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Brother PDS-5000 Service Manual

Advanced document scanner
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Brother Advanced Document Scanner
Read this manual thoroughly before maintenance work.
Keep this manual in a convenient place for quick and easy reference at all times.
May 2015
SM-PT080
(2)
SERVICE MANUAL
MODEL:
PDS-5000/6000
Confidential

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Summary of Contents for Brother PDS-5000

  • Page 1 Brother Advanced Document Scanner SERVICE MANUAL MODEL: PDS-5000/6000 Read this manual thoroughly before maintenance work. Keep this manual in a convenient place for quick and easy reference at all times. May 2015 SM-PT080 Confidential...
  • Page 2 © Copyright Brother 2015 All rights reserved. No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher. All other product and company names mentioned in this manual are trademarks or registered trademarks of their respective holders.
  • Page 3 TRADEMARKS BROTHER is either a trademark or a registered trademark of Brother Industries, Ltd. Microsoft, Windows, Windows Vista, Windows Server, Outlook and Internet Explorer are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries.

  • Page 4: Table Of Contents

    CONTENTS SAFETY INFORMATION CHAPTER 1 SPECIFICATIONS LIST 1. GENERAL ........................... 1-1 2. NETWORK CONNECTIVITY ....................... 1-3 3. SERVICE INFORMATION ......................1-3 4. PAPER ............................1-4 Paper Handling ........................1-4 Media Specifications ......................1-4 5. SCANNER ........................... 1-5 CHAPTER 2 ERROR INDICATIONS & TROUBLESHOOTING 1.
  • Page 5 4.5.2 Control panel is inoperable ................... 2-23 Troubleshooting for Other Problems ................. 2-24 4.6.1 Cannot update firmware ..................2-24 4.6.2 Machine is not turned ON ..................2-24 CHAPTER 3 DISASSEMBLY/REASSEMBLY 1. SAFETY PRECAUTIONS ......................3-1 2. PACKING ............................ 3-2 3. SCREW CATALOGUE ........................ 3-3 4.
  • Page 6 9.24 First side CCD glass ......................3-48 9.25 Feed roller ASSY / Exit roller ASSY ................. 3-49 9.26 Pick-up drive belt / Pick-up motor ..................3-50 9.27 First side LED light PCB ASSY ..................3-51 9.28 First side CCD unit / First side CCD flat cable ..............3-52 9.29 Multi-feed sensor PCB (Receive) / Multi-feed sensor PCB flat cable (Receive) ..............

  • Page 7: Safety Information

    SAFETY INFORMATION WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injuries. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injuries. Important Important indicates a potentially hazardous situation which, if not avoided, may result in damage to property or loss of product functionality.
  • Page 8  To use the Machine Safely Please keep these instructions for later reference and read them before attempting any maintenance. If you do not follow these safety instructions, there is a possibility of a fire, electrical shock, burn or suffocation. WARNING DO NOT expose the machine to direct sunlight, excessive heat, open flames, corrosive gasses, moisture or dust.
  • Page 9 Important • DO NOT place your machine next to sources of interference, such as speakers or the base units of non-Brother cordless telephones. Doing so may interfere with the operation of the machine's electronic components. • DO NOT connect your machine to an AC power outlet controlled by wall switches or automatic timers.
  • Page 10 • DO NOT use the machine or handle the cord if the cord has become worn or frayed. If unplugging the machine, DO NOT touch the damaged/frayed part. • Brother strongly recommends that you DO NOT use any type of extension cord. AC Adapter Safety Only use the supplied AC adapter with the unit.
  • Page 11 Do not disassemble or modify the machine, otherwise fire or electric shock may result. If the machine requires repair, contact the place of purchase or Brother Authorized Service Personnel. If the machine becomes hot, releases smoke, or generates any strong or unusual odors, immediately unplug the machine from the power outlet and call Brother Customer Service.
  • Page 12 DO NOT put your hands on the edge of the machine. Doing this may cause the machine to slip out of your hands resulting in injury to yourself or others, and/or damage to the machine. DO NOT touch the shaded area shown below when the top cover is open. Doing this may cause injury to your fingers by pinching them.
  • Page 13  Legal Limitations for Copying Observe all copyright laws when using this product. Color reproductions of certain documents are illegal and may result in either criminal or civil liability. This memorandum is intended to be a guide rather than a complete listing of every possible prohibition.
  • Page 14  Notice Regarding the Faithful Reproduction of Scanned Documents After scanning a document, confirm that the accuracy and quality of the corresponding scan data meets your needs by confirming the size of the scan data, the amount of image data captured, image fidelity, color tones, etc.

  • Page 15: Chapter 1 Specifications List

    CHAPTER 1 SPECIFICATIONS LIST 1. GENERAL Model PDS-5000 PDS-6000 Scanning Method Dual CCD Resolution From ADF 600 x 600 dpi (Optical) Resolution (Interpolated) 600 x 600 dpi Scanning One-sided 60 ppm @200/300 dpi 80 ppm @200/300 dpi Speed Monochrome 15 ppm @600 dpi...
  • Page 16 <Computer requirements> Hard Disk Space Processor Recom- Supported to Install Computer Platform & Minimum Minimum mended Operating System Version Speed Interface Drivers Applications ® ® ® Windows Windows Intel 1 GB 2 GB 50 MB 1.5 GB Operating Home Core ®...

  • Page 17: Network Connectivity

    2. NETWORK CONNECTIVITY Model All Models Wired Network node network type Network type Network security Wireless Network node network type Network type Communication mode Network security Specifications are subject to change without notice. 3. SERVICE INFORMATION Part Approximate Life (pages) Machine life 600,000 sheets (A4/LTR) or 5 years MTBF...

  • Page 18: Paper

    4. PAPER 4.1 Paper Handling Model All Models ADF Input 100 sheets ADF Output 100 sheets Duplex (Scan) Plastic Card Yes (incl. emboss, w/ card carrier sheet) Specifications are subject to change without notice. 4.2 Media Specifications Model All Models Paper Plain Paper, Business Card, Plastic Card (w/ emboss) Input...

  • Page 19: Scanner

    Windows XP in this Service Manual includes Windows XP Home Edition and Windows XP Professional. For the latest driver updates for the Mac OS X you are using, visit us at http://solutions.brother.com/. Specifications are subject to change without notice. Confidential...

  • Page 20: Chapter 2 Error Indications & Troubleshooting

    CHAPTER 2 ERROR INDICATIONS & TROUBLESHOOTING 1. INTRODUCTION Troubleshooting is a collection of solution procedures that service personnel should follow if an error or malfunction occurs in the machine. It is difficult to determine troubleshooting procedures for all possible problems that may occur in the future. Therefore, this chapter describes typical problems and recovery procedures for these.

  • Page 21: Checks Before Commencing Troubleshooting

    1.2 Checks before Commencing Troubleshooting Check the following items before commencing repairs on the machine.  Operating environment (1) The machine is placed on a flat, stable surface. (2) The machine is used in a clean environment where the temperature is 10°C (50°F) to 32.5°C (90.5°F), and the relative humidity is maintained between 20% and 80%.

  • Page 22: Overview

    2. OVERVIEW 2.1 Cross-section Drawing Document tray Paper detection sensor Reverse roller Multi-feed sensor PCB (Transmit) Second side CCD unit Pick-up roller Separation roller Second side LED light PCB Feed roller Exit roller First side LED light PCB Multi-feed sensor PCB (Receive) First side CCD unit Fig.

  • Page 23: Document Feed Path

    2.2 Document Feed Path Document feed path <Front side> <Back side> Fig. 2-2 Confidential...

  • Page 24: Operation Of Each Part

    2.3 Operation of Each Part Part name Operation Pick-up roller Feeds document from the document tray. Reverse roller Separates the document fed from the document tray into Separation roller single sheets. Feeding roller Feeds document to the scanner part. Paper detection sensor Detects the document set in the document tray.

  • Page 25: Block Diagram

    2.4 Block Diagram Control panel ASSY LCD PCB ASSY Upper base Second side CCD unit Multi-feed sensor PCB ASSY Sensor PCB ASSY (Transmit) (Paper jam sensor) (ADF cover sensor) Second side LED light PCB ASSY Paper detection sensor Bottom base First side CCD unit Double feeding PCB ASSY (Receive) Main PCB ASSY...

  • Page 26: Error Indications

    3. ERROR INDICATIONS If the machine does not work normally it judges that an error has occurred, and indicates the corresponding error message on the LCD, which in turn helps the service men to quickly find out the problem. Error Refer Description codes...
  • Page 27 Error Refer Description codes Multifeed. The multi-feed sensor detected the double 3101 2-14 document feeding. NVRAM R/W test error. When the power switch is turned ON, write a certain value to NVRAM then read again, 2024 2-12 the value is different. Ultrasonic error.

  • Page 28: Troubleshooting

    4. TROUBLESHOOTING 4.1 Error Cause and Remedy  Error code 0014 USB R/W test error. When the power switch is turned ON, write a certain value to USB register then read again, the value is different. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.
  • Page 29  Error code 0024 AFE LVDS test error. When the power switch is turned ON, write a certain value to first side LVDS register then read again, the value is different. Step Cause Remedy Main PCB failure Replace the main PCB ASSY. ...
  • Page 30  Error code 2013 Document Jam/too Long. • Scan sensor is ON when the power switch is turned ON. • Paper jam sensor remains ON after the specified time during document scanning. • Scan sensor detected that the smaller size of paper was ejected during the document feeding.
  • Page 31  Error code 2014 ADF cover open. ADF cover sensor detected an open ADF cover. <User Check> • Close the ADF cover properly. Step Cause Remedy Sensor PCB attachment failure Reattach the sensor PCB ASSY. Abrasion of the ADF cover hook Replace the ADF cover hook. ADF cover sensor failure Replace the sensor PCB ASSY.
  • Page 32  Error code 3003 DRAM R/W test error. When the power switch is turned ON, write a certain value to DRAM then read again, the value is different. Step Cause Remedy Main PCB failure Replace the main PCB ASSY.  Error code 3006 ADF front lamp error.
  • Page 33  Error code 3101 Multifeed. The multi-feed sensor detected the double document feeding. <User Check> • Set a document within the specified size. • Adjust the document guide according to the document width. • Check that the document is not damp. Step Cause Remedy...

  • Page 34: Troubleshooting For Document Feeding Problems

    4.2 Troubleshooting for Document Feeding Problems 4.2.1 No document is fed <User Check> • Set the document properly and check that the display on the LCD changes. • Check that the number of documents set is within the standard. • Close the ADF cover properly. Step Cause Remedy...

  • Page 35: Document Becomes Jammed

    4.2.3 Document becomes jammed  Document jam in the paper feed path <User Check> • Check that paper used for the document is not thinner than the standard. • Set a document within the specified size. • Check that the number of documents set is within the standard. •...

  • Page 36: Document Becomes Wrinkled

    4.2.4 Document becomes wrinkled <User Check> • Adjust the document guide according to the document width. • Check that the document is not curled. • Check that the document is not damp. Step Cause Remedy Abrasion of the reverse roller Replace the reverse roller.

  • Page 37: Troubleshooting For Scanned Image Defects

    4.3 Troubleshooting for Scanned Image Defects 4.3.1 Defect examples Light (2-18) Faulty registration (2-19) Dark (2-19) Completely All black blank (2-19) (2-20) Vertical streaks (2-20) White vertical Partial shading Colored background (2-21) streaks (2-21) (2-21) Fig. 2-5 4.3.2 Troubleshooting according to image defect ...
  • Page 38  Faulty registration <User Check> - Check that the document scanning position setting is not deviated. Step Cause Remedy OD adjustment value failure Acquire OD adjustment value. (Refer to “3.1 OD Adjustment (Optical Density Learning)” in Chapter Main PCB failure Replace the main PCB ASSY.
  • Page 39  All black Step Cause Remedy Connection failure of the sensor Reconnect the sensor PCB flat cable. PCB flat cable Connection failure of the first side Reconnect the first side LED light PCB or LED light PCB or second side LED second side LED light PCB flat cable.
  • Page 40  White vertical streaks <User Check> - Clean the scanning area. Step Cause Remedy Dirt on the first side glass or second Clean the first side glass ASSY or second side glass side glass ASSY. Foreign object inside the scanner Remove the foreign object inside the scanner mechanism mechanism and attach the sponge.

  • Page 41: Troubleshooting For Software Problems

    4.4 Troubleshooting for Software Problems End users can solve problems related to software, for instance, scanning is not possible from a computer although scanning setting is available in the machine, as long as they follow the User Check items. If the problem still cannot be solved, implement each procedure according to the step numbers in the tables below.

  • Page 42: Troubleshooting For Control Panel Problems

    4.5 Troubleshooting for Control Panel Problems 4.5.1 Nothing is displayed on the LCD <User Check> - Turn the power switch OFF and then ON again. - Check the DC terminal connection. Step Cause Remedy Key attachment failure Reattach the key. Connection failure of the LCD PCB Reconnect the LCD PCB flat cable.

  • Page 43: Troubleshooting For Other Problems

    4.6 Troubleshooting for Other Problems 4.6.1 Cannot update firmware <User Check> - Make sure that there is no other function running. - Turn the power switch OFF and then ON again. Step Cause Remedy Main PCB failure Replace the main PCB ASSY. 4.6.2 Machine is not turned ON <User Check>...

  • Page 44: Chapter 3 Disassembly/Reassembly

    CHAPTER 3 DISASSEMBLY/REASSEMBLY 1. SAFETY PRECAUTIONS To avoid creating secondary problems by mishandling, follow the warnings and precautions below during maintenance work. • Be careful not to lose screws, washers, or other parts removed. • Be sure to apply grease to applicable positions specified in this chapter. •...

  • Page 45: Packing

    2. PACKING Fig. 3-1 Confidential...

  • Page 46: Screw Catalogue

    3. SCREW CATALOGUE Taptite bind B Taptite bind B M3x8 (black) Taptite bind B M3x10 (black) Taptite cup S Taptite cup S M3x6 Taptite cup B Taptite cup B M3x8 Screw pan (S washer) Screw pan (S washer) M3x10 Fig. 3-2 Confidential...

  • Page 47: Screw Torque List

    4. SCREW TORQUE LIST Tightening torque Location of screw Screw type Q’ty N·m (kgf·cm) Shaft mount ASSY Taptite bind B M3x10 (black) 0.8±0.05(8±0.5) Bottom cover ASSY Taptite bind B M3x10 (black) 0.8±0.05(8±0.5) Main PCB shield plate Taptite cup S M3x6 0.6±0.05(6±0.5) Panel ASSY Taptite bind B M3x10 (black)

  • Page 48: Lubrication

    5. LUBRICATION There are no parts that require lubrication. Confidential...

  • Page 49: Overview Of Gears

    6. OVERVIEW OF GEARS <Left side> Fig. 3-3 <Right side> Fig. 3-4 Confidential...

  • Page 50: Harness Routing

    7. HARNESS ROUTING Main PCB ASSY Sensor PCB FG First side LED light PCB Multi-feed sensor PCB First side CCD LCD PCB harness (BK) harness (RD, BK) flat cable (Receive) flat cable flat cable Sensor PCB Feed motor harness Main PCB ASSY Pick-up motor harness Second side flat cable...
  • Page 51 Left side of machine Sensor PCB FG harness (BK) LCD PCB flat cable LCD PCB ASSY LCD PCB flat cable LCD PCB ASSY Confidential...
  • Page 52 Second side LED light PCB harness Second side LED light PCB ASSY Upper base ASSY Second side LED light PCB harness (RD, BK) Upper base ASSY Multi-feed sensor Multi-feed sensor PCB Second side LED light Sensor PCB PCB (Transmit) flat cable (Transmit) PCB harness (RD, BK) flat cable Upper base ASSY...
  • Page 53 Second side CCD flat cable Upper base ASSY Second side CCD unit Second side CCD flat cable First side LED light PCB harness First side LED light PCB harness (RD, BK) Lower base First side LED light PCB ASSY Harness colors are subject to change for some reason. 3-10 Confidential...
  • Page 54 First side CCD flat cable First side CCD flat cable First side CCD unit First side CCD flat cable / Multi-feed sensor PCB flat cable (Receive) First side CCD flat cable Multi-feed sensor PCB flat cable (Receive) 3-11 Confidential...

  • Page 55: Disassembly Flow Chart

    8. DISASSEMBLY FLOW CHART Disassembly / Reassembly (second) 9.2 Reverse roller 9.2 Separation roller 9.3 Reverse roller 9.2 Pick-up roller ASSY 9.6 Top cover ASSY 9.7 Upper back cover ASSY ASSY cover ASSY 10/15 10/15 9.16 ADF cover hook 9.8 Bottom cover ASSY 9.5 Shaft mount ASSY 20/15 20/20...

  • Page 56: Disassembly Procedure

    9. DISASSEMBLY PROCEDURE 9.1 Preparation  Disconnecting Cables Prior to proceeding with the disassembly procedure, (1) Disconnect the following: • USB cable (if connected) • AC power cord (if connected) USB cable AC power cord Fig. 3-5 3-13 Confidential...

  • Page 57: Paper Feed Roller Kit (Reverse Roller Assy / Pick-Up Roller Assy / Separation Roller Assy)

    9.2 Paper feed roller kit (Reverse roller ASSY / Pick-up roller ASSY / Separation roller ASSY) (1) Open the top cover ASSY, and pull the cover release lever to open the upper base ASSY. (2) Push the two hooks inward to open the reverse roller cover ASSY. (3) Remove the reverse roller ASSY.
  • Page 58 (6) Slide the two document guides outward. (7) Open the pick-up roller cover. (8) Pull the left side of pick-up roller ASSY to remove it. Document guide Pick-up roller cover Pick-up roller ASSY Document guide Fig. 3-8 (9) Turn the lever in the direction of the arrow to remove the separation roller ASSY. Lever Pick-up roller cover Separation roller ASSY...

  • Page 59: Reverse Roller Cover Assy

    9.3 Reverse roller cover ASSY (1) Push the two hooks of reverse roller cover ASSY inward to open it. (2) Push the right side of reverse roller cover ASSY in the direction of the arrow to remove the boss, and remove it. Reverse roller cover ASSY Hooks Fig.

  • Page 60: Shaft Mount Assy

    9.5 Shaft mount ASSY (1) Remove the two taptite bind B M3x10 (black) screws to remove the shaft mount ASSY. Shaft mount ASSY Taptite bind B M3x10 (black) Fig. 3-12 9.6 Top cover ASSY (1) Push the right side arm to remove the boss, and remove the top cover ASSY. Top cover ASSY Document guides Fig.

  • Page 61: Upper

    9.7 Upper back cover (1) Push the arm to remove the boss, and remove the upper back cover. Upper back cover Fig. 3-14 Assembling Note: • When attaching the upper back cover, insert the spring into the groove (two locations). Groove Spring Fig.

  • Page 62: Bottom Cover Assy / Output Tray Assy

    9.8 Bottom cover ASSY / Output tray ASSY (1) Close the upper base ASSY, and turn over the machine. (2) Remove the four taptite bind B M3x10 (black) screws from the bottom cover ASSY. Release each hook to remove the bottom cover ASSY. Assembling Note: •...

  • Page 63: Back Cover

    9.9 Back cover (1) Release the two hooks to remove the back cover. Back cover Hooks Fig. 3-18 3-20 Confidential...

  • Page 64: Side Cover L/R

    9.10 Side cover L/R (1) Turn over the machine, and pull the cover release lever to open the upper base ASSY. (2) Release each hook to remove the side cover L. Side cover L Upper base ASSY Fig. 3-19 (3) Release each hook. Turn the side cover R slightly around the inner boss to remove it from the machine.

  • Page 65: Main Pcb Assy

    9.11 Main PCB ASSY (1) Turn over the machine. (2) Remove the four taptite cup S M3x6 screws to remove the main PCB shield plate and the sensor PCB FG harness. Taptite cup S M3x6 Fig. 3-21 Main PCB shield plate Taptite cup S M3x6 Taptite cup S M3x6 “A”...
  • Page 66 (3) Disconnect the feed motor harness, the pick-up motor harness, the first side LED light PCB harness, the sensor PCB flat cable, the LCD PCB flat cable, the second side CCD flat cable, and the first side CCD flat cable. Pull out each flat cable from each flat core. Note: •...
  • Page 67 <Attachment Procedure> 1) Attach the double-sided tape as shown in the figure below. (two places) Double-sided tapes Fig. 3-24 2) Pass the first side CCD flat cable through the flat core “A”, and connect it to the main PCB ASSY. 3) Fold the second side CCD flat cable within the red frame as necessary, pass it through the flat core “B”, connect it to the main PCB ASSY, and attach it to the double-sided tape.
  • Page 68 6) Fold the LCD PCB flat cable within the red frame as necessary, pass it through the flat core “C”, connect it to the main PCB ASSY, and attach it to the double-sided tape. LCD PCB flat cable Flat core “C” Main PCB ASSY Fig.

  • Page 69: Upper Base Assy

    9.12 Upper base ASSY (1) Release the LCD PCB flat cable, the sensor PCB flat cable, the second side CCD flat cable and the sensor PCB FG harness from the securing fixtures. Turn over the machine, and pull the cover release lever to open the upper base ASSY. (2) Pull the left side of upper base ASSY to remove the boss, and remove it.

  • Page 70: Lcd Pcb Assy / Panel Assy / Lcd Sheet / Lcd Pcb Flat Cable

    9.13 LCD PCB ASSY / Panel ASSY / LCD sheet / LCD PCB flat cable Note: • Be careful not to snap or bend the anti static brush. (1) Remove the two taptite bind B M3x10 (black) screws from the upper base ASSY. (2) Release three hooks to remove the panel ASSY from the upper base ASSY.
  • Page 71 Assembling Note: • When attaching the panel ASSY, insert the two tabs of panel ASSY into the two grooves of upper base ASSY. • When assembling the upper base ASSY, do not catch flat cables and the FG harness. Upper base ASSY Grooves Tabs Panel ASSY...
  • Page 72 (3) Unlock the lock to disconnect the LCD PCB flat cable from the LCD PCB ASSY. Note: • After disconnecting flat cable, check that the cable is not damaged at its end or short-circuited. • When connecting flat cable, do not insert it at an angle. After insertion, check that the cable is not at an angle.
  • Page 73 (5) Remove the LCD sheet from the panel ASSY. Panel ASSY LCD sheet Fig. 3-34 <Attachment Procedure> 1) Fold the LCD PCB flat cable as shown in the figure below. LCD PCB flat cable Fig. 3-35 3-30 Confidential...

  • Page 74: Second Side Ccd Glass Assy / Second Side Ccd Glass Spring / Second Side Led Light Pcb Assy

    9.14 Second side CCD glass ASSY / Second side CCD glass spring / Second side LED light PCB ASSY (1) Push the two hooks outward to remove the second side CCD glass ASSY from the upper base ASSY. Hooks Upper base ASSY Second side CCD glass ASSY Fig.
  • Page 75 (2) Remove the two second side CCD glass springs from the upper base ASSY. (3) Remove the two taptite bind B M3x10 (black) screws to remove the second side LED light PCB ASSY from the upper base ASSY, and disconnect the second side LED light PCB harness from the second side LED light PCB ASSY.

  • Page 76: Reverse Roller Gear Assy

    9.15 Reverse roller gear ASSY (1) Release the hook of reverse roller gear S to pull out the reverse roller gear ASSY from the upper base ASSY, and remove the reverse roller gear S. Hook Upper base ASSY Reverse roller gear S Reverse roller gear ASSY Fig.

  • Page 77: Adf Cover Hook

    9.16 ADF cover hook (1) Remove the retaining ring to remove the ADF cover hook from the left side of upper base ASSY. Upper base ASSY ADF cover hook Retaining ring Fig. 3-39 (2) Remove the retaining ring to remove the ADF cover hook from the right side of upper base ASSY.

  • Page 78: Cover Release Lever

    9.17 Cover release lever Note: • Be careful not to snap or bend the anti static brush. (1) Turn over the upper base ASSY. (2) Remove the two taptite cup S M3x6 screws to remove the cover release lever from the upper base ASSY.

  • Page 79: Adf Cover Sensor Pcb / Sensor Pcb Flat Cable

    9.18 ADF cover sensor PCB / Sensor PCB flat cable (1) Unlock the lock to disconnect the sensor PCB flat cable from the ADF cover sensor PCB. Disconnect the second side LED light PCB harness, the paper detection sensor harness and the multi-feed sensor PCB flat cable (Transmit) from the ADF cover sensor PCB.
  • Page 80 <Attachment Procedure> 1) Attach the double-sided tape as shown in the figure below. (two places) Double-sided tapes Fig. 3-43 2) Attach the flat core and the sensor PCB flat cable to the double-sided tapes as shown in the figure below. Sensor PCB flat cable Flat core Fig.

  • Page 81: Paper Detection Sensor

    9.19 Paper detection sensor (1) Release the paper detection sensor harness from the securing fixtures. (2) Turn the paper detection sensor in the direction of the arrow while pushing the hook, and remove it from the upper base ASSY. Paper detection sensor Upper base ASSY Hook Paper detection sensor harness...

  • Page 82: Second Side Ccd Unit / Second Side Ccd Flat Cable

    9.20 Second side CCD unit / Second side CCD flat cable (1) Release the second side CCD flat cable from the securing fixtures. Note: • Be sure to replace the double-sided tape with a new one, after taking off the flat cable from the double-sided tape.
  • Page 83 (4) Unlock the lock to disconnect the second side CCD flat cable, and release it from the securing fixtures. Note: • Be sure to replace the double-sided tape with a new one, after taking off the flat cable from the double-sided tape. •...
  • Page 84 <Attachment Procedure> 1) Pass the second side CCD flat cable through the flat core, connect it to the PCB, and attach it to the double-sided tape. Flat core Second side CCD flat cable Fig. 3-49 2) Attach the double-sided tape as shown in the figure below. (two places) Double-sided tapes Fig.
  • Page 85 3) Attach the second side CCD flat cable to the double-sided tape as shown in the figure below. Second side CCD flat cable Fig. 3-51 4) Fold the second side CCD flat cable at the position described below.  1 mm Second side CCD flat cable Fig.

  • Page 86: Multi-Feed Sensor Pcb (Transmit) / Multi-Feed Sensor Pcb Flat Cable (Transmit)

    9.21 Multi-feed sensor PCB (Transmit) / Multi-feed sensor PCB flat cable (Transmit) (1) Unlock the lock to disconnect the multi-feed sensor PCB flat cable (Transmit) from the multi-feed sensor PCB (Transmit). (2) Remove the taptite cup B M3x8 screw to remove the multi-feed sensor PCB (Transmit) from the upper base ASSY while lifting the FG plate.
  • Page 87 If the “Vertical streaks” “White vertical streaks” in Chapter 2 happens, attach the sponge by following the instruction below.  Where to attach the sponge on the second side CCD unit side Use the following parts from SPONGE ASSY PDS (D00DFL001). Shield plate Shield plate Fig.
  • Page 88 Sponge attaching surface Upper base ASSY Fig. 3-55 Assembling Note: • Attach the sponge on the upper base ASSY along the dotted line. • Sponge should be attached so that it is not projected to the outside of the attaching surface.

  • Page 89: Main Pcb Shield

    9.22 Main PCB shield (1) Remove the screw pan (S washer) M3x10 screw from the right side of machine. Screw pan (S washer) M3x10 Fig. 3-56 (2) Remove the two taptite bind B M3x10 (black) screws to remove the main PCB shield. Main PCB shield Tabs Multi-feed sensor PCB flat cable (Receive)

  • Page 90: Feed Drive Belt S / Feed Drive Belt / Feed Motor

    9.23 Feed drive belt S / Feed drive belt / Feed motor (1) Remove the feed drive belt S. (2) Loosen the taptite cup S M3x6 screw. (3) Remove the feed drive belt while pushing the tension pulley holder in the direction of the arrow.

  • Page 91: First Side Ccd Glass

    9.24 First side CCD glass (1) Turn over the lower base. (2) Remove the four taptite bind B M3x8 (black) screws, and release the five hooks to remove the first side CCD glass. Taptite bind B M3x8 (black) Hooks First side CCD glass Fig.

  • Page 92: Feed Roller Assy / Exit Roller Assy

    9.25 Feed roller ASSY / Exit roller ASSY (1) Turn the conductive bushing in the direction of the arrow to remove the feed roller ASSY. Feed roller ASSY Conductive bushing Fig. 3-61 (2) Turn the conductive bushing in the direction of the arrow to remove the exit roller ASSY. Exit roller ASSY Conductive bushing Fig.

  • Page 93: Pick-Up Drive Belt / Pick-Up Motor

    9.26 Pick-up drive belt / Pick-up motor (1) Remove the three retaining ring E3 to remove the gear “A”, “B” and “C”. Release the hook to remove the gear “D”, and remove the pick-up drive belt. (2) Remove the two taptite cup S M3x6 screws to remove the pick-up motor. Retaining ring E3 Gear “C”...

  • Page 94: First Side Led Light Pcb Assy

    9.27 First side LED light PCB ASSY (1) Remove the two taptite bind B M3x10 (black) screws to remove the first side LED light PCB ASSY, and disconnect the first side LED light PCB harness from the first side LED light PCB ASSY.

  • Page 95: First Side Ccd Unit / First Side Ccd Flat Cable

    9.28 First side CCD unit / First side CCD flat cable (1) Turn over the lower base. (2) Remove the taptite bind B M3x10 (black) screw from the upper base ASSY. Note: • Do not touch the glass surface of first side CCD unit. Taptite bind B M3x10 (black) Upper base ASSY First side CCD unit...
  • Page 96 (4) Unlock the lock to disconnect the first side CCD flat cable, and release it from the securing fixtures. Note: • Be sure to replace the double-sided tape with a new one, after taking off the flat cable from the double-sided tape. •...
  • Page 97 <Attachment Procedure> 1) Attach the two double-sided tapes as shown in the figure below. Double-sided tapes Fig. 3-69 2) Fold the first side CCD flat cable and attach it to the double-sided tapes as shown in the figure below. First side CCD flat cable Fig.

  • Page 98: Multi-Feed Sensor Pcb (Receive) / Multi-Feed Sensor Pcb Flat Cable (Receive)

    9.29 Multi-feed sensor PCB (Receive) / Multi-feed sensor PCB flat cable (Receive) (1) Remove the two taptite bind B M3x10 (black) screws to remove the multi-feed sensor PCB (Receive). (2) Disconnect the multi-feed sensor PCB flat cable (Receive) from the multi-feed sensor PCB (Receive).
  • Page 99 If the “Vertical streaks” “White vertical streaks” in Chapter 2 happens, attach the sponge by following the instruction below.  Where to attach the sponge on the first side CCD unit side Use the following parts from SPONGE ASSY PDS (D00DFL001). “B”...
  • Page 100 “A” section-1 Hook Fig. 3-73 Assembling Note: • Stick the sponge 1 and 2 together along with the dotted line. • Attach the double-sided tape on the hook of the lower base ASSY. “A” section-2 Fig. 3-74 Assembling Note: • Attach the sponge on the lower base ASSY along the dotted line. 3-57 Confidential...
  • Page 101 “B” section Double feeding sensor shield Fig. 3-75 Assembling Note: • Attach the sponge on the double feeding sensor shield along the dotted line. 3-58 Confidential...
  • Page 102 “C” section-1 Sponge attaching surface Fig. 3-76 Assembling Note: • Attach the sponge on the sponge attaching surface of the lower base ASSY along the dotted line. “C” section-2 Fig. 3-77 Assembling Note: • Attach the sponge on the lower base ASSY along the dotted line. 3-59 Confidential...

  • Page 103: Chapter 4 Adjusting And Updating Settings As Required After Parts Replacement

    CHAPTER 4 ADJUSTING AND UPDATING SETTINGS AS REQUIRED AFTER PARTS REPLACEMENT 1. IF YOU REPLACE THE MAIN PCB ASSY  What to do after replacement • Installing Firmware (Sub Firmware, Panel Firmware, and Main Firmware) • Setting Serial Number • Setting Multi-feed Sensor Threshold •...
  • Page 104 (6) OD/MF Chart ASSY • White paper • Mech Chart • OD Chart • White A4 150g paper • Crease paper • A4 28g paper Confidential...

  • Page 105: Installing Firmware (Sub Firmware, Panel Firmware, And Main Firmware)

    1.1 Installing Firmware (Sub Firmware, Panel Firmware, and Main Firmware) 1.1.1 Checking firmware version Check whether the firmware installed on the machine is the latest version. If it is the latest version, there is no need to install the firmware. If it is not, be sure to install the firmware to the machine as described in “1.1.2 Installing firmware”.
  • Page 106 (7) The window below appears on the screen. Click the [Information] tab. Scroll down and check "F/W Version". Confidential...

  • Page 107: Installing Firmware

    1.1.2 Installing firmware Note: • Do not disconnect the AC cord or USB cable from the machine or computer during installing. • If the install is failed, turn OFF the machine and turn it back on. The machine enters the firmware install mode automatically. Continue to the operation procedures (2) and later below.

  • Page 108: Setting Serial Number

    1.2 Setting Serial Number (1) Double-click "Service Tool.exe" in the "serial_number" folder. (2) The window below appears on the screen. Click the [NVRAM Modify] button. (3) The window below appears on the screen. Enter the serial number described on the label at the back of the machine and press the [Reset] button.
  • Page 109 (5) Follow the operation procedure (1) to (6) for checking firmware version, and check that the serial number written is correct. Confidential...

  • Page 110: Setting Multi-Feed Sensor Threshold

    1.3 Setting Multi-feed Sensor Threshold (1) Press the [Start] button on your computer and click "All Programs". Click and open "Standard Learning Tool II" to start "Standard Learning Tool II". (2) When "Please Input ID or Station Name" and "Please Input Password" windows appear, enter "service".
  • Page 111 (4) The window below appears on the screen. Click the [Start] button. (5) The window below appears on the screen. Set the adjustment chart (White A4 150g paper) shown in the picture to the machine and click the [OK] button. (6) The following window appears after feeding the chart.
  • Page 112 (7) The following window appears after feeding the chart. Set the adjustment chart (Crease paper) shown in the picture again to the machine and click the [OK] button. (8) The following window appears after feeding the chart. Set the adjustment chart (A4 28g) shown in the picture to the machine and click the [OK] button.

  • Page 113: Od Adjustment (Optical Density Learning)

    1.4 OD Adjustment (Optical Density Learning) (1) Turn ON the machine. Press the [Start] button on your computer and click "All Programs". Click and open "Standard Learning Tool II" to start "Standard Learning Tool II". (2) When "Please Input ID or Station Name" and "Please Input Password" windows appear, enter "service".
  • Page 114 (4) The window below appears on the screen. Click the [Start] button. (5) The window below appears on the screen. Enter the number (ex: 47N-1-0195-030 in the picture below) on the adjustment chart (White paper) and click the [OK] button. (6) The window below appears on the screen.
  • Page 115 (7) The window below appears on the screen. Enter the number (ex: 421-E-0345-120 in the picture below) on the adjustment chart (OD Chart) and click the [OK] button. (8) The window below appears on the screen after the countdown. Set the adjustment chart (White paper) shown in the picture to the machine and click the [OK] button.
  • Page 116 (10) The window below appears on the screen. Set the adjustment chart (OD Chart) shown in the picture so that the "A" comes at the bottom and click the [OK] button. (11) The window below appears on the screen. Set the adjustment chart (OD Chart) shown in the picture again so that the "A" comes at the bottom and click the [OK] button.
  • Page 117 (12) The window below appears on the screen. Set the adjustment chart (OD Chart) shown in the picture again so that the "A" comes at the bottom and click the [OK] button. (Same sheet as the procedure (10)) Note: • If you set the OD Chart on the ADF right after the procedure (11) completes, the screen below doesn't appear and the adjustment starts immediately.

  • Page 118: Checking Operation After Repair

    1.5 Checking Operation after Repair Perform the steps below to check the machine's condition after repair or adjustment. (1) Confirm that the machine is connected to your computer via USB cable. (2) Set the test charts (density chart TC-027, density chart CTC-001, and density chart TC-023) in the document feeder.
  • Page 119 (5) Click the Multi-Feed Detection tab (“C”), check the Ultrasonic Detection box (“D”), and click the [OK] button (“E”). “C” “D” “E” (6) Scanning starts once you click the [Scan] button. 4-17 Confidential...
  • Page 120 (7) Set the test chart used in procedure (2) again and click the [Setup] button. (8) Uncheck the Front Color box (“F”), check the Back Color box (“G”), and click the [OK] button (“H”). “F” “G” “H” (9) Scanning starts once you click the [Scan] button. (10) Check the two scanned images for color difference and image distortion.

  • Page 121: If You Replace The Multi-Feed Sensor Pcb

    2. IF YOU REPLACE THE MULTI-FEED SENSOR PCB  What to do after replacement • Setting Multi-feed Sensor Threshold • Checking Multi-feed Function  What you need to prepare (1) One USB cable ® (2) Computer (Windows XP or later) (3) Service setting tools (StdL2Setup.exe, SetupAddon.exe) Pre-install them into computer according to APPENDIX...

  • Page 122: Setting Multi-Feed Sensor Threshold

    2.1 Setting Multi-feed Sensor Threshold (1) Press the [Start] button on your computer and click "All Programs". Click and open "Standard Learning Tool II" to start "Standard Learning Tool II". (2) When "Please Input ID or Station Name" and "Please Input Password" windows appear, enter "service".
  • Page 123 (3) Select "ultrasonic" and click the [Ok] button. (4) The window below appears on the screen. Click the [Start] button. (5) The window below appears on the screen. Set the adjustment chart (White A4 150g paper) shown in the picture to the machine and click the [OK] button.
  • Page 124 (6) The following window appears after feeding the chart. Set the adjustment chart (Crease paper) shown in the picture to the machine and click the [OK] button. (7) The following window appears after feeding the chart. Set the adjustment chart (Crease paper) shown in the picture again to the machine and click the [OK] button.

  • Page 125: Checking Multi-Feed Function

    (10) The following window appears and the machine turns OFF. Click the [OK] button. The window shown below closes. 2.2 Checking Multi-feed Function Perform the steps below to check the machine's condition after repair or adjustment. (1) Confirm that the machine is connected to your computer via USB cable. (2) Set the test charts (density chart TC-027, density chart CTC-001, and density chart TC-023) in the document feeder.
  • Page 126 (4) The window below appears on the screen. Check the Front Color box (“A”) and uncheck the Front B&W box (“B”). “A” “B” (5) Click the Multi-Feed Detection tab (“C”), check the Ultrasonic Detection box (“D”), and click the [OK] button (“E”). “C”...
  • Page 127 (6) Scanning starts once you click the [Scan] button. (7) Set the test chart used in procedure (2) again and click the [Setup] button. (8) Uncheck the Front Color box (“F”), check the Back Color box (“G”), and click the [OK] button (“H”).
  • Page 128 (9) Scanning starts once you click the [Scan] button. (10) Check the two scanned images for color difference and image distortion. 4-26 Confidential...

  • Page 129: If You Replace The Ccd Unit Or Led Pcb Assy

    3. IF YOU REPLACE THE CCD UNIT OR LED PCB ASSY  What to do after replacement • OD Adjustment (Optical Density Learning) • Checking Operation after Repair  What you need to prepare (1) One USB cable ® (2) Computer (Windows XP or later) (3) Service setting tools (StdL2Setup.exe, SetupAddon.exe) Pre-install them into computer according to...

  • Page 130: Od Adjustment (Optical Density Learning)

    3.1 OD Adjustment (Optical Density Learning) (1) Press the [Start] button on your computer and click "All Programs". Click and open "Standard Learning Tool II" to start "Standard Learning Tool II". (2) When "Please Input ID or Station Name" and "Please Input Password" windows appear, enter "service".
  • Page 131 (4) The window below appears on the screen. Click the [Start] button. (5) The window below appears on the screen. Enter the number (ex: 47N-1-0195-030 in the picture below) on the adjustment chart (White paper) and click the [OK] button. (6) The window below appears on the screen.
  • Page 132 (7) The window below appears on the screen. Enter the number (ex: 421-E-0345-120 in the picture below) on the adjustment chart (OD Chart) and click the [OK] button. (8) The window below appears on the screen after the countdown. Set the adjustment chart (White paper) shown in the picture to the machine and click the [OK] button.
  • Page 133 (10) The window below appears on the screen. Set the adjustment chart (OD Chart) shown in the picture so that the "A" comes at the bottom and click the [OK] button. (11) The window below appears on the screen. Set the adjustment chart (OD Chart) shown in the picture again so that the "A" comes at the bottom and click the [OK] button.
  • Page 134 (12) The window below appears on the screen. Set the adjustment chart (OD Chart) shown in the picture again so that the "A" comes at the bottom and click the [OK] button. (Same sheet as the procedure (10)) Note: • If you set the OD Chart on the ADF right after the procedure (11) completes, the screen below doesn't appear and the adjustment starts immediately.

  • Page 135: Checking Operation After Repair

    3.2 Checking Operation after Repair Perform the steps below to check the machine's condition after repair or adjustment. (1) Confirm that the machine is connected to your computer via USB cable. (2) Set the test charts (density chart TC-027, density chart CTC-001, and density chart TC-023) in the document feeder.
  • Page 136 (5) Click the Multi-Feed Detection tab (“C”), check the Ultrasonic Detection box (“D”), and click the [OK] button (“E”). “C” “D” “E” (6) Scanning starts once you click the [Scan] button. 4-34 Confidential...
  • Page 137 (7) Set the test chart used in procedure (2) again and click the [Setup] button. (8) Uncheck the Front Color box (“F”), check the Back Color box (“G”), and click the [OK] button (“H”). “F” “G” “H” (9) Scanning starts once you click the [Scan] button. (10) Check the two scanned images for color difference and image distortion.

  • Page 138: Chapter 5 Service Functions

    CHAPTER 5 SERVICE FUNCTIONS Service mode is not equipped with this product. Confidential...

  • Page 139: Chapter 6 Wiring Diagram

    CHAPTER 6 WIRING DIAGRAM 1. WIRING DIAGRAM J5 5 J14 26 Sensor J9 20 Paper DGND Main PCB DGND DGND DGND DGND DGND detection DGND 10V UP DGND PAPER_DETECT 5V_SAV 3.3VU sensor 3.3V 5V_SAV DGND +3.3V ULTRASONIC EMITIER2 J3 4 Second SH_R DGND...

  • Page 140: Chapter 7 Periodical Maintenance

    CHAPTER 7 PERIODICAL MAINTENANCE 1. PERIODICAL MAINTENANCE PARTS There are no applicable parts for periodical maintenance. Confidential...

  • Page 141: Appendix 1 Serial Numbering System

    APPENDIX 1 SERIAL NUMBERING SYSTEM  Serial number label (1 location) <How to Read> Serial number L 5 U 1 1 1 1 2 2 Product identification Serial number (6-digit) code Manufacturing factory No. Year of manufacture 5: 2015 6: 2016 Month of manufacture A: January E: May...

  • Page 142: Appendix 2 Installing Adjustment Tools

    APPENDIX 2 INSTALLING ADJUSTMENT TOOLS (OD LEARNING AND DOUBLE FEEDING) Note: • Install “StdL2Setup.exe” first, and then “SetupAddon.exe”.  Installing StdL2Setup tool (1) Double-click “StdL2Setup.exe” to start it. (2) The window below appears on the screen. Select the language to use and click the [OK] button.
  • Page 143 (4) The confirmation window below appears on the screen. Select "I accept the agreement" and click the [Next] button. (5) The information window below appears on the screen. Click the [Next] button. App. 2-2 Confidential...
  • Page 144 (6) The window below appears on the screen. Select the destination to save the file and click the [Next] button. (7) The window below appears on the screen. Do not check the box and click the [Next] button if you do not want to display the program in the start menu.
  • Page 145 (8) The window below appears on the screen. Do not check the box and click the [Next] button if you do not want to display the desk top icon. (9) The window below appears on the screen. If there is no problem, click the [Install] button.
  • Page 146 (10) Installation starts. (11) The screen below appears when installing is completed. If you want to start the program immediately, check the box and click the [Finish] button to complete. App. 2-5 Confidential...
  • Page 147  Installing additional data tool (1) Double-click “SetupAddon.exe” to start it. (2) The window below appears on the screen. Select the language to use and click the [OK] button. (3) The opening window below appears on the screen. Click the [Next] button. (4) The information window below appears on the screen.
  • Page 148 (5) The window below appears on the screen. Click the [Install] button. (6) The screen below appears when installing is completed. Click the [Finish] button to complete. App. 2-7 Confidential...

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Pds-6000

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