

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 Figure 27a

Figure 27b

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 Figure 27c

28. Fasten the Back Cover to the unit using nine (9) 6-32 x 3/8” flathead undercut screws (Fig 28).

Figure 28

29. Once the machine is fully re-assembled, go to the Settings page, set BOTH PMT Voltages to 6.25, click
“Save Settings”, and exit.

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