DM515 Service Manual

DM515

Contents
1. INTRODUCTION .......................................................................................... 1-1 1.1 1.2 2. 3. GENERAL NOTES FOR SERVICING ....................................................................1-1 GENERAL DESCRIPTION ..............................................................................1-1

SPECIFICATION .......................................................................................... 2-1 UNPACKING, INSTALLATION, AND TRANSPORTATION ............................... 3-1 3.1 3.2 3.3 PRECAUTIONS OF INSTALLATION ....................................................................3-1 UNLOCKING THE PRODUCT ...........................................................................3-2 TRANSPORTATION ....................................................................................3-3 INTRODUCTION ...................................................................................4-1 MAIN CONTROL UNIT ............................................................................4-2 4.2.1 SYSTEM DIAGRAM .....................................................................4-2 4.2.2 MAIN CONTROL CIRCUIT.............................................................4-3 4.2.3 VIDEO CIRCUIT: ........................................................................4-4 4.2.4 LED & BUTTON MODULE CIRCUIT ...................................................4-7 4.2.5 SENSOR INPUT ..........................................................................4-8 4.2.6 SUB POWER SUPPLY CIRCUIT ......................................................4-8 4.2.7 POWER SUPPLY .........................................................................4-9 DIAGNOSTICS .....................................................................................5-1 5.1.1 ONLINE DIAGNOSTICS ...............................................................5-1 5.1.2 OFFLINE DIAGNOSTICS ..............................................................5-3 5.1.3 DIAGNOSTIC FLOWCHARTS.........................................................5-4 TROUBLESHOOTING .............................................................................5-7 5.2.1 FLOWCHARTS ...........................................................................5-7 5.2.2 TABLES .................................................................................. 5-12 TOOLS .......................................................................................6-1

4.

THEORY OF OPERATION.............................................................................. 4-1 4.1 4.2

5.

PROBLEM SOLVING ..................................................................................... 5-1 5.1

5.2

6.

DISASSEMBLY ............................................................................................. 6-1 6.1 6.2 6.3

SERVICE LUBRICANTS ...........................................................................................6-2

6.2.1 MECHANICAL UNIT LUBRICATION.........................................................6-2 PROCEDURE FOR DISASSEMBLY AND REASSEMBLY ................................................6-4 6.3.1 NOTES ON DISASSEMBLY ..................................................................6-4 6.3.2 DOCUMENT COVER REMOVAL ..............................................................6-4 6.3.3 UPPER HOUSING REMOVAL ................................................................6-5 6.3.4 CONTROL PANEL PCBA REMOVAL .........................................................6-6 6.3.5 MAIN CONTROL BOARD REMOVAL ........................................................6-7 6.3.6 MOTOR BELT REMOVAL .....................................................................6-8 6.3.7 OPTICAL CHASSIS REMOVAL ...............................................................6-9 6.3.8 CCFL INVERTER PCBA REMOVAL ...................................................... 6-10 6.3.9 LAMP ASSEMBLY REMOVAL ............................................................... 6-11

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6.3.10 6.3.11 6.3.12 6.3.13 6.3.14 6.3.15 6.3.16 6.3.17 7. 7.1

................................................................. 6-12 ADF PAPER-TRAY REMOVAL ........................................................... 6-13 ADF SNAP-IN PAD REMOVAL.......................................................... 6-14 ADF FRONT COVER REMOVAL .......................................................... 6-15 ADF MAIN CASE REMOVAL .............................................................. 6-16 ADF SENSOR REMOVAL .............................................................. 6-17 AB BOARD REMOVAL ................................................................... 6-18 DOCUMENT HINGES REMOVAL......................................................... 6-19
MOTOR UNIT REMOVAL

PARTS ......................................................................................................... 7-1

SPARE PART

DIAGRAM ................................................................................7-1

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1.

INTRODUCTION
1.1 General Notes for Servicing 1.2 General Description

This manual is intended to be used by the maintenance engineers. It describes areas to be maintained, the detailed installation, the disassembly of optional ADF, 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 DM515 before serving the unit.

1.1 GENERAL NOTES FOR SERVICING

(1) Before trying to disassemble the DM515, make sure the power supply cord of the DM515 is disconnected from the power outlet. Under any circumstance, do not remove or install the connectors on the DM515 with the power supply turned ON. 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. Do not pull the connector cable when disconnecting it. Keep the document table glass surface always clean. clean cloth for cleaning. Hold the connector. If contaminated, use a dry When carrying the scanning head unit, put it in an anti-static bag.

(2) (3) (4) (5) (6)

Use caution not to injure your fingers or hands when disassembling or reassembling the unit.

1.2 GENERAL DESCRIPTION

DM515 is a fantastic color USB scanner with an Automatic Document Feeder. The digital solution makes your reproduction exceedingly clear. Without further leaning, you can get a scan image and link the image to a variety of applications, for example, the image-editing software, the OCR(Optical character recognition) software, to make your jobs done.

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2.
2.1

SPECIFICATION
Basic Specification

Product Name: Type: Resolution: Color Depth: Image Type:

DM515 ADF/Flatbed scanner up to 600 x 1200 dpi (1% increments) 48-bit single pass color (R, G, B) Black and White Gray Color 20 pages per minute Flatbed: up to European A4 (8.5 x 11.69) ADF: minimum: 4.5 x 5.5 ADF: maximum: up to legal size (8.5 x 14) A4, A5, Letter, Legal, B5, Business card 3.5" x 2.0" (Flatbed Mode) 16 28 lbs/0.002" ~ 0.006" Up to 50 sheets Width: 445 mm Depth: 332 mm Height: 179 mm 5.5kgs USB 2.0 24Vdc,1.25A 30 Watts

ADF Scan Speed: (at 200dpi B&W A4 size) Scan Area:

Paper Size: Paper Thickness: Paper Input (ADF): Physical Dimension:

Weight: Interface: Power Requirements Power Consumption:

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3. UNPACKING, INSTALLATION, AND TRANSPORTATION

3.1 3.2 3.3 Precautions of Installation Unlocking the product Transportation

3.1 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 DM515 out of direct sunlight. Do not install near a heat source. Do not place the DM515 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 DM515 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 DM515 on a level surface.

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3.2 UNLOCKING THE PRODUCT

Before you use DM515, be sure to unlock it by moving the lock switch under the DM515 to the Unlock position (See the following figure). The lock switch is designed to protect the scanning head in case of any damage during shipment.

Lock

Unlock

Unlock DM515

Note: If you need to transport DM515, be sure to first move the lock switch to the Lock position to prevent any damage during transportation.

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3.3 TRANSPORTATION
To move the DM515 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 DM515. If the scanning head is located at a place other than the home position, turn the DM515 on to return the scanning head to the home position. Before making sure the scanning head is returned to the home position, turn the power supply off.

Home Position

Document Glass

Flatbed of Scanner (2) (3) (4) Move the lock switch to the lock position. Remove the power cable. Put the DM515 in the packing case with the packing material.

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4. THEORY OF OPERATION
4.1 4.2 Introduction Main Control Unit

Figure 4.1 Theory of Operation

4.1 INTRODUCTION
The reflected rays of your original as shown in the above Figure 4.1 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 flows to the image processor to store into a host computer acceptable format then goes to USB2.0 controller to transfer to a host computer.

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4.2 MAIN CONTROL UNIT 4.2.1 SYSTEM DIAGRAM

LED Unit UIA71

Figure 4.2 System block diagram

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4.2.2

MAIN CONTROL CIRCUIT

This scanner is controlled by the tensilica 32 bits CPU. The CPU is configured with a 512-KB external ROM program area, a 32-MB external SDRAM work area, 2 timer / counters, 3 external interrupts. Address Maps:

ROM program area: 0000 7FFFF 512KB Program

External SDRAM working area: 00 1FFFFFF 32MB Internal Registers

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4.2.3

VIDEO CIRCUIT:
The video circuit of this scanner includes: 1. CCD driving circuit, 2. CCD signal processing circuit. 1. CCD Driving Circuit

The CCD driving circuit is used to generate correct signals to the CCD, so that the CCD may generate the correct image data. Signals for CCD: Pin Assignment for CCD cable Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Name INV_V INV_V MGND INVGND 24VM 24VM 3.3V M_Vref2 M_Vref1 /Reset /MTR_Sleep1 Step Dir MS2 MS1 12VC VOB AGND VOG AGND VOR AGND Function Inverter Power Supply Inverter Power Supply Motor Ground Inverter Ground Motor Driver Power Supply Motor Driver Power Supply Digital 3.3V Power Supply Motor Driver Mixed Decay Setting Motor Driver Mixed Decay Setting Motor Driver Logic Input Motor Driver Logic Input Motor Driver Logic Input Motor Driver Logic Input Motor Driver Logic Input Motor Driver Logic Input CCD Power Supply CCD Blue Channel Output Signal Analog Ground CCD Green Channel Output Signal Analog Ground CCD Red Channel Output Signal Analog Ground

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Pin No. 23 24 25 26 27 28 29 30 31 32

Name DGND 5VD RS CP NC PH2A PH1A SH HMSEN DGND

Function Digital Ground Digital 5V Power Supply CCD RGB Channel Reset Gate CCD RGB Channel Clamp Gate No Connection CCD Clock Phase CCD Clock Phase CCD RGB Channel Shift Gate Home Sensor Signal Digital Ground

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2. CCD signal processing circuit

R CCD G

CDS

PGA

CDS

PGA

MUX

ADC

Dout

B
CDS PGA

CCD Signal Processor

The CCD signal processor includes all the necessary circuitry to perform threechannel conditioning and sampling. The signal chain consists of three-channel correlated double sampling (CDS) and programmable gain adjustment of the CCD output (PGA) is a 16 bits analog to digital connector (ADC) quantizes the analog signal.

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4.2.4 LED & BUTTON MODULE CIRCUIT

The circuit includes one bi-color LED, three buttons, and one 7-segment LED displayer. Pin assignment of LED and Button module Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Name 5VD GND FUNC_BUT SEND_BUT SCAN_BUT LEDG LEDR x x x x x x x x x Function Power Supply Ground Function Button Send Button Scan Button LED Green LED Red x x x x x x x x x

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4.2.5 SENSOR INPUT

The sensor input includes home position sensor. Home position sensor The home position of the carrier motor is detected by photo sensor. The photo transistor transmission to the photo sensor receiver circuit is shown below.
+5V +5V

Figure 4.3 Home position sensor The home position is detected when the carrier passes between the LED and the photo transistor.

4.2.6 SUB POWER SUPPLY CIRCUIT

The sub power supply circuit is provided for the internal analog circuit. Input is 24V and output is 5VD and +12VC. The circuit configuration is shown below:

+24Vdc

Switching Regulator

Linear Regulator
+5VD

3.3V

Linear Regulator
+24Vdc

2.5V_Core

Linear Regulator

+12Vc

The sub power supply is used for: CCD, A/D, and logic circuits.

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4.2.7 POWER SUPPLY

In this system, there is only one type of power supply. details. Table 4.1 Type Characteristic Input voltage range Input current (max.) Input frequency Max. in-rush current(@230Vac, cold start) Output voltage Min. load current Max. load current Total Power Power Adapter Desk 100-240V 0.95A (rms) 50-60Hz 70A +24Vdc 1A 2A 48W Please see Table 4.1 for

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5. PROBLEM SOLVING
5.1 5.2 Diagnostics Troubleshooting

This chapter supplies two paths for dealing with operational problems. The first relies on the scanners 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 5.2 Troubleshooting.

5.1 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.

5.1.1 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 LED Green Light Short Blinking Long Blinking Off

Double-colored LED Red Light Off Off Blinking

7-segment SDD Circle Blinking Off Refer to table 5-2

State Power on diagnostics Sleeping Mode Group Error

Table 5.1

Online diagnostics

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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:

0.3 sec 0.3 sec

3 sec

The Blue LED blinks longer during the sleeping mode.

1 sec

2 sec

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5.1.2 OFFLINE DIAGNOSTICS

To run the offline diagnostics, and turn the power back on. When you first turn the scanner back 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. Doublecolored LED Blue Light OFF OFF OFF OFF OFF OFF OFF OFF Double-colored LED Red Light 1 blinks 2 blinks 3 blinks 4 blinks 5 blinks 6 blinks 8 blinks 9 blinks Error indication

DRAM FAILURE. Refer to Table 5.8 (Replace the M/B). NVRAM RD/WR failure. Refer to Table 5.8 (Replace the M/B). AFE Test error. Refer to Table 5.8 (Replace the M/B). USB Test error. Refer to Table 5.8 (Replace the M/B). Group 2 error(Home Sensor Test error) Light Check failure. Refer to Table 5.5 (Replace the CB243). Group 3 error (Paper Jam Error ) Chassis locked. Refer to Table 5.4 (Replace the PCBA). Offline diagnostics results

Table 5.2

To return the scanner to online operation, turn off the scanner, turn the scanner back on.

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5.1.3 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 6 for parts replacement.

5.1.3.1

Group 1 error flowchart (CCFL assembly)

This flowchart applies when the Check LED blinks 6 times the same while, with the scanner offline.

Group 1 Error

Yes
CCFL is on?

No
Inverter error Replace lamp inverter circuit

CCD error Replace optical assembly

End of test

Yes

CCFL is on?

No Replace the CCFL

5.1.3.2 Group 2 error flowchart (Flatbed motor)

This flowchart applies when the offline diagnostics error indication is the simultaneous blinking 5 times of the Check LED.

Group 2 error

Flatbed motor moves? Yes Flatbed home position sensor error Replace home position sensor

No

Flatbed motor error Replace flatbed motor

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5.1.3.3 Group 3 error flowchart (paper in ADF paper tray)

This flowchart applies when the Check LED blinks 8 times the same while with the scanner online, and there is paper in the ADF paper tray.

Group 3 error
Remove the paper from ADF input paper tray, and wait for 3 seconds

Yes

ADF motor moves?

No

ADF paper-in sensor error Replace ADF PCBA

Wait for 30 seconds

When paper jam happens, the LED will blink in red 8 times.

Yes

Paper Jam ?

No

ADF Motor error Replace ADF unit

Paper Jam

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5.1.3.4 Group 3 error flowchart (no paper in ADF paper tray)

This flowchart applies when the Check LED blinks 8 times the same while with the scanner online, and there is no paper in the ADF paper tray.

Group 3 error

Put a piece of paper into ADF input paper tray, and wait for 3 seconds

No
Wait for 30 seconds

ADF motor moves and ejects paper?

Yes

ADF paper-out sensor error Replace ADF PCA

No
ADF paper-in sensor error Replace ADF PCBA

Paper Jam ?

When paper jam happens, the LED will blink in red 8 times.

Yes
ADF motor error Replace ADF unit

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

5.2.1 FLOWCHARTS
This section provides the following troubleshooting flowcharts: Troubleshooting from power on to scanner ready Online troubleshooting (flatbed operation) Online troubleshooting (ADF operation) Offline troubleshooting (flatbed operation)

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5.2.1.1 Troubleshooting flowchart: power on to scanner ready.

Troubleshooting From Power on

Power LED on Yes

DRAM Test NVRAM Test AFE Test USB Test

No

See Table 5.3

Scan module moves to shipping retainer position

No

See Table 5.4

Yes
Light Check (About 5 seconds)

Scan module moves to home position

No

See Table 5.5

Yes Warm Up (about 30 seconds)

When the product is in the ready state, the LED will stay in blue.

No
Ready ?

See Table 5.6

Yes Wait for command from host

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5.2.1.2 Troubleshooting flowchart: online flatbed operation

Online Troubleshooting

(Flatbed Operation)

Scan module moves to flatbed home position

No

See Table 5.7

Yes
Scan module moves to the top of scan window

No

See Table 5.8

Yes Image appears No

See Table 5.9

Yes Yes See Table 5.10

Large jitter No Reading position deviation No

Yes

See Table 5.11

Yes Image unclear No Strange sound generated No End Yes

See Table 5.12

See Table 5.13

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5.2.1.3 Troubleshooting flowchart: online ADF operation

Online Troubleshooting (ADF mode)

Frequent Paper Jam? No Frequent double feed No Large skew volume? No

Yes

See Table 5.14

Yes

See Table 5.15

Yes

See Table 5.15

Large jitter

Yes

See Table 5.10

No
Reading position

Yes

See Table 5.11

deviation? No Image unclear No Strange sound generated? No End Yes See Table 5.16 Yes See Table 5.12

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5.2.1.4 Troubleshooting flowchart: Offline flatbed operation

Offline Troubleshooting

(Flatbed operation)
Power LED on Yes
DRAM Test NVRAM Test AFE Test USB Test

No

See Table 5.3

See Table 5.4

Scan module moves to shipping retainer position

No

Yes
Light Check (About 5 seconds)

Scan module moves to home position

No

See Table 5.5 When the product is in the ready state, the LED will stay in blue.

Yes
Warm Up (about 30 seconds)

Ready ?

No

See Table 5.6 When the product is in the ready state, the LED will stay in blue.

Yes Wait for command from host

Ready ?

No

See Table 5.2

Yes Scan one page of Image

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5.2.2 TABLES
The tables in this section provide detailed troubleshooting information.

5.2.2.1 The Power LED does not go on

Cause Unplugged from outlet AC power unplugged at unit Power switch is OFF AC voltage failure Power unit AC input connector disconnected Power switch connector disconnected Power unit-main PCBA connection failure Power unit output voltage failure PCBA Failure

Relevant Unit None

Check Method Visual check

Maintenance Method Insert the AC plug into the outlet. Insert the AC cable into unit. Turn the power switch on. None Connect the connector. Connect the connector. Connect the connector. Replace the power unit Remove the cause or replace the PCBA. Connect the connector

None

Visual check

None None None

Visual check AC outlet voltage check Visual check

None

Visual check

None

Visual check

Power unit

Output voltage (+15V) check Tester check (+24V, GND) Visual check

LED board-main PCBA connection failure

main control PCBA LED board None

Table 5.3

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5.2.2.2 Scan module does not move to shipping retainer position

Cause Sensor boardmain control PCBA connection failure Home position sensor boardmain control PCBA cable failure. Home position sensor board failure Motor-main control PCBA connection failure Motor failure

Relevant Unit None

Check Method Visual check

Maintenance Method Connect the connector.

Sensor boardmain control PCBA cable

Tester or visual check

Replace the home position cable.

Home position sensor PCBA None

Tester check

Replace the PCBA Connect the connector.

Visual check

Motor

Visual check

Replace the motor.

Table 5.4

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5.2.2.3 Scan module does not move to the home position

Cause Home position sensor boardmain control PCBA connection failure Home position sensor boardmain control PCBA cable failure Home position sensor board failure Lamp failure Inverter failure CCD board-main control board connection failure CCD board fails

Relevant Unit None

Check Method Visual check

Maintenance Method Connect the connector.

Sensor boardmain control PCBA cable

Tester or visual check

Replace the home position sensor cable.

Sensor board

Tester check

Replace the PCBA. Replace the lamp. Replace the inverter. Connect the connector

Lamp Inverter None

Visual check Visual check Visual check

CCD board

Tester check

Replace the optical unit

Table 5.5

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5.2.2.4 Ready and Power LED does not light on

Cause Home position sensor boardmain control PCBA cable failure Home position sensor board failure

Relevant Unit Sensor boardmain control PCBA cable

Check Method Tester or visual check

Maintenance Method Replace the home position sensor cable.

Sensor board

Tester check

Replace the PCBA.

Table 5.6

5.2.2.5 Scan module does not move to the flatbed position

Cause Motor-main control PCBA connection failure Motor failure

Relevant Unit None

Check Method Visual check

Maintenance Method Connect the connector.

Motor

Visual check

Replace the motor module.

Table 5.7

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5.2.2.6 Scan module does not move to the top of the scan window

Cause CCD board-main control board connection failure CCD board fails

Relevant Unit None

Check Method Visual check

Maintenance Method Connect the connector. Replace the optical unit.

CCD Board

Visual check

Table 5.8

5.2.2.7 Image does not appear

Cause CCD boardmain control board connection failure CCD board fails.

Relevant Unit None

Check Method Visual check

Maintenance Method Connect the connector.

CCD Board

Visual check

Replace the optical unit.

Table 5.9

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5.2.2.8 Large jitter

Cause Motor-main control PCBA connection failure Motor failure Relevant Unit None Check Method Visual check Maintenance Method Connect the connector. Replace the motor.

Motor

Visual check

Table 5.10

5.2.2.9 Reading position deviation

Cause Home position sensor boardmain control PCBA cable failure Home position sensor boardmain control PCBA cable failure Home position sensor board failure

Relevant Unit None

Check Method Visual check

Maintenance Method Connect the connector

Sensor boardmain control PCBA cable

Tester or visual check

Replace the home position sensor cable

Sensor board

Tester check

Replace the PCBA.

Table 5.11

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5.2.2.10 Image unclear

Cause Lamp too dark Dirt on calibration reference plate Dirt on calibration reference plate Relevant Unit Lamp Calibration reference plate Check Method Visual check Visual check Maintenance Method Replace with a new lamp. Clean the flatbed glass with isopropyl alcohol. Clean the calibration reference plate with isopropyl alcohol. Clean the mirrors with an air compressor. If the problem still exists, replace the optical unit. Clean the mirrors with an air compressor. If the problem still exists, replace the optical unit.

Calibration reference plate

Visual check

Dirt on the mirrors

Mirrors

Visual check

Dirt on the lens

Lens

Visual check

Table 5.12

5.2.2.11 Strange sound generated (flatbed)

Cause Motor unit failure Main control PCBA failure Scanning module failure Dirt on rail Relevant Unit Motor unit Main control PCBA Scanning module None Check Method Replace the motor unit. Replace the main control PCBA. Check if scanning module is loose. Visual check Maintenance Method Replace the motor unit. Replace the main control PCBA. Replace the optical unit. Clean the rail with isopropyl alcohol Clean the gears with oil or change the gears

Gears not smooth

Gears

Gears

Table 5.13

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5.2.2.12 Frequent paper jam

Cause Paper setting failure

Relevant Unit Operation error

Check Method Is the paper correctly set in the paper chute? Is the specified paper used? Visual check of motor rotation Check the pad assembly for wear and tear Visual check the ADF unit including motor, AB board, paperin sensor, and roller. Table 5.14

Maintenance Method Educate users to properly position the paper. None

Paper failure

operation error ADF unit Pad assembly

ADF connector slip-off Pad assembly failure ADF unit failure

ADF unit

Connect the connector. Replace the pad assembly/ touch spring unit. Replace the ADF unit.

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5.2.2.13 Frequent double feed and skew

Cause Paper setting failure Relevant Unit Operation error Check Method Is the paper correctly set in the paper chute? Is the specified paper used Visual check of motor rotation Check the pad assembly for wear and tear. Visual check the ADF unit including motor, AB board, and gears. Table 5.15 Maintenance Method Teach users to properly position the paper None

Paper failure

Operation error ADF unit Pad assembly

ADF connector slip-off Pad assembly failure ADF unit failure

ADF unit

Connect the connector. Replace the pad assembly/ touch spring unit. Replace the ADF unit.

5.2.2.14 Strange sound generated (ADF)

Cause Paper setting failure paper failure ADF connector slip-off ADF unit failure Relevant Unit Operation error Operation error ADF unit ADF unit Check Method Is the paper correctly set in the paper chute? Is the specified paper used? Visual check of motor rotation Replace the ADF unit Table 5.16 Maintenance Method Teach users to properly position the paper None Connect the connector. Replace the ADF unit.

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6. DISASSEMBLY
6.1 6.2 6.3 Service Tools Lubricants Procedure for Disassembly and Reassembly

6.1 SERVICE TOOLS

The following table describes the maintenance tools necessary for the maintenance of this equipment.

No . 1 2 3 4 5 6 7 8

Name Minus screwdriver Philips screwdriver (magnetic) Oil Grease Alcohol (Isopropyl 91% >) Digital voltmeter Oscilloscope Blower

Description Idler pulley module screw Nominal No.2 M3, M4 Shell Terrace Oil 46 Shell Alvania Grease No.2 Cleaning With 0.01 V range 100 MHz or more with external sweep Cleaning

Maintenance tools

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6.2 LUBRICANTS
This section describes the items to check and the places to lubricate when maintenance parts are replaced.

6.2.1 MECHANICAL UNIT LUBRICATION

This lubrication method:
1ACY

Lubrication cycle Amount of lubricant Lubricant type Positions need to be lubricated

(show in number)
1. 2. Positions need to be lubricated: The positions need to be lubricated is indicated in numbers. Lubricant type: A: Shell Alvania Grease No. 2 B: Shell Terrace Oil 46 Amount of lubricant: C: Coat thinly uniformly Lubrication cycle: Y: Every year

3. 4.

The following table shows the position to be lubricated. Lubrication Lubricant Lubricant Lubrication Lubrication Position Type Amount Cycle Position 1 B C Y Sliding rod 2 A C Y Sliding frame

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Sliding Rod

Sliding Guide

Lubricated Position

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6.3 PROCEDURE FOR DISASSEMBLY AND REASSEMBLY 6.3.1 NOTES ON DISASSEMBLY

(1) (2) (3) (4) (5) (6) Clean the disassembly and assembly location. Disconnect the power cable and remove the AC plug from the outlet before disassembly and assembly. Follow the disassembly and assembly procedures. Never loosen the screws of parts that must not be disassembled. Store the disassembled parts in a clean place to avoid loss. After replacement, check the contacts and spare part mounting. Assemble the parts in reverse order of disassembly procedure.

6.3.2 DOCUMENT COVER REMOVAL

As shown in the figure below, unplug the ADF cable, and then lift the document cover to remove the studs from the hinge holes. The studs are loosely attached to the hinge holes in the purpose to cover your original when it is a few inches high.

b
Document Cover

Stud Hinge Holes ADF Cable

Document Cover Removal

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6.3.3 UPPER HOUSING REMOVAL

(1) (2) (3) (4) (5) Remove the document cover as described in section 6.3.2. Turn the machine over and loosen the fixing screws with a screwdriver as illustrated. Turn the machine to its normal position and remove the robber pads (x 2 pcs) as illustrated. Remove the fixing screw at the front as illustrated. Remove the upper housing by lifting it gently.

Rubber Pad

Fixing Screws at

Upper Housing

Upper Housing Removal

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6.3.4 CONTROL PANEL PCBA REMOVAL

(1) (2) (3) (4) Remove the document cover as described in section 6.3.3. Turn the machine over as illustrated and loosen the fixing screws (x 4 pcs) at the front of the scanner. Loosen the control panel and unplug the cable as illustrated. Loosen the fixing screw on the PCBA of the control panel. Remove the board of the control panel by lifting it gently.

(5)

Control Panel

Control Panel Cable Connector

PCBA of Control Panel

Control Panel PCBA Removal

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6.3.5 MAIN CONTROL BOARD REMOVAL

(1) (2) (3)

Turn the machine over and loosen the fixing screws (x 4 pcs) of the metal cover as shown in the figure below. Lift the metal cover and disconnect the flat cable as illustrated. Loosen the screws fixed on the rear panel, and remove the rear panel.

Flat Cable

Rear Panel

Main Control PCBA Removal

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6.3.6 MOTOR BELT REMOVAL

(1) (2)

Remove upper housing and main control PCBA as described in section 6.3.3 and 6.3.5. Remove the motor belt by detaching the belt spring.

Spring

Motor belt

Belt Removal

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6.3.7 OPTICAL CHASSIS REMOVAL

(1) (2) (3)

Remove upper housing as described in section 6.3.3. Lift the end of the sliding rod and pull it out from the hole of the optical chassis. Disconnect the flat cable of the optical chassis.

Sliding Rod

Sliding Rod

Flat Cable

Optical Chassis

Optical Chassis Removal

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6.3.8 CCFL INVERTER PCBA REMOVAL

(1) (2) (3)

Remove optical chassis as described in section 6.3.7. Remove the cable bandage of the CCFC inverter PCBA. Disconnect the CCFL inverter cable and CCFL inverter PCBA cable.

Optical chassis

Lamp Cable

Cable Bandage

CCFL inverter

Inverter PCBA Removal

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6.3.9 LAMP ASSEMBLY REMOVAL

(1) (2) (3) (4) Remove the CCFC inverter as described in section 6.3.8. Pull one end of the lamp holder and remove it from the optical chassis as illustrated. Pull the other end of the lamp holder and remove it from the optical chassis. Remove the lamp assembly.

Optical Chassis

The Other End of the Lamp Holder

One end of the lamp holder

One end of the lamp holder Lamp Holder

Lamp Assembly Removal

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6.3.10 MOTOR UNIT REMOVAL

(1) (2) (3) (4) (5)

Remove the optical chassis and the CCFL inverter PCBA as described in section 6.3.7 and section 6.3.8. Remove the lamp assembly as described in section 6.3.9. Loosen the fixing screws (2 pcs) as shown in the figure below. Disconnect the motor cable. Remove the motor from the optical chassis.

Motor Cable

Motor Unit

Fixing Screws

Motor Removal

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DM515 Service Manual

6.3.11 ADF PAPER-TRAY REMOVAL

Move the adjusting guides to the medium place, and then remove the paper tray support.

Paper Tray Support ADF Unit

ADF Paper-tray Removal

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DM515

6.3.12 ADF SNAP-IN PAD REMOVAL

After scanning approximately 20,000 pages through the ADF, the pad may be worn out and you may experience problems with document feeding. In this case, it is highly recommended that you replace the pad module with a new one. To order a pad module, please consult your nearest dealer and follow the procedure below to replace it. (1). (2). Gently open the ADF front cover to the left. Press both arms of the ADF snap-in pad module inwardly with your fingers to pull out the ADF snap-in pad module.

ADF Front Cover ADF Pad

ADF Snap-in Pad Removal

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DM515 Service Manual

6.3.13 ADF FRONT COVER REMOVAL

(1). (2). (3). (4). (5). Move the front cover to the left as illustrated. Loosen the fixing screws (2 pcs) as illustrated. Turn the ADF cover upside down and loosen the fixing screws (2 pcs) on both sides as illustrated. Insert a flat screwdriver into the two indicated holes to release the ADF cover. Hold one side to lift the ADF front cover assembly. ADF Front Cover

Holes

e
ADF Front Cover

ADF Front Cover Removal

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6.3.14 ADF MAIN CASE REMOVAL

(1). (2). (3). Remove ADF front cover as described in section 6.3.13. Remove the ADF upper cover. Loosen the fixing screws (2 pcs) on both sides as indicated. ADF Upper Cover

c
ADF Front Cover

ADF Main Case Assembly

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6.3.15 ADF SENSOR REMOVAL

(1). (2). (3). (4). (5). Remove ADF front cover assembly as described in section 6.3.14. Unplug the cable as shown below. Remove the first sensor as illustrated. Loosen the screw as illustrated. Remove the second sensor as illustrated.

Cable

1st ADF Sensor

Fixing Screw

2nd ADF Sensor

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6.3.16 AB BOARD REMOVAL

(1). (2). Loosen the screws as shown below. Unplug all cable to remove the ADF main board as indicated.

ADF Main Board

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DM515 Service Manual

6.3.17 DOCUMENT HINGES REMOVAL

Loosen all screws to remove two hinges located on both side of the document cover as illustrated below.

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7. PARTS
7.1 Spare Part Diagram/Table

7.1 SPARE PART DIAGRAM

7-1

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7-2

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7-3

DM515

ITEM

P/N

DESCRIPTION

REV.

ADF MODULE 1 1-1 1-2 1-3 1-4 1-5 002-3518-0-SP 002-2975-0-SP 051-2870-0-SP 002-3516-0-SP 002-4104-0-SP 002-1193-0-SP S-PARTS:ASS'Y,ADF MODULE,RoHS S-PARTS:ASS'Y,FRONT CASE,RoHS SPARTS:COVER,UPPER:PC,2.5t,272x117x66,RoH S S-PARTS:ASS'Y,MAIN CASE,RoHS S-PARTS:ASS'Y,DOCUMENT COVER,XEROXDM515,VISIONEER,RoHS S-PARTS: ASS'Y, ADF PAD,RoHS 100 100 500 100 100 100

FLATBED SCANNER 2 3 4 5 6 6-1 7 8 9 10 10-1 002-2982-0-SP 002-3513-0-SP 003-2178-0-SP 004-1582-9-SP 003-6400-0-SP 051-1035-0-SP 008-0144-09-SP 003-6399-0-SP 054-0366-0-SP 002-3505-0-SP 002-3508-0-SP S-PARTS:ASS'Y,UPPER HOUSING,RoHS S-PARTS:ASS'Y,FRONT COVER,RoHS S-PARTS: ASS'Y, BELT S-PARTS:PCBA:LBA89,RoHS S-PARTS:HOUSING LOWER: 447x292x60, ABS, BLACK,RoHS S-PARTS: LOCK: 24x20x30mm, PC, GRAY S-PARTS:ASS'Y, POWER S/W,DWA-003, 5P,P=2.5mm,L=50mm,W/TUBE,RoHS S-PARTS:PCBA,MBA423+F/W,XEROX DM515,RoHS S-PARTS: MOUNT, PCBA-U, 232x413x32.5, SECC, MB169, ADF26P S-PARTS:ASS'Y,OPTICAL:600 GEAR RATION,RoHS S-PARTS:ASS'Y,LAMP:RoHS 100 100 500 100 100 400 100 100 100 200 200

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DM515 Service Manual

10-2

005-0000-09-SP

10-3

065-0088-09-SP

S-PARTS: INVERTER,24V,7mA,50KHz,01-B1180014,COTEK,FOR 1 CCFL,Lead Free,W/FUSE,RoHS S-PARTS:MOTOR:STEPING BIPOLAR,24V,0.62A,3.75,4Phase,6,MITSUMI ,M42SP-4N,RoHS S-PARTS:FFC CABLE,32P,P=1.0mm,L=400mm,F14D32A,Tenn Rich, ,RoHS S-PARTS:AC POWER CORD:US,3P,10A/125V,L=1800mm,3C*18AWG ,BLACK,PH8B2EDJF0A-05B,RoHS S-PARTS:AC POWER CORD,EUR.(CEE),2P+G. BASE,16A/250V,L=1800mm,3C*0.75mm2,BLA CK,PG8B9CIJG0A-05B,RoHS S-PARTS:AC POWER CORD,UK(BS/PSB),3P,3A/250V,L=1800mm,3C *0.75mm2,BLACK,PG8B9X3JG0A-05B S-PARTS:ASS'Y,PAPER TRAY S-PARTS:ASS'Y,PAPER SUPPORTRoHS S-PARTS:USB2.0 CABLE,L=1850mm,C041370448-A,28AWG,W/CORE,PANTONE 432C(BLACK),RoHS S-PARTS: ASS'Y, STOPPERRoHS S-PARTS:ADAPTER:DESK-TOP,IEC 320C6,3P,100~240Vac,24Vdc,1A,24W,HEG42240100-7L(A) LF,HITRON ,CLASS I,W/2 CORE:R5 RH 12x20x5.6 & FH21.2x7.7x14.4,ENERGY STAR & RoHS FOAM, EPS,L:575x250x100,62.5,RoHS FOAM, EPS,R:575x250x100,62.5,RoHS CARTON:592x400x285mm,AB/F,RoHS ACCESSORY BOX : 280x245x48 , B/F,RoHS S/W PACKAGE:UNIVERSAL,RoHS CD QUICK GUIDE TECHNICAL SUPPORT CARD

300

300

11

104-5051-09-SP

100

ACCESSARY

A-1

104-8007-09-SP

400

A-2

104-8006-09-SP

300

A-3 B C

104-8011-09-SP 002-2971-0-SP 002-2964-0-SP

100 100 100

D E F

104-0285-09-SP 002-1583-0-SP 005-3025-09-SP

100 200

100 100 100 100 300 200 100 200 500

G H I J K K-1 K-2 K-3

072-0493-0 072-0494-0 073-1580-0 073-0590-0 003-2863-0 256-0387-0 251-0600-0 255-0739-0

7-5