Lexmark 4036-304 manual

X4500 Scanner 4036-304 • T able of Conten ts • Pro blem Solving • Safet y and Notices • T rademarks • Inde x Le xmark and Le xm ark with dia mo nd des ig n are trad emarks of Le xma rk Inter national, Inc ., registere d in the U nited Stat es and/or other coun tries.[...]

E d ition: M a y 2 0 0 4 The f ollo wing p aragrap h does not ap ply to a ny country wh ere such p ro visions are inco nsistent wi th local law : LEXMARK INTERNA TIONAL, INC . PR O VIDES THIS PUBLI CA TION “AS IS” WITHOUT W ARRANTY OF ANY KIND , EITHER EXPRESS OR IMPLIED , INCLUDING, BUT NO T LIMITED T O , THE IMPLIED W ARRANTIES OF MERCHANT AB[...]

iii 4036-304 Table of Content s Safety Inform ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Safety In formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Over view . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

iv 4036-304 Hard Disk Drive, MFD Cont roller Card, 1394 Commu nication s Card and Power Distributi on Board Rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -19 Main Contr ol Board R emoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Connector Locations . . . . . . . . . . .[...]

Safety Inf or mat ion v 4036-304 Safety Inf ormation Safety Inf ormation • This prod uct is desi gned, tested and a pproved to meet stri ct global sa f ety standards with t he use of s pecific Lexmark com ponents. Th e safety f e atures of s ome par ts may not always be obvious. Le xmar k is not res ponsible f or the u se of othe r replacemen t p[...]

vi Ser vice M anual 4036-304 Sich erheitshinweise • Dies es Produk t und die zugeh ö rige n K om ponenten wu rden entworfen und geteste t, um beim Einsa tz die weltweit g ü l tigen Siche rheitsa nf orderungen zu erf ü llen. D ie sicherhe itsrelev anten Fu nktionen der Bauteil e und Option en sind n icht immer offensichtlich. S of er n T eile e[...]

Safety Inf or ma t io n vii 4036-304 Inf ormaci ó de Seguretat • Aquest p roducte est à dissenyat, comprovat i aprovat per tal d'acom plir les e str ictes nor mes de seguretat gl obals am b la utili litzaci ó de com ponents esp ec í fics de Lexmark. Les caracte r í stiques de segur etat d'algu nes peces pot se r que no sempre sigui[...]

viii Ser vice M anual 4036-304[...]

Over view 1-1 4036-304 1. Overview This m anual is for maintenan ce engin eers. It desc ribes the maint enance area s, insta llation, dis assembly , and the ma in troublesh ooting guides. T ake your time to read this manual thoroughly to obtain co mprehens iv e knowledge abou t the scan ner before ser vicin g the unit. Service Guidelines 1. Before [...]

1-2 Ser vice Manual 4036-304 Digital Copi er and Full-function Fax Machine When the s canner is connected to a Lexmark printer, it perf or ms convenient digita l copying. When c onnected to t elephone l ine, the scanne r performs a full fax function - to send and to recei ve f a xes. Net wor k S c an nin g The scanner u ses two Color Charge-Coupled[...]

Over view 1-3 4036-304 Pr oduct Specifications The scann er is desi gned to me et the following produ ct specifi cations: Scanner Scann er T ype Flatbed Sc anner wit h ADF built in Optic al Resolution Flatbed: 300x600 d pi ADF: 300x 300 dpi Enhanc ed Resoluti on 9600x9600 dpi Scan S peed 10 ppm at 300 dpi col or for single pag e scanning 20 ppm a t[...]

1-4 Ser vice Manual 4036-304 Environm ent: -Op erating -S torage 10 ° C to 35 ° C (50 ° F to 95 ° F) 20% to 80% RH ( Relative Humidity) -40 ° C t o 65 ° C (-40 ° F to 149 ° F) 10% to 90% RH ( Relative Humidity) Rand om Vibration: -U npack e d non-op -Pac kage -B ump -D rop 10-200Hz, 0.0 05 p .s.d. (G^2/Hz) 5-200Hz, 0.015 p.s .d. -6 dB /oct [...]

Over view 1-5 4036-304 Theory of Operation System Descri ption The Lexmar k X4500 is a duplexing scann er option which can sy nchronous ly scan bo th the top an d bottom s ides of a d ocument in color. The major s ystem comp onents i nclude a main scann er control board, a n automatic d ocument feeder , flatbe d, two optical CCD modules (one in ADF[...]

1-6 Ser vice Manual 4036-304 A uto Document Fe eder Oper ation When usi ng the Auto Document Feeder (ADF) mec hanism , a page is fed into the ADF by a pick roller an d through the ADF by a feed roller . A separation p ad locate d opposite to the pick roller is used to pro perl y f ee d the pages one at a time when placed on the inpu t tra y . T he [...]

Over view 1-7 4036-304 Scanner Mechanism Overvie w and Locations This sec tion con tains an over view of the majo r compo nents of th e scanne r hardware. External Vie w[...]

1-8 Ser vice Manual 4036-304 Internal C omponents[...]

Over view 1-9 4036-304 Abbreviations ADF A uto Docum ent F eeder CCD Cha rge-Co uple Device CCFL Cold Cath ode Fluores cent Lam p CDB Com mand Des cri ptor B locks DMM Dig ital Mult imete r LED Light Emit ting Diode MFD Multi Functi on De vice PCBA Printed Circuit Board Assembly UI User I n t e r f ace[...]

1-10 Ser v ic e Manual 4036-304[...]

Prob lem Solv in g 2-1 4036-304 2. Pr oblem Solving This chap ter descr ibes two m ethods to sol v e the operational problems. The first re lies on the scan ner inter nal diagnosti cs to repo r t error c odes. The seco nd uses troubleshooting techniqu es to isol ate the p rob lem. In many cases, the inter nal err or codes will help you to locate th[...]

2-2 Ser vice Manual 4036-304 Note: F or generat ion 2 MFD co ntroller cards, ther e are f our pairs of LEDs. The LE Ds are viewab l e after th e controll er cage is remov ed from t he scanner . The L ED patter n shown depicts which LEDs ar e illuminated i n the two rows. Error n umber and description Number of beeps MFD controller car d gener ation[...]

Prob lem Solv in g 2-3 4036-304 Error: 24 - Serial por t f ailure 2 1st Probl em with TTY/Serial P or t. Replac e the MFD controll er card. 2nd Error: 28 - Problem wit h the CPU 2 1st Replac e the MFD controll er card. 2nd Error : 3 1 - No hard d rive found. Note: Err or message not displa yed. Onl y beep c ode and LED p atterns are generate d for [...]

2-4 Ser vice Manual 4036-304 Error: 41 - Scanner interf ace not f ou nd 4 1st The sca nner imag e proc essor board wa s not f ound. Chec k connect ions to the interf ace board. If conn ections a re good , replace the im age proc essor board. 2nd N/A Error : 51 - Not enough memory Note: Err or message not displa yed. Onl y beep c ode and LED p atter[...]

Prob lem Solv in g 2-5 4036-304 Scanner Er ror s Scanner Errors are errors detec ted within the scan ner mechani sm and auto d ocument f e eder asse mbly . T hese errors ap pear on th e user interface touch s creen alon g with a number of flas hes of the fla tbed CCD lamp (the flash seque nce is repeat ed 10 times). See the following table for an e[...]

2-6 Ser vice Manual 4036-304 None Could n ot match sca nner , abor t ing The MFD co ntroller c age could not find the r est of the scanner. Mak e sure the USB- style c abl e is pr operly connecte d between the 13 94 communicat ion s boar d and main sca nner contr ol board. If problem persists, replac e the main scanne r board. If problem persis ts,[...]

Prob lem Solv in g 2-7 4036-304 T roubleshooting The tables in th is sect ion provide de tailed tr oubleshooting inf or mation. The P ower does not come on * Check explains how to check the failed i tem.T o do a v isual check obse rve the pa r t or obser ve the offline tes t display on the front pa nel. T o do a t ester check, che c k the v oltage [...]

2-8 Ser vice Manual 4036-304 Scan module does not mo ve to lock position Cause Re levant Uni t Check A ction Hom e position sens or bo ard fai l u re CCD bo ard T ester check Replace th e CCD PCBA. Motor -main contro l PCBA connec tion fai l u re None Visu al check Conn ect the connecto r . Motor f ai lure Carr ier moto r Visual che ck Replace th e[...]

Prob lem Solv in g 2-9 4036-304 Scan module does not mo ve to the home position Cause Relevant Unit Check Ac tion Hom e position sens or bo ard- main c ontrol PCBA connec tion fai l u re None Visual c heck Connec t the connecto r . Hom e position sens or bo ard fai l u re Se nsor in the flatbed CCD assem b ly T ester check Repl ace the flatbed CCD [...]

2-10 Ser v ic e Manual 4036-304 Scan module does not mo ve to the flat bed position Reading is not perf ormed Cause Re levant Uni t Check A ction Po we r s u p p l y - main s canner board connec tion fai l u re None Visu al check Conn ect the connecto r . Po we r s u p p l y fai l s P ower s uppl y T e ster ch eck (+5V , +2 4V , GND ) Replace th e [...]

Prob lem Solv in g 2-11 4036-304 Image d oes not appear Large jitter Cause Relevant Unit Check Ac tion ADF cov er open ADF cov er Visua l chec k Cl ose the AD F cover . 1394 Communic a- tion bo ard- main c ontrol board connec tion fai l u re None Visual c heck Connec t the connecto r . Lamp I nv er ter fai l u re Lam p inv e r ter Visual c heck Rep[...]

2-12 Ser v ic e Manual 4036-304 Reading position deviation Cau se Relevant Uni t Check A ction Motor -main scann er PCBA connec tion fai l u re None Visu al check Conn ect the connecto r . Motor f ai lure Carr ier moto r Visual che ck Replace th e carr ier mo tor . Hom e position sens or bo ard- main s canner PCBA ca ble fai l u re Flatbed C CD opt[...]

Prob lem Solv in g 2-13 4036-304 Ima ge unc lear Cau se Relevant Unit Check Ac tion Lamp t oo dark Lamp Visual che c k Repl ace CCD opt ical unit. Dirt on calibrati on ref erence plat e Calibration referen ce plate Vis ual ch ec k Clean the flatbed glass with isop rop yl alcoh ol. Dir t o n the mirrors Mi rrors Visual check Cle an the mirrors wi th[...]

2-14 Ser v ic e Manual 4036-304 Strange Sound Generated (flatbed) Frequent paper jam, double feed or skew Cau se Relevant Uni t Check A ction Motor unit fai l u re M otor unit Vi sual check Repl ace the carr ier mo tor . Main s canner card f ailure Mai n scanner card Replace the main scanne r card. Replace th e main scanne r card . Scann ing modu l[...]

Prob lem Solv in g 2-15 4036-304 Strange sound ge nerated (ADF) Cau se Relevant Unit Check Ac tion P aper set tin g fai l u re Operati on error Is t he paper corre ctly set in the p aper chute? T each user s to proper ly pos i tion the paper . P aper failure Operation error Is the spec ified paper us ed? None ADF connec tor slip-off ADF u nit Visua[...]

2-16 Ser v ic e Manual 4036-304[...]

Maintenanc e 3-1 4036-304 3. Maintenance This cha pter desc ribes cleaning m ethods ma intenance par ts re placemen t, and adjustme nt and lub rication n ecessar y f o r nor mal scann er operation. P erform pre ventative maintenan ce in the shor ter te rm ei ther ev er y s ix month s or ev er y 60,000 sheets sca nning. Cleaning Co ver and Glass Wit[...]

3-2 Ser vice Manual 4036-304 Maintenance T ools The following table descr ibes the tools neces sar y for the mainte nance of t his scanne r . Remov als P ar ts Replaceme nt 1. Clean the d isassembly and a ssembly location. 2. T ur n off the power switch and r emov e the A C pl ug from the ou tlet before disass embly and as sembly . 3. F ollow the d[...]

Maintenanc e 3-3 4036-304 CCD Board Scre ws Screws for the CCD board in the opti cal unit are a s shown. Th ese screws hav e a red coating i ndicating t hey should never be loosened . Flatbe d CCD Optica l Unit A DF CCD Optical Uni t[...]

3-4 Ser vice Manual 4036-304 ADF Snap-in P ad Modu le Remov al and Mounting After s canning ap prox imately 100, 000 pages through the ADF , the ADF pad mo dule may be wor n and you may e xper ience problem s with docum ent f eeding. In this c ase, replace the A DF pad mo dul e. T o rem ov e the ADF snap- in pad module : 1. Push the ADF uni t backw[...]

Maintenanc e 3-5 4036-304 Document Co ver Remo val Lift the do cument c ov er t o remove the studs from the hing e holes. The s tuds are lo osely attached t o the hinge holes to accommodate the depth o f the or iginal. ADF Co ver Remov al Remov e the two ADF cover screws and lif t the ADF cover .[...]

3-6 Ser vice Manual 4036-304 ADF Optical CCD Unit Remo val W arning: Do no t loosen any scr e ws with red coating . 1. Remov e the ADF c ov er. Go to “ ADF Cover Remov al ” on pa ge 3-5 . Rem ov e the two screws from the ADF opt ical CCD unit as sh own, and pull out th e unit. 2. Use a flat screwdriver to raise the latch and remove the inv er t[...]

Maintenanc e 3-7 4036-304 4. Disconnect the two CCD connectors. 5. Remov e the ADF o ptical CCD uni t. ADF Unit (Upper and Lo wer Unit) Remo val 1. Remov e the ADF o ptical CCD uni t. Go to “ ADF Optical CCD Uni t Remo val ” on page 3-6 . 2. Remov e the screws located at the f our co rn ers of the A DF unit.[...]

3-8 Ser vice Manual 4036-304 3. Disconn ect 15PIN ADF motor/sen sor cable from ADF m otor/sen sor card. 4. Lift the A DF unit and r emov e it.[...]

Maintenanc e 3-9 4036-304 Note: The upper and lower units of the ADF unit can now be sep arated. User Interface Remo v al 1. Remov e the document outp ut tra y and do cument cover . 2. Place th e scanner on its back. 3. Remov e the three screws to lo osen the use r interface from the s canner .[...]

3-10 Ser v ic e Manual 4036-304 4. Place th e scanner right side up and sl ide the us er interface f orward. 5. Disconn ect the ca b l es.[...]

Maintenanc e 3-11 4036-304 6. Remov e the right sid e touch scree n suppor t b rac ket to discon nect the ground wire. 7. Remov e the user inter f ace gently .[...]

3-12 Ser v ic e Manual 4036-304 Upper Housing Remo v al 1. Remov e the ADF u nit. Go to “ ADF Unit (Upper and Lo wer Unit) Remov al ” on page 3-7 . 2. Remov e the user interface. Go to “ User Inte rface Removal ” on page 3- 9 . 3. Remov e the f o ur rubber pa ds with a flat screwdr iv er . 4. Remov e the screws beneath the r ubber pad s.[...]

Maintenanc e 3-13 4036-304 5. Remov e the four screws on the l eft side of the housing. 6. Remov e the five screws form th e front of the housing. 7. Remov e the upper housi ng.[...]

3-14 Ser v ic e Manual 4036-304 Flatbed CCD Optical Unit Remo val Wa r n i n g : Do not loose n any screws with red coating. 1. Remov e the upper housi ng. Go to “ Upper Housing Remova l ” on page 3-12 . 2. Press the pulley on the carriage belt pull e y assem bly tow ard the c enter of th e unit and remove the carr iage bel t from the pul ley .[...]

Maintenanc e 3-15 4036-304 3. Remov e the sliding r od and the flat cable. (See following fig ures.) Wa r n i n g : Be ver y careful when handlin g the flatbe d optical CCD . The lamp is e xpo sed and c an be easily broken. Do not touch. 4. T ake out the flatb ed optical C CD . 5. Disconn ect the belt from the side of the flatbed optical C CD .[...]

3-16 Ser v ic e Manual 4036-304 Carriage Motor Assembly Remo val 1. Remov e the upper housi ng unit. Go t o “ Upper Housing Remov al ” on page 3-12 . 2. Press the pulley on the carriage belt pull e y assem bly tow ard the c enter of th e unit and remove the carr iage bel t from the pul ley . 3. Disconn ect connect or from car riage motor as sem[...]

Maintenanc e 3-17 4036-304 4. Lower MFD contro ller cage and disconn ect the three connect ors and ground wire.[...]

3-18 Ser v ic e Manual 4036-304 5. Swing the MF D controller ca ge assembly to the r ight and disc onnect the two cables. Use a sc re wdr iver on the lower cable connec tor to unlatc h the con nector . 6. Remov e the MFD controll er cage. Note: When re installing the USB-sty le cable to the main cont rol board, connect the cable to the uppe r conne[...]

Maintenanc e 3-19 4036-304 Har d Disk Dri ve, MFD Contr oller Car d, 1394 Communications Car d and P ower Distrib uti on Board Remov al 1. Remov e the MFD controll er cage. Go to “ MFD Contr oller Cage Removal ” on pa ge 3-16 . 2. With the M FD contro ller cage p ositioned u pside down nea r an edge of a table, remove the two screws from the ba[...]

3-20 Ser v ic e Manual 4036-304 4. Remov e the componen t y ou want fro m within the M FD cage.[...]

Maintenanc e 3-21 4036-304 Main Con tr ol B oar d Removal 1. Remov e the MFD controll er cage. Go to “ MFD Contr oller Cage Removal ” on pa ge 3-16 . 2. Remov e the screws securi ng the main c ontrol boar d. 3. Disconn ect the cables and r emov e the board.[...]

3-22 Ser v ic e Manual 4036-304 Note: When repla cing the mai n scanner control boa rd with a new one, remove the EPROM from t he old boa rd (with a c hip puller ) and insta ll it in the new board. Thi s EPROM contai ns settings unique t o the scanner.[...]

Conn ector Locat ions 4-1 4036-304 4. Connecto r Lo catio ns The pin assignment s shown are v ol tages and grounds whic h can be test ed in the fi eld. Use a multimete r grounded to t he scann er MFD contro ller cage when measur ing the v olta ge f or the m ain scan ner board. Main Sc anner Boar d ADF Vi deo Circuit J7: ADF Vi deo Circuit J8: Flatb[...]

4-2 Ser vice Manual 4036-304 MFD Contr oller Cage All com ponents wi thin the M FD control ler cage a re self diagnose d. Any errors ar e repor ted a s MFD cont roller ca ge errors. Low V oltage P ower Supply The following diagram and c har t repres ents the p ow er sup ply outpu t connect or . Pin No. Wire Color Assignment 1 Black Ground 2 Black G[...]

Pa r t s C a t a l o g 5-1 4036-304 5. P ar ts Catalog[...]

5-2 Ser vice Manual 4036-304 Assemb l y 1: Upper Scanner 1 2 3 4 5 6 7 9 8 10 11 12 13[...]

Pa r t s C a t a l o g 5-3 4036-304 Assembl y 1: Upper Scanner Asm- Index Par t Number Units Description 1 56P2717 1 T ra y , Document Input 2 56P0024 1 Cov er , Scanner Document 3 56P0032 1 Cov er , Upper with Glass 4 56P0020 1 User Interf ace, Complete 5 56P0030 1 Assembly , Low er ADF 6 56P0023 1 T ra y , Document Output 7 56P0025 1 Assembly , A[...]

5-4 Ser vice Manual 4036-304 Assemb ly 2: Lo wer Scanner 1 2 3 4 6 7 8 9 10 13 14 15 16 20 24 5 11 12 17 18 19 21 22 23[...]

Pa r t s C a t a l o g 5-5 4036-304 Assemb l y 2: Lower Scanner Asm- Index Par t Number Units Description 1 56P0036 1 Cable , ADF CCD (6PIN + 14PIN) 2 56P0 035 1 Cable, ADF Motor/S ensor (15PIN) 3 56P0 033 1 P ulley Asse mbly , Carr iage Belt 4 56P0 031 1 Asse mbly , Flatbed CCD Optical Unit 5 56P1466 1 Lamp, Flatbed CCD 6 56P0 308 1 Card A ssembly[...]

5-6 Ser vice Manual 4036-304 Assemb l y 2 (cont.): Lower Scanner 1 2 3 4 6 7 8 9 10 13 14 15 16 20 24 5 11 12 17 18 19 2 23[...]

Pa r t s C a t a l o g 5-7 4036-304 Assembly 2 (cont.): Lower Scan ner Note : • R e f er to L E D pa t te r n i m a ges on pa g e “ M FD C o nt r oll e r E r r o r s ” on p a g e 2 - 1 to i de n ti f y c on t r o l l e r bo a r d ge n e r at i on. • If r e pl a c i ng a ge n e r at i on 1 M F D c o nt r o l l er boa r d w i th a g en e r a [...]

5-8 Ser vice Manual 4036-304[...]

I-1 4036-304 Index A Abbreviations 1-9 C Cleaning ADF Unit 3-1 Cover and Glass 3-1 Touch Screen 3-1 Connector Locations 4-1 E Error Codes MFD Controller 2-1 Scanner 2-5 M Maintenance 3-1 Maintenance Tools 3-2 O Overview 1-1 P Parts Catalog 5-1 Parts Replacement 3-2 Problem Solving 2-1 Product Description 1-1 Product Features 1-1 Product Specificati[...]

I-2 Ser vice Manual 4036-304 56P0558 5-7 56P0559 5-7 56P1211 5-7 56P1466 5-5 56P1472 5-5 56P1473 5-5 56P1808 5-7 56P2042 5-7 56P2110 5-7 56P2112 5-7 56P2401 5-3 56P2406 5-7 56P2467 5-5 56P2554 5-5 56P2555 5-5 56P2717 5-3 56P9910 5-7 99A0471 5-5[...]