December 2016

Version 2

Xerox® DocuMate® 6440

Service Manual
Design © 2016 Xerox Corporation. All rights reserved. Xerox®, Xerox and Design® and
DocuMate® are registered trademarks of Xerox Corporation in the United States and/or other
countries.

Content © 2016 Visioneer, Inc. All rights reserved. The Visioneer brand name and OneTouch®
logo are registered trademarks of Visioneer, Inc.

Reproduction, adaptation, or translation without prior written permission is prohibited, except as

allowed under the copyright laws.

Copyright protection claimed includes all forms of matters of copyrightable materials and
information now allowed by statutory or judicial law or hereinafter granted, including without
limitation, material generated from the software programs which are displayed on the screen such
as styles, templates, icons, screen displays, looks, etc.

WARNING: this service information is designed for experienced repair technicians only and
is not designed for use by the general public.

It does not contain warnings or cautions to advise non-technical individuals of potential dangers in
attempting to service a product. Products powered by electricity should be serviced or repaired
only by experienced professional technicians. Any attempt to service or repair the product or
products dealt with in this service information by anyone else could result in serious injury or
death.

Document Version: v2.0 (December 2016)

Changes are periodically made to this document. Changes, technical inaccuracies, and typographic
errors will be corrected in subsequent editions. Information is subject to change without notice and
does not represent a commitment on the part of Visioneer. The software described is furnished
under a licensing agreement. The software may be used or copied only in accordance with the
terms of such an agreement. It is against the law to copy the software on any medium except as
specifically allowed in the licensing agreement. No part of this document may be reproduced or
transmitted in any form or by any means, electronic or mechanical, including photocopying,
recording, or information storage and retrieval systems, or translated to another language, for any
purpose other than the licensee's personal use and as specifically allowed in the licensing
agreement, without the express written permission of Visioneer.

Restricted Rights Legend

Use, duplication, or disclosure is subject to restrictions as set forth in contract subdivision

(c)(1)(ii) of the Rights in Technical Data and Computer Software Clause 52.227-FAR14. Material
scanned by this product may be protected by governmental laws and other regulations, such as
copyright laws. The customer is solely responsible for complying with all such laws and
regulations.
Contents
1. INTRODUCTION ............................................................................................. 1-1

1.1 GENERAL NOTES FOR SERVICING ............................................................. 1-1

2. PRECAUTIONS OF INSTALLATION/TRANSPORTATION .................................. 2-1

2.1 PRECAUTIONS OF INSTALLATION ............................................................. 2-1

2.2 TRANSPORTATION ................................................................................. 2-1

3. THEORY OF OPERATION ................................................................................ 3-1

3.1 INTRODUCTION ..................................................................................... 3-1

3.2 MAIN CONTROL UNIT .............................................................................. 3-2
3.2.1 Cable Connection......................................................................... 3-2
3.2.2 Power supply .............................................................................. 3-2
4. PROBLEM SOLVING........................................................................................ 4-1

4.1 DIAGNOSTICS ....................................................................................... 4-1

4.1.1 ONLINE DIAGNOSTICS ................................................................. 4-1
4.1.2 OFFLINE DIAGNOSTICS ................................................................ 4-3
4.1.3 Diagnostic flowcharts ................................................................... 4-4
4.2 TROUBLESHOOTING .................................................................................... 4-7
4.2.1 Flowcharts .................................................................................. 4-7
4.2.2 Tables ...................................................................................... 4-10
5. CLEANING THE SCANNER............................................................................... 5-1

5.1 CLEANING THE ADF.................................................................................... 5-1

5.2 CLEANING THE ADF GLASS ........................................................................... 5-4

6. DISASSEMBLY................................................................................................ 6-1

6.1 PROCEDURE FOR DISASSEMBLY AND REASSEMBLY ..................................... 6-1

6.1.1 Notes on disassembly ................................................................... 6-1
6.1.2 Removing the Output Tray ............................................................ 6-2
6.1.3 Removing the Input Tray .............................................................. 6-3
6.1.4 Removing the Reverse Roller ......................................................... 6-5
6.1.5 Removing the Reverse Roller Cover ................................................ 6-7
6.1.6 Removing the Front Cover ............................................................ 6-8
6.1.7 Removing the UI Board .............................................................. 6-11
6.1.8 Removing the Flat Cable to the UI Board ....................................... 6-12
6.1.9 Removing the Optical Chassis from Upper Base.............................. 6-13
6.1.10 Removing the Ultrasonic Transmitter from the Upper Base............... 6-15
6.1.11 Removing Sensor Board from Upper Base ..................................... 6-17
6.1.12 Removing the Conductive Brush .................................................. 6-19
6.1.13 Removing the Top Cover and Bottom Cover................................... 6-20
6.1.14 Removing the Left/Right Covers................................................... 6-23
6.1.15 Removing the Upper Base and Bottom Base .................................. 6-24

ii
Service Manual

6.1.16 Removing the Flat Cable ............................................................. 6-27

6.1.17 Removing the Idle Roller/Metal Cover/Spring from the Upper Base ... 6-28
6.1.18 Removing the Second Idle Roller/Metal Cover/Spring /Jam Sensor
from the Upper Base .................................................................. 6-31
6.1.19 Removing the Plastic Hooks, Shaft from the Upper Base.................. 6-35
6.1.20 Removing the Latch Hook, and Spring from the Upper Base ............. 6-37
6.1.21 Removing the Paper-in Sensor from the Upper Base ....................... 6-38
6.1.22 Removing the Glass Assembly from the Upper Base........................ 6-40
6.1.23 Removing the LED Light Guide from the Upper Base ....................... 6-41
6.1.24 Removing the ADF Release Button ............................................... 6-43
6.1.25 Removing the Gears from Bottom Base......................................... 6-44
6.1.26 Removing the Top Cover from the Bottom Base ............................. 6-45
6.1.27 Removing the Roller Cover from the Bottom Base........................... 6-46
6.1.28 Removing the Pick-up Roller and ADF Roller from the Bottom Base ... 6-48
6.1.29 Removing the Shaft Mount from the Bottom Base........................... 6-52
6.1.30 Removing the Glass Assembly from the Bottom Base ...................... 6-53
6.1.31 Removing the Belt from the Bottom Base ...................................... 6-54
6.1.32 Removing the Feeding Rollers from the Bottom Base ...................... 6-59
6.1.33 Removing the LED Light Guide from the Bottom Base ..................... 6-61
6.1.34 Removing the Main Board ........................................................... 6-63
6.1.35 Removing the Metal Mount for the Main Board ............................... 6-65
6.1.36 Removing the Optical chassis from the Bottom Base ....................... 6-67
6.1.37 Removing the Ultrasonic Receiver from the Bottom Base ................. 6-69
6.1.38 Removing the Motor Assembly from the Bottom Base ..................... 6-70
6.1.39 Checking Conductivity After Replacement...................................... 6-71

iii
1. INTRODUCTION

General Notes for Servicing

General Description

This manual is intended to be used by the maintenance engineers. It describes areas to be

maintained, the detailed installation, and the component replacement procedures as well as the
main trouble shooting guides.

Please take your time to read this manual thoroughly to obtain comprehensive knowledge about
the scanner before serving the unit.

1.1 GENERAL NOTES FOR SERVICING

(1) Before trying to disassemble the scanner, make sure the power supply cord of the scanner is
disconnected from the power outlet. Under any circumstance, do not remove or install the
connectors on the scanner with the power supply turned ON.
(2) Use caution not to drop small parts or screws inside the unit when disassembling and
reassembling. If left inside, they might cause the malfunction of the unit.
(3) Do not pull the connector cable when disconnecting it. Hold the connector.
(4) When carrying the scanning head unit, put it in an anti-static bag.
(5) Keep the document table glass surface always clean. If contaminated, use a dry clean cloth
for cleaning.
(6) Use caution not to injure your fingers or hands when disassembling or reassembling the
unit.

1-1
2. PRECAUTIONS OF
INSTALLATION/TRANSPORTATION

Precautions of Installation
Transportation

2.1 PRECAUTIONS OF INSTALLATION

Pay attention to the following matters before unpacking and installation.

 Do not install in a place where vibration may occur.

 Keep the scanner out of direct sunlight. Do not install near a heat source.
 Do not place the scanner around materials which shut off the circulation of air.
 Do not install in a humid or dusty place.
 Use care not to scratch the glass surface of the scanner or the document holding pad
with a clip or staple.
 Do not use the wall socket with connecting devices which may generate noise, for
example, air-conditioner, etc.
 Use a suitable AC power source.
 Place the scanner on a level surface.

2.2 TRANSPORTATION

To move the scanner from where it is installed, for repair or any other reason, make sure to
observe the following conditions:

(1) Turn off the power of the scanner.

(2) Remove the power cable.
(3) Put the scanner in the packing case with the packing material.

2-1
3. THEORY OF OPERATION

Introduction
Main Control Unit

3.1 INTRODUCTION

Cold
Fluorescent
LED Light Guide
Hos
Analogu
Analogue
Signal
Signa Digital
Digital
Len Mai Signa
Reflecte CCD Main Host
Reflected Boar
Board 1 0 0
1 0
Ray
Ray USB 2.0
Controller

Figure 3.1 Theory of Operation

The reflected rays of your original as shown in the above Figure 3.1 pass through the lens and
create an image on the CCD (Charged Coupled Device). Then, according to the different light
intensity perceived by the CCD, the CCD will transfer these data into a series of analog signals
to the main board, where the signals are turned into digital signals. These digital signals flow
to the USB 2.0 Controller to transfer to a host computer.

3-1
3.2 MAIN CONTROL UNIT

3.2.1 Cable Connection

J2 (20pin)
FFC
J2 (20pin)
FFC
Figure 3.2 DM6440 Cable Connection Drawing

3.2.2 Power supply

In this system, there is only one type of power supply. Please see Table 3.1 for
details.

Type
Wall-mount
Characteristic
Input voltage range 100-240V
Input current (at the 2A type or less
rated input/output)
Input frequency 50-60Hz
Max. in-rush 45A
current(@full load,
cold start)
Output voltage +24Vdc
Min. load current 0.0A
Max. load current 2A
Total power (at full 48W
load)

Table 3.1 Power Adapter

3-2
4. PROBLEM SOLVING

Diagnostics
Troubleshooting

This chapter supplies two paths for dealing with operational problems. The first relies on the
scanner’s internal diagnostics. The second uses troubleshooting flowcharts and tables to
isolate the problem. In many cases, the internal diagnostics will help you to locate the source
of the problem quickly. Use these diagnostics first. If the diagnostics do not locate the source
of the problem, refer to Section 4.2 Troubleshooting.

4.1 DIAGNOSTICS

The scanner has internal diagnostics to help you determine the cause of operational
problems. Some of the diagnostics function with the scanner online, while others are
part of a separate offline diagnostics feature.

4.1.1 ONLINE DIAGNOSTICS

Determine operational problems by observing the display panel and check the LED.
With the scanner online and operating normally, the LED is on. Other LED indications
is described in the following table.

Double-colored Double-colored 7-segment State

LED – Blue Light LED – Red Light SDD
Short Blinking Off Circle Blinking Power on
diagnostics
Long Blinking Off Off Sleeping Mode
Off Blinking Refer to table Group Error
4-2

Table 4.1 Online diagnostics

4-1
When the machine starts, each of the 7-segment LEDs is lighted for 0.6 seconds in
turn until the system gets ready.

0.6 0.6
sec sec

When the machine starts, the blue LED blinks. The frequency is shown below:

0.3 sec 0.3 sec

If there is a problem, the red LED blinks. The LED blinks in turn to indicate various
error codes, which one can use to debug the machine. The 7-segment LEDs also
indicate error codes, as shown below:

For example: Error code 3

The Red LED indicates:

1 sec 1 sec 2 sec

The 7-segment LEDs indicate:

1 sec 1 sec

The blue LED blinks longer during the sleeping mode.

1 sec 2 sec

If the ADF cover is open, close it. For the group errors, see the flowcharts later in this
section.

4-2
4.1.2 OFFLINE DIAGNOSTICS

To run the offline diagnostics, turn the power button on. When you first turn the
scanner on, the LED light will blink, indicating that the diagnostics are in progress.
Observe the front panel LED closely. In a short time, the LED indicates the results of
the offline diagnostics as explained in the table below.

Double-colored Double-colored 7-segment Error indication

LED – Blue LED – Red Light Display
Light
OFF 4 blinks “E4” Group 2 error (Paper Jam
Error )
OFF 5 blinks “E5” Multi-Feed error
OFF 6 blinks “E6” Group 3 error (Cover Open
Error )
OFF 7 blinks “E7” Group 1 error
(Upper optical unit light
check error)
OFF 8 blinks “E8” Group 1 error
(Lower optical unit light
check error)
OFF 12 blinks “E-12” NVRAM RD/WR failure.
(Replace the main board).
OFF 13 blinks “E-13” AFE read and write test
error.
(Replace the main board).
OFF 20 blinks “E-20” Download firmware error.
(Download the firmware
again).

Table 4.2 Offline diagnostics results

4-3
4.1.3 Diagnostic flowcharts

Use the flowcharts that follow to determine the exact problem when either the online or
offline diagnostics indicate a group error. Refer to Chapter 4 for parts replacement.

4.1.3.1 Group 1 error flowchart (LED Light guide assembly)

This flowchart applies when the Seven segment display shows Error code 7 and 8.

Group 1 Error

Yes No
LED is on?

CCD error Main board error

Replace optical Replace main board.
assembly

No
Replace the upper
Upper LED is
on? LED light guide.

Yes
Lower LED is
on? Replace the lower
Yes LED light guide.

End of test

4-4
4.1.3.2 Group 2 error flowchart (paper jam in the ADF paper tray)

This flowchart applies when the Red LED is blinking and Seven segment display shows
Error code 4 with the scanner online, and there is a paper jam in the ADF paper tray.

Group 2 error

Open cover and then

remove the pages from
the ADF paper tray, and
then close the cover.

Yes Check if error code

has been removed?

No

Open cover and check if Set paper detect

Paper detect sensor is off Sensor to off

OK Replace paper
Detect sensor

4-5
4.1.3.3 Group 3 error flowchart (no paper in paper tray)

This flowchart applies when the Red LED is blinking and Seven segment display shows
Error code 6 with the scanner online, and there is no paper in the paper tray.

Group 3 Error

Open cover, then close the

cover

No Yes
Check Green light LED
on? OK

Refer to the Result in Place a piece of paper

Table 4.2 Offline into ADF Input Paper
diagnostics results on Tray.
page 4-3.

4-6
4.2 Troubleshooting

Refer first to the applicable troubleshooting flowchart in the following three sections.
The flowcharts refer you to the appropriate table for detailed troubleshooting.

4.2.1 Flowcharts

This section provides the following troubleshooting flowcharts:

 Troubleshooting from power on to scanner ready

 Online troubleshooting

4-7
4.2.1.1 Troubleshooting flowchart: power on to scanner ready.

Troubleshooting From Power on

Power No
See Table 4.3
LED on

Yes

Face down light check

Face up light check

Yes
Wait for command
from host
(Blue LED on)

4-8
4.2.1.2 Troubleshooting flowchart: online operation

Online Troubleshooting (ADF mode)

Frequent Yes
See Table 4.9
Paper Jam?

No

Frequent Yes
See Table 4.10
double feed

No

Large skew Yes

See Table 4.10
volume?

No

Yes
Large jitter See Table 4.6

No

Reading Yes
position See Table 4.7
deviation?

No

Image Yes See Table 4.8

unclear

No

Strange Yes See Table 4.11

sound
generated?

No
End

4-9
4.2.2 Tables

The tables in this section provide detailed troubleshooting information.

4.2.2.1 The Power LED does not go on

Cause Relevant Unit Check Method Maintenance

Method
Unplugged from None Visual check Insert the AC plug
outlet into the outlet.
AC power None Visual check Insert the AC
unplugged at cable into unit.
unit
AC voltage None AC outlet voltage None
failure check
Power unit AC None Visual check Connect the
input connector connector.
disconnected
Power unit-main None Visual check Connect the
PCBA connection connector.
failure
Power unit Power unit Output voltage Replace the power
output voltage (+24V) check unit
failure *
PCBA Failure -main control Tester check Remove the cause
PCBA (+24V, GND) or replace the
-LED board * PCBA.
LED board-main None Visual check Connect the
PCBA connection connector
failure

Table 4.3

*: Check method explains how to check the failed item.

The visual check can be made by physically observing the part or observing the
offline test display on the front panel. The tester check is made by checking the
voltage levels of the relevant units.

4-10
4.2.2.2 Reading is not performed

Cause Relevant Check Maintenance Method

Unit Method
cover open cover Visual check Close the cover.

Table 4.4

4.2.2.3 Image does not appear

Cause Relevant Check Maintenance

Unit Method Method
cover open cover Visual check Close the cover
Power supply- None Visual check Connect the
main control connector.
board
connection
failure
Power supply Power supply Tester check Replace the power
fails. (+24V, GND) supply.
*
LED Light Bar LED Light Visual check Replace the LED Light
failure Bar Bar.
Inverter failure Inverter Visual check Replace the inverter.
CCD board- None Visual check Connect the
main control connector.
board
connection
failure
CCD board CCD Board Visual check Replace the optical
fails. unit.

Table 4.5

4-11
4.2.2.4 Large jitter

Cause Relevant Check Maintenance Method

Unit Method
Power supply- None Visual check Connect the connector.
main control
board connection
failure
Power supply fails Power Tester check Replace the power
supply (+24V, GND) supply.
*
Motor-main None Visual check Connect the connector.
control PCBA
connection failure
Motor failure Motor Visual check Replace the motor.

Table 4.6

4-12
4.2.2.5 Reading position deviation

Cause Relevant Unit Check Method Maintenance

Method
Power supply- None Visual check Connect the
main control connector.
board
connection
failure
Power supply Power supply Tester check Replace the power
fails (+24V, GND) supply.
*
Motor- main None Visual check Connect the
control PCBA connector.
connection
failure
Motor failure Motor Visual check Replace the motor
Sensor board- None Visual check Connect the
main control connector
PCBA cable
failure
Sensor board- Sensor board- Tester or visual Replace the IR
main control main control check sensor cable
PCBA cable PCBA cable
failure

Table 4.7

4-13
4.2.2.6 Image unclear

Cause Relevant Unit Check Method Maintenance Method

Light Bar too Light Bar Visual check Replace with a new
dark Light Bar.
Dirt on Calibration Visual check Clean the glass with
calibration reference plate isopropyl alcohol.
reference plate
Dirt on the Mirrors Visual check Clean the mirrors with
mirrors a blower
Dirt on the lens Lens Visual check Clean the lens with a
blower

Table 4.8

4.2.2.7 Frequent paper jam

Cause Relevant Check Maintenance Method

Unit Method
Paper setting Operation Is the paper Teach users how to
failure error correctly set in properly load the paper.
the paper
chute?
Paper failure operation Is the None
error specified
paper used?
Reverse roller Reverse roller Check if the 1. Clean the reverse roller.
failure assembly reverse roller 2. If the error still occurs,
has been worn replace the reverse
out. roller.

Table 4.9

4-14
4.2.2.8 Frequent double feed and skew

Cause Relevant Check Maintenance Method

Unit Method
Paper setting Operation Is the paper Teach users to properly
failure error correctly set in position the paper
the paper
chute?
Paper failure Operation Is the None
error specified
paper used
Ultrasonic Function fail Retry the None
function fail ultrasonic
setup, or
replace the
ultrasonic
receiver
board.

Table 4.10

4.2.2.9 Strange sound generated

Cause Relevant Check Method Maintenance

Unit Method
Paper setting Operation Is the paper Teach users to
failure error correctly set in properly position the
the paper chute? paper
paper failure Operation Is the specified None
error paper used?
Motor noise Assembly Is the motor None
error correctly
assembled on the
metal plate?

Table 4.11

4-15
5. Cleaning the Scanner

Cleaning the ADF

Cleaning the Glass

5.1 Cleaning the ADF

From time to time, the Reverse Roller and the Feeding Rollers may be contaminated with ink,
toner particles, or paper dust. In this case, the paper may not be fed smoothly. Please follow the
following steps to clean the Reverse Roller and the Feeding Rollers to ensure the best of the
scanner.

The Cleaning Steps:

1. Soak a clean cloth with some isopropyl alcohol (95%).

2. Press the ADF Release button and open the front door.

5-1
3. Wipe the Feeding Rollers until they are cleaned.

4. Press both sides of the Cover of the ADF Reverse Roller and pull the Cover down.

5-2
5. Press and wipe the rollers one by one. Rotate the Roller until the surfaces are completely
cleaned.

5-3
5.2 Cleaning the ADF Glass

1. Press the ADF Release button. Open the front door.

2. Wet a clean cloth with some isopropyl alcohol. (95%)
3. Wipe the glass as illustrated below by moving the swab from side to side to rid the dust or dirt.

5-4
6. DISASSEMBLY

Procedure for Disassembly and Reassembly

6.1 PROCEDURE FOR DISASSEMBLY AND REASSEMBLY

6.1.1 Notes on disassembly

(1) Clean the disassembly and assembly location.

(2) Disconnect the power cable and remove the AC plug from the outlet before
disassembly and assembly.
(3) Follow the disassembly and assembly procedures. Never loosen the screws of parts
that must not be disassembled.
(4) Store the disassembled parts in a clean place to avoid loss.
(5) After replacement, check the contacts and spare part mounting.
(6) Assemble the parts in reverse order of disassembly procedure.

6-1
6.1.2 Removing the Output Tray

1. Release the right tab of the output tray inward to remove the output tray as shown.

Output Tray

6-2
6.1.3 Removing the Input Tray

1. Press the ADF Release button and open the front cover to the left.

2. Pull the end of the paper guide outward as shown.

3. Press the tab of the input tray inward to remove the input tray.

6-3
 Input Tray

6-4
6.1.4 Removing the Reverse Roller

1. Remove the Input Tray as described in the preceding section 6.1.3.

2. Press both sides of the reverse roller cover, as shown below:

3. Pull the cover down, as shown below:

6-5
4. Lift the right end of the reverse roller and remove it from the notch as shown.

Reverse Roller

6-6
6.1.5 Removing the Reverse Roller Cover

1. Remove the Reverse Roller as described in the preceding section 6.1.4.

2. Push the right side of the reverse roller cover inwardly, and remove the reverse roller cover,
as shown below:

Reverse roller Cover

6-7
6.1.6 Removing the Front Cover

1. Remove the Input Tray as described in the preceding section 6.1.3.

2. Remove 2 fixing screws on the upper base, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type:TAP-2, 3x10 / PN: 077-1010-0)

3. Detach 3 adjoining hooks from their slots on the front cover with a flat screw driver as shown.

6-8
4. Lift the front cover to temporarily detach it from the scanner as shown.

5. Disconnect the cable of the UI board to remove the front cover.

(Tip: Unlock the black cable connector switch, and remove the cable.)

6-9
 Front Cover

6-10
6.1.7 Removing the UI Board

1. Remove the Front Cover as described in the preceding section 6.1.6.

2. Remove the tape on the UI board as shown and remove 2 fixing screws on the UI board to
remove the UI board, as indicated below:

Tape on
the UI
Board

UI Board

(Torque：6±0.5Kgf.cm / Screw Type: TAP-2, M3x8 / PN: 077-8023-0)

Warning:
In case the buttons on the UI board may be lost, be sure to place the UI board with the buttons (5
pcs) facing up on a flat surface.

6-11
6.1.8 Removing the Flat Cable to the UI Board

1. Remove the UI board as described in the preceding section 6.1.7.

2. Detach the flat cable on the front cover as shown.

Flat Cable

6-12
6.1.9 Removing the Optical Chassis from Upper Base

1. Remove the Front Cover as described in the preceding section 6.1.6.

2. Disconnect the flat cable to the optical chassis as shown.

3. Remove the fixing screw on the Optical chassis, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, 3x10 / PN: 077-1010-0)

6-13
4. Remove the optical chassis from the upper base, as indicated below:

Optical
Chassis

Optical Chassis

6-14
6.1.10 Removing the Ultrasonic Transmitter from the Upper Base

1. Remove the front cover as described in the preceding section 6.1.6.

2. Remove the fixing screw on the ultrasonic transmitter, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: M3x8 / PN: 077-8023-0)

3. Disconnect the cables from the ultrasonic transmitter to remove the ultrasonic transmitter, as
indicated below: (Tip: Unlock the black cable connector switch, and remove the cable.)

Ultrasonic
Transmitter

6-15
Reassembling:
While connecting the cable of the ultrasonic transmitter, please refer to the connector illustration
in the preceding chapter 3.2.2.

6-16
6.1.11 Removing Sensor Board from Upper Base

1. Remove the Ultrasonic Transmitter as described in the preceding section 6.1.10.

2. Remove the fixing screw on the sensor board from the upper base, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: M3x8 / PN: 077-8023-0)

3. Disconnect 4cables from the sensor board to remove the sensor board.
(Tip: Unlock the black cable connector switch, and remove the cable.)

6-17
4. Remove the fixing screw on the metal plate as shown.

(Torque：6±0.5Kgf.cm / Screw Type: M3x8 / PN: 077-8023-0)

5. The sensor board is removed.

Sensor board

Reassembling:
While connecting the cable of the ultrasonic transmitter, please refer to the connector illustration
in the preceding chapter 3.2.2.

6-18
6.1.12 Removing the Conductive Brush

1. Remove the front cover as described in the preceding section 6.1.16.

2. Tear off the conductive brush along the upper base.

Conductive Brush

Reassembling:
1. Once the conductive brush has been removed, it can not be reused. Please prepare a
replacement to stick it on the upper base.
2. When the conductive brush is removed, there is some glue remaining on the upper base.
Strip the remaining glue with a soft cloth wet with some isopropyl alcohol (95%).
3. After the isopropyl alcohol has been vaporized, align a new conductive brush with the red
dash line, and stick it along the slot from the left to the right as indicated below:

Conductive Brush

6-19
6.1.13 Removing the Top Cover and Bottom Cover

1. Remove 2 fixing screws on the top cover, as indicated below:

Top Cover

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, 3x10 / PN: 077-1010-0)

2. Remove the top cover from the scanner unit.

Top Cover

6-20
3. Remove 2 fixing screws on the bottom cover, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: M3x6 / PN: 077-0603-0)

4. Lift the bottom cover to remove the bottom cover from the bottom base.

6-21
 Bottom Cover

6-22
6.1.14 Removing the Left/Right Covers

1. Remove the Front Cover as described in the preceding section 6.1.6.

2. Remove the Top Cover and Bottom Cover as described in the preceding section 6.1.13.
3. Push the left cover and right cover outward and remove them.

Left/Right Covers

6-23
6.1.15 Removing the Upper Base and Bottom Base

1. Remove the Left/Right Covers as described in the preceding section 6.1.14.

2. Disconnect the 2 cables from the main board.
(Tip: Unlock the black cable connector switch, and remove the cable.)

3. Lift the upper base from the bottom base.

6-24
4. Remove 2 fixing screws on the main board to detach the upper base from the bottom base, as
indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: M3x6 / PN: 077-0603-0)

Upper Base

Bottom Base

6-25
Reassembling:
While installing the upper base to the bottom base, align the 2 pins of the upper base with the 2
holes on the bottom base, and then install the upper base firmly to the bottom base.

2 pins on Upper Base

2 holes on
Bottom Base

6-26
6.1.16 Removing the Flat Cable

1. Remove the front cover as described in the preceding section 6.1.6.

Flat Cable

2. Remove the flat cable as shown.

6-27
6.1.17 Removing the Idle Roller/Metal Cover/Spring from the Upper Base

1. Remove the Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Remove the 4 fixing screws on the metal cover from the upper base, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: M3x8 / PN: 077-8023-0)

3. Remove the metal cover from the upper base, as indicated below:

6-28
 Metal Cover

4. Remove the spring from the upper base, as indicated below:

5. Remove the 3 idle rollers from the slot in the upper base, as indicated below:

6-29
 Idle Roller

6-30
6.1.18 Removing the Second Idle Roller/Metal Cover/Spring /Jam Sensor from the
Upper Base

1. Remove the Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Remove the 3 fixing screws on the metal cover from the upper base, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: M3x8 / PN: 077-8023-0)

Metal Cover

6-31
3. Remove the spring from the upper base, as indicated below:

4. Remove the fixing screw on the upper base, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: M3x8 / PN: 077-8023-0)

6-32
5. Remove the jam sensor on the upper base, as indicated below:

Jam Sensor

6-33
6. Remove the 3 idle rollers from the slot in the upper base, as indicated below:

Idle Rollers

6-34
6.1.19 Removing the Plastic Hooks, Shaft from the Upper Base

1. Remove the front cover as described in the preceding section 6.1.6.

2. Remove the washer from the one side of the upper base, as indicated below:

Washer

3. Remove the white plastic hook.

4. Follow the same steps to remove the e-ring and plastic hook on the other side of the upper
base.

Plastic
Hook

6-35
4. Pull the shaft out of the track as shown.

Shaft

Washer

Plastic Hook

Shaft

6-36
6.1.20 Removing the Latch Hook, and Spring from the Upper Base

1. Remove the second idle roller as described in the preceding section 6.1.18.
2. Remove the fixing screw as shown.

3. Remove the latch hook and spring from the upper base, as indicated below:

Latch Hook
and Spring

6-37
6.1.21 Removing the Paper-in Sensor from the Upper Base

1. Remove the front cover as described in the preceding section 6.1.6.

2. Remove the paper-in sensor cable along the slot, as shown below:

Paper-In
Sensor
Cable

3. Press down the Reverse Roller Cover and remove the paper-in sensor together with its cable
from the slot, as shown below:

Paper-in Sensor

6-38
Reassembling:
For correct cable connection of the paper-in sensor, refer to the connector illustration in the
preceding section 3.2.2.

6-39
6.1.22 Removing the Glass Assembly from the Upper Base

1. Remove the Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Press the 2 latches outward on both sides of the glass assembly, as shown below:
3. Remove the glass assembly from the upper base.

Glass Assembly
(Upper Base)

6-40
6.1.23 Removing the LED Light Guide from the Upper Base

1. Remove the Upper base and Bottom Base as described in the preceding section 6.1.15.
2. Remove 2 fixing screws on the LED light guide, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, 3x10 / PN: 077-1010-0)

3. Lift the LED light guide to remove it.

LED Light Guide

(Upper Base)

6-41
Reassembling:
To reassemble the cable of LED light guide, refer to the following figure:

Install the
cable alone
the track.

Wind the
cables
several times
to fit in

6-42
6.1.24 Removing the ADF Release Button

1. Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Remove 2 fixing screws on the ADF release button as shown.

(Torque：6±0.5Kgf.cm / Screw Type: M3x8 / PN: 077-0603-0)

ADF
Release
Button

6-43
6.1.25 Removing the Gears from Bottom Base

1. Remove the Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Remove the fixing screw as shown.

Screw b

Screw a

Screw a (Torque：8±0.5Kgf.cm / Screw Type: +R-H, M3x6 / PN: 077-1010-0)

Screw b (Torque：6±0.5Kgf.cm / Screw Type: +R-H, M3x6 / PN: 077-1000-0)

Gear

6-44
6.1.26 Removing the Top Cover from the Bottom Base

1. Remove the Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Have the surface of the top cover convex by pressing the 2 sides of the top cover inward, and
remove the top cover, as shown below:

Top Cover

Top Cover

6-45
6.1.27 Removing the Roller Cover from the Bottom Base

1. Remove the Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Pull out the center of the roller cover to open it.

3. Have the surface of the roller cover convex by pressing two sides of the roller cover outward,
and remove the roller cover, as shown below:

6-46
 Roller Cover

6-47
6.1.28 Removing the Pick-up Roller and ADF Roller from the Bottom Base

1. Remove the Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Pull the center of the roller cover to open it.

3. Move the tab of the ADF roller DOWN as indicated.

6-48
4. Detach the right end of the ADF roller from the scanner and remove the ADF roller.

5. Hold the right end of the pick-up roller to detach it from the slot.

6-49
 ADF Roller

Pick-up Roller

6-50
Reassembling:

1. Before installing the pick-up roller back to the bottom base, be sure to lubricate the areas
(indicated in yellow) with MS-54 oil as illustrated.

2. While installing the ADF roller back to the bottom base, mount the copper sleeve at one end
of the ADF roller to the clamp first.

Copper Sleeve Pick-up Roller

ADF Roller

6-51
6.1.29 Removing the Shaft Mount from the Bottom Base

1. Remove the Pick-up Roller and ADF Roller from the Bottom Base as described in the preceding
section 6.1.28.
2. Remove the 2 fixing screws on the shaft mount from the bottom base, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, 3x10 / PN: 077-1010-0)

3. Lift and remove the shaft mount from the bottom base, as shown below:

Shaft Mount

6-52
6.1.30 Removing the Glass Assembly from the Bottom Base

1. Remove the Upper Base and Bottom Base as described in the preceding section 6.1.15.
2. Remove the 4 fixing screws on the glass assembly from the bottom base, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, M3x8 / PN: 077-1010-0)

3. Remove the glass assembly from the bottom base, as indicated below:

Glass Assembly
(Bottom Base)

6-53
6.1.31 Removing the Belt from the Bottom Base

1. Remove the Left/Right Covers as described in the preceding section 6.1.14.

2. Loosen the 2 fixing screws on the plate from the bottom base, as indicated below:

3. Remove the short belt from the 2 gears as indicated below:

6-54
 Short Belt

4. Loosen the fixing screw on the plate from the bottom base, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, M3x8 / PN: 077-1010-0)

5. Remove the long belt from the 3 gears as indicated below:

6-55
 Long Belt

6. Remove the fixing screw on the plate from the bottom base, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, 3x10 / PN: 077-1010-0)

6-56
7. Release the spring on the plate by pushing out the spring hook, as shown below:

Plate with the Idle

Spring Pulley

6-57
Reassembling:

1. Install the belt to the pulleys and gears with the smooth side facing upward, as shown.

Smooth side
facing upward

2. Plug one end of the spring hook into the bottom base, elongate the other end to touch the
metal plate, and adjust the plate to an appropriate tightness

Plate

The spring hook is plugged into

the bottom base.
The spring hook is elongated to
hook the plate.

6-58
6.1.32 Removing the Feeding Rollers from the Bottom Base

1. Remove the Glass Assembly as described in the preceding section 6.1.30.

2. Rotate the right end of the feeding roller 90 degrees clockwise from the bottom base, as
indicated below:

6-59
3. Remove the feeding roller from the bottom base, as indicated below:

4. Follow the similar steps to remove the other feeding roller.

Feeding Rollers

6-60
6.1.33 Removing the LED Light Guide from the Bottom Base

1. Remove the Feeding Rollers as described in the preceding section 6.1.32.

2. Remove 2 fixing screws on the LED light guide, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, 3x10 / PN: 077-1010-0)

3. Remove the bottom cover as described in the preceding section and disconnect two cables as
shown.

6-61
3. Remove the LED light guide.

Light
Guide

6-62
6.1.34 Removing the Main Board

1. Remove the Bottom Cover as described in the preceding section 6.1.13.

2. Remove 2 fixing screws on the main board, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: +R-H, M3x6 / PN: 077-0603-0)

3. Disconnect all cables from the main board to remove the main board.
(Tip for Connector Switch: Unlock the black cable connector switch, and remove the cable.)

6-63
 Main Board

6-64
6.1.35 Removing the Metal Mount for the Main Board

1. Remove the main board as described in the preceding section 6.1.34.

2. Remove the latch on the metal mount as shown.

Latch

3. Remove the fixing screw on the gear on the bottom base as shown.

(Torque：6±0.5Kgf.cm / Screw Type: +R-H, M3x6 / PN: 077-1001-0)

6-65
4. Remove the bottom cover from the bottom base, as shown below:

Metal Mount for

the Main Board

6-66
6.1.36 Removing the Optical chassis from the Bottom Base

1. Remove the metal mount for the main board as described in the preceding section 6.1.35.
2. Remove the fixing screw on the Optical chassis, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, 3x10 / PN: 077-1010-0)

3. Remove the Optical chassis from the bottom base, as indicated below:

6-67
 Optical chassis
(Bottom Base)

Reassembling:
While connecting the cable of the ultrasonic transmitter, please refer to the connector illustration
in the preceding chapter 3.2.2.

6-68
6.1.37 Removing the Ultrasonic Receiver from the Bottom Base

1. Remove the Optical chassis as described in the preceding section 6.1.36.

2. Remove 1 fixing screw on the ultrasonic receiver, as indicated below:

(Torque：8±0.5Kgf.cm / Screw Type: +B-H, TAP-2, M3x8 / PN: 077-1010-0)

3. Remove the ultrasonic receiver from the bottom base.

Ultrasonic Receiver

Reassembling:
While connecting the cable of the ultrasonic transmitter, please refer to the connector illustration
in the preceding chapter 3.2.2.

6-69
6.1.38 Removing the Motor Assembly from the Bottom Base

1. Remove the Left/Right Covers as described in the preceding section 6.1.20.

2. Remove 2 fixing screws on the plastic plate, as indicated below:

(Torque：6±0.5Kgf.cm / Screw Type: +R-H, M3x6 / PN: 077-0603-0)

3. Remove the gear, and the motor assembly, as indicated below:

Motor Assembly

6-70
6.1.39 Checking Conductivity After Replacement

Check conductivity with a multi-meter for metal parts such as ADF Roller, Feeding Roller and ADF
Pad after replacement:

1. Turn on a multi-meter and connect probes (if necessary). The negative probe is black and the
positive will be red. Set the multi-meter to conductivity (tone).

2. Use the probes to check conductivity by placing the positive (red) probe to one metal
component (as shown in figure a) and placing the negative (black) probe to the other metal
component (as shown in figure b~g, point#1~)at the main board as shown.

Fig. a

Place the red probe here

6-71
 1.
Fig. b

2.

Fig. c

6-72
 4.

3.

Fig. d Fig. e

5.

Fig. f

6.

Fig. g

3. If there is conductivity, the multi-meter should make a tone.

4. Turn the meter off when not in use and store probes so as not to be damaged.

6-73