Brother PDS-5000 Service Manual Download Page 129

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4-27

Confidential

3. IF YOU REPLACE THE CCD UNIT OR LED

PCB ASSY



What to do after replacement

• OD Adjustment (Optical Density Learning)

• Checking Operation after Repair



What you need to prepare

(1) One USB cable
(2) Computer (Windows

XP or later)

(3) Service setting tools (StdL2Setup.exe, SetupAddon.exe)

Pre-install them into computer according to

APPENDIX 2

(4) Product driver

Pre-install it into computer according to QSG.

(5) OD/MF Chart ASSY

• White paper

• Mech Chart

• OD Chart

Summary of Contents for PDS-5000

Page 1: ...d this manual thoroughly before maintenance work Keep this manual in a convenient place for quick and easy reference at all times May 2015 SM PT080 2 Brother Advanced Document Scanner SERVICE MANUAL MODEL PDS 5000 6000 ...

Page 2: ...tion may be reproduced in any form or by any means without permission in writing from the publisher All other product and company names mentioned in this manual are trademarks or registered trademarks of their respective holders Specifications are subject to change without notice ...

Page 3: ... Micro Devices Inc Linux is the registered trademark of Linus Torvalds in the U S and other countries Android is a trademark of Google Inc ISIS Captiva and QuickScan are either registered trademarks or trademarks of EMC Corporation in the United States and or other countries Intel is a trademark of Intel Corporation in the U S and or other countries Adobe Reader and Photoshop are either registered...

Page 4: ...3 Operation of Each Part 2 5 2 4 Block Diagram 2 6 3 ERROR INDICATIONS 2 7 4 TROUBLESHOOTING 2 9 4 1 Error Cause and Remedy 2 9 4 2 Troubleshooting for Document Feeding Problems 2 15 4 2 1 No document is fed 2 15 4 2 2 Multiple documents are fed 2 15 4 2 3 Document becomes jammed 2 16 4 2 4 Document becomes wrinkled 2 17 4 3 Troubleshooting for Scanned Image Defects 2 18 4 3 1 Defect examples 2 18...

Page 5: ...over 3 16 9 5 Shaft mount ASSY 3 17 9 6 Top cover ASSY 3 17 9 7 Upper back cover 3 18 9 8 Bottom cover ASSY Output tray ASSY 3 19 9 9 Back cover 3 20 9 10 Side cover L R 3 21 9 11 Main PCB ASSY 3 22 9 12 Upper base ASSY 3 26 9 13 LCD PCB ASSY Panel ASSY LCD sheet LCD PCB flat cable 3 27 9 14 Second side CCD glass ASSY Second side CCD glass spring Second side LED light PCB ASSY 3 31 9 15 Reverse ro...

Page 6: ...re version 4 3 1 1 2 Installing firmware 4 5 1 2 Setting Serial Number 4 6 1 3 Setting Multi feed Sensor Threshold 4 8 1 4 OD Adjustment Optical Density Learning 4 11 1 5 Checking Operation after Repair 4 16 2 IF YOU REPLACE THE MULTI FEED SENSOR PCB 4 19 2 1 Setting Multi feed Sensor Threshold 4 20 2 2 Checking Multi feed Function 4 23 3 IF YOU REPLACE THE CCD UNIT OR LED PCB ASSY 4 27 3 1 OD Adj...

Page 7: ...which if not avoided may result in damage to property or loss of product functionality Prohibition icons indicate actions that must not be performed Electrical Hazard icons alert you to possible electrical shock Fire Hazard icons alert you to the possibility of fire Note Notes tell you how you should respond to a situation that may arise or give tips about how the operation works with other featur...

Page 8: ...ct with the machine there may be a risk of fire or electric shock In particular organic solvents or liquids such as benzene paint thinner polish remover or deodorizer may melt or dissolve the plastic cover and or cables resulting in a risk of fire or electric shock These or other chemicals may also cause the machine to malfunction or become discolored The product should be placed so as not to come...

Page 9: ...o may cause a risk of damage to the document WARNING ELECTRICAL HAZARDS Failure to follow the warnings in this section may create the risk of an electrical shock In addition you could create an electrical short which may create the risk of a fire There are high voltage electrodes inside the machine Before you access the inside of the machine including for routine maintenance such as cleaning make ...

Page 10: ...sponsibility for any damage resulting from using an AC adapter other than the one specified DO NOT use a damaged AC adapter DO NOT place heavy objects on damage or modify the AC adapter DO NOT forcibly bend the cord of the AC adapter DO NOT forcibly pull the cord of the AC adapter DO NOT drop hit or otherwise damage the AC adapter DO NOT use or touch the unit during a thunderstorm when the AC adap...

Page 11: ...o clean the inside or outside of the machine Doing this may cause a risk of fire or electrical shock Do not disassemble or modify the machine otherwise fire or electric shock may result If the machine requires repair contact the place of purchase or Brother Authorized Service Personnel If the machine becomes hot releases smoke or generates any strong or unusual odors immediately unplug the machine...

Page 12: ... your fingers by pinching them DO NOT carry the machine by holding the top cover Doing this may cause the machine to slip out of your hands Only carry the machine by placing your hands under the entire machine Use caution when operating the machine to prevent clothing particularly sleeves neckties etc hair or accessories from being drawn into the machine otherwise injury may result In the event th...

Page 13: ...ssued by the United States Canadian Government or any of its Agencies may not be copied Money Bonds or other certificates of indebtedness Certificates of Deposit Internal Revenue Stamps canceled or uncanceled Selective Service or draft papers Passports United States Canadian Postage Stamps canceled or uncanceled Food Stamps Immigration Papers Checks or drafts drawn by Governmental agencies Identif...

Page 14: ...tured A portion of the document may not be scanned or the size may be too small The document may only be scanned up to a certain point after which scan data will be lost Blank pages may not be deleted or pages may be deleted unnecessarily Margins may be added to the edges of the scan data Refer to the User s Guide for information about how to configure the scan settings Depending on the condition ...

Page 15: ...120 ipm 200 300 dpi 15 ppm 30 ipm 600 dpi 80 ppm 160 ipm 200 300 dpi 20 ppm 40 ipm 600 dpi Memory 512 MB 128 MB x 4 DDR2 Interface Hi Speed USB 3 0 USB 2 0 Power Consumption Scanning Approximately 46 5 W Ready Approximately 16 5 W Deep Sleep Approximately 2 9 W Power Off Approximately 0 5 W Power Source AC 100 240 V 50 60 Hz DC 24 V 2 A Noise Level Sound Pressure Scanning 47 dB or less Sound Power...

Page 16: ... Intel CoreTM 2 Duo or equivalent 1 GB 2 GB 50 MB 1 5 GB USB Windows XP Professional x64 Edition 64 bit Intel 64 or AMD 64 supported CPU Windows Vista Intel CoreTM2 Duo or equivalent 64 bit Intel 64 or AMD 64 supported CPU Windows 7 1 1 GB 32 bit 2 GB 64 bit 2 GB 32 bit 4 GB 64 bit Windows 8 8 1 1 Macintosh Operating System OS X v10 8 Intel Processor 2 GB 4 GB 50 MB 400 MB OS X v10 9 OS X v10 10 1...

Page 17: ...ork security N A Wireless network Network node type N A Network type N A Communication mode N A Network security N A Part Approximate Life pages Machine life 600 000 sheets A4 LTR or 5 years MTBF 5 000 hours MTTR 0 5 hours Maximum monthly volume 60 000 sheets A4 LTR Periodical maintenance parts Pickup roller 200 000 sheets A4 LTR or 5 years Reverse roller 200 000 sheets A4 LTR or 5 years Separatio...

Page 18: ...Plastic Card w emboss Media Weight ADF multiple paper 28 to 400 g m2 7 5 lb to 106 lb ADF single paper 28 to 400 g m2 7 5 lb to 106 lb ADF plastic card thickness ISO JIS 0 76 mm 30 mil Min 0 4 mm 16 mil Max 0 76 mm 30 mil Embossed up to 1 25 mm 49 mil Media Size ADF multiple paper Width 51 to 218 mm 2 0 to 8 58 Length 54 to 356 mm 2 13 to 14 0 ADF single paper Width 51 to 218 mm 2 0 to 8 58 Length...

Page 19: ...mpliant Macintosh OS X v10 6 OS X v10 7 v10 8 v10 9 or later Web download only 2 ISISTM Compliant Windows Windows XP 1 Windows Vista Windows 7 Windows 8 or later Color Depth Input 48 bit color processing Output 24 bit color processing Resolution Interpolated 600 x 600 dpi Optical 600 x 600 dpi Scanning Width 216 mm 8 5 Gray Scale 8 bits 1 Windows XP in this Service Manual includes Windows XP Home ...

Page 20: ...ng or disconnecting the cable Be sure to hold the connector 3 Static electricity charged in your body may damage electronic parts Before handling the PCBs touch a metal section of the machine to discharge static electricity When transporting PCBs be sure to wrap them in conductive sheets When replacing the PCBs wear a grounding wrist band and perform replacement on an antistatic mat Also take care...

Page 21: ...ocument 1 The recommended paper is used for the document Refer to 4 2 Media Specifications in Chapter 1 2 The document is not damp 3 Short grained paper or acid paper is not used Others 1 Condensation When the machine is moved to a warm room from a cold location condensation may occur inside the machine causing various problems as listed below Condensation on the surface of optical devices may cau...

Page 22: ... Document tray Reverse roller Second side CCD unit Multi feed sensor PCB Transmit Exit roller Paper detection sensor Multi feed sensor PCB Receive Pick up roller Separation roller First side LED light PCB Feed roller Second side LED light PCB First side CCD unit ...

Page 23: ...2 4 Confidential 2 2 Document Feed Path Fig 2 2 Front side Document feed path Back side ...

Page 24: ...anner part Paper detection sensor Detects the document set in the document tray Multi feed sensor Transmit Receive Detects whether multiple documents are fed into the machine Feed roller Feeds the document to the scanner part First side Second side CCD unit Scans the document First side Second side LED light PCB A light source for the scanning Exit roller Feeds the document to the output tray ADF ...

Page 25: ...SY ADF cover sensor Multi feed sensor PCB ASSY Transmit Paper jam sensor Double feeding PCB ASSY Receive Paper detection sensor Paper scan sensor Second side LED light PCB ASSY First side LED light PCB ASSY Paper detection sensor Upper base First side CCD unit Bottom base Pick up motor Feed motor Fan Main PCB ASSY ...

Page 26: ...wer switch is turned ON write a certain value to first side LVDS register then read again the value is different 0024 2 10 AFE R W test error When the power switch is turned ON write a certain value to first side AFE register then read again the value is different 2037 2 12 Document Jam too Long Scan sensor is ON when the power switch is turned ON 2013 2 11 Paper jam sensor remains ON after the sp...

Page 27: ...in value to NVRAM then read again the value is different 2024 2 12 Ultrasonic error When the power switch is turned ON an error occurred in the read value of the multi feed sensor 2036 2 12 USB R W test error When the power switch is turned ON write a certain value to USB register then read again the value is different 0014 2 9 LCD Description Error codes Refer to ...

Page 28: ...medy 1 Main PCB failure Replace the main PCB ASSY Learning error Step Cause Remedy 1 Connection failure of the USB cable Check the connection of the USB cable 2 Wrong service tool Use the dedicated service tool 3 Old or faded test chart Use a new test chart 4 Main PCB failure Replace the main PCB ASSY Download firmware error Step Cause Remedy 1 Connection failure of the USB cable Check the connect...

Page 29: ...LVDS register then read again the value is different Error code 0029 When the power switch is turned ON write a certain value to second side AFE register then read again the value is different AFE LVDS test error Step Cause Remedy 1 Main PCB failure Replace the main PCB ASSY ADF AFE LVDS test error Step Cause Remedy 1 Main PCB failure Replace the main PCB ASSY ADF AFE R W test error Step Cause Rem...

Page 30: ...lean the optical sensor section Refer to the figure below Step Cause Remedy 1 Paper detect actuator caught in sections of the machine Reattach the paper detect actuator 2 Connection failure of the sensor PCB flat cable Reconnect the sensor PCB flat cable 3 Connection failure of the paper detection sensor harness Reconnect the paper detection sensor harness 4 Connection failure of the feed motor ha...

Page 31: ...SY 2 Abrasion of the ADF cover hook Replace the ADF cover hook 3 ADF cover sensor failure Replace the sensor PCB ASSY 4 Main PCB failure Replace the main PCB ASSY NVRAM R W test error Step Cause Remedy 1 Main PCB failure Replace the main PCB ASSY Ultrasonic error User Check Remove the document in the product if any Step Cause Remedy 1 Deviated adjustment value of the multi feed sensor Readjust the...

Page 32: ... to 3 1 OD Adjustment Optical Density Learning in Chapter 4 3 Serious dirt on first side glass Replace the first side glass ASSY 4 First side LED light PCB failure Replace the first side LED light PCB 5 First side CCD failure Replace the first side CCD 6 Main PCB failure Replace the main PCB ASSY ADF rear lamp error User Check Clean the scanning area Step Cause Remedy 1 Dirt inside the second side...

Page 33: ...ure Replace the multi feed sensor PCB ASSY Receive 3 Multi feed sensor PCB Transmit failure Replace the multi feed sensor PCB ASSY Transmit 4 Main PCB failure Replace the main PCB ASSY Document misfeed User Check Reset the document correctly Adjust the document guide according to the document width Check that the document is not damp Step Cause Remedy 1 Connection failure of the multi feed sensor ...

Page 34: ... pick up roller 9 Abrasion of the separation roller Replace the separation roller 10 Damaged pick up drive belt Replace the pick up drive belt 11 Damaged feed drive belt Replace the feed drive belt 12 Shaft mount failure Replace the shaft mount 13 ADF cover sensor failure Replace the sensor PCB ASSY 14 Pick up motor failure Replace the pick up motor ASSY 15 Feed motor failure Replace the feed moto...

Page 35: ...ed drive belt Replace the feed drive belt 8 ADF cover sensor failure Replace the sensor PCB ASSY 9 Multi feed sensor PCB Receive failure Replace the multi feed sensor PCB ASSY Receive 10 Multi feed sensor PCB Transmit failure Replace the multi feed sensor PCB ASSY Transmit 11 Feed motor failure Replace the feed motor 12 Main PCB failure Replace the main PCB ASSY User Check Clean the optical sensor...

Page 36: ...p Step Cause Remedy 1 Abrasion of the reverse roller Replace the reverse roller 2 Abrasion of the pick up roller Replace the pick up roller 3 Abrasion of the separation roller Replace the separation roller 4 Abrasion of the feed roller Replace the feed roller ASSY 5 Abrasion of the exit roller Replace the exit roller 6 Paper scan sensor failure Replace the multi feed sensor PCB ASSY Receive ...

Page 37: ... 2 Dirt on the first side glass or second side glass Clean the first side glass ASSY or second side glass ASSY 3 First side LED light PCB or second side LED light PCB failure Replace the first side LED light PCB or second side LED light PCB 4 First side CCD unit or second side CCD unit failure Replace the first side CCD unit or second side CCD unit 5 Main PCB failure Replace the main PCB ASSY Ligh...

Page 38: ...spring in the second side glass ASSY 3 First side LED light PCB or second side LED light PCB failure Replace the first side LED light PCB or second side LED light PCB 4 First side CCD unit or second side CCD unit failure Replace the first side CCD unit or second side CCD unit 5 Main PCB failure Replace the main PCB ASSY User Check Check that the document is not reversed Step Cause Remedy 1 Connect...

Page 39: ...it or second side CCD unit 7 Main PCB failure Replace the main PCB ASSY User Check Clean the scanning area Clean each roller Check that the document is not wrinkled Step Cause Remedy 1 Dirt on the first side glass or second side glass Clean the first side glass ASSY or second side glass ASSY 2 Serious dirt on rollers Replace the rollers with serious dirt 3 Foreign object inside the scanner mechani...

Page 40: ...or second side CCD unit failure Replace the first side CCD unit or second side CCD unit 5 Main PCB failure Replace the main PCB ASSY Step Cause Remedy 1 Second side glass ASSY spring attachment failure Reattach the second side glass ASSY spring 2 First side LED light PCB or second side LED light PCB failure Replace the first side LED light PCB or second side LED light PCB 3 First side CCD unit or ...

Page 41: ...follow the User Check items If the problem still cannot be solved implement each procedure according to the step numbers in the tables below 4 4 1 Cannot receive data User Check Check that the USB cable or LAN cable is not damaged Check the relevant section in the User s Guide Check the driver settings Reset the machine to the default settings Refer to the User s Guide Step Cause Remedy 1 Main PCB...

Page 42: ...e LCD PCB flat cable 3 Connection failure of the LCD flat cable Reconnect the LCD flat cable 4 AC cord failure Replace the AC cord 5 AC adapter failure Replace the AC adapter 6 LCD PCB failure Replace the LCD PCB ASSY 7 Main PCB failure Replace the main PCB ASSY User Check Turn the power switch OFF and then ON again Step Cause Remedy 1 Key attachment failure Reattach the key 2 Connection failure o...

Page 43: ...PCB ASSY User Check Check the DC terminal connection Turn the power switch OFF and then ON again Step Cause Remedy 1 Key attachment failure Reattach the key 2 Connection failure of the LCD PCB flat cable Reconnect the LCD PCB flat cable 3 Connection failure of the LCD flat cable Reconnect the LCD flat cable 4 AC cord failure Replace the AC cord 5 AC adapter failure Replace the AC adapter 6 LCD PCB...

Page 44: ...rounding wrist band and perform the job on a static mat Also take care not to touch the conductor sections on the flat cables or on the wire harness After disconnecting flat cables check that each cable is not damaged at its end or shortcircuited When connecting flat cables do not insert them at an angle After insertion check that the cables are not at an angle When connecting or disconnecting con...

Page 45: ...3 2 Confidential 2 PACKING Fig 3 1 ...

Page 46: ...dential 3 SCREW CATALOGUE Fig 3 2 Taptite cup S Screw pan S washer Taptite bind B Taptite bind B M3x8 black Taptite bind B M3x10 black Taptite cup S M3x6 Screw pan S washer M3x10 Taptite cup B Taptite cup B M3x8 ...

Page 47: ...F cover sensor PCB Taptite cup B M3x8 1 0 6 0 05 6 0 5 Second side CCD unit Taptite bind B M3x10 black 1 0 8 0 05 8 0 5 Multi feed sensor PCB Transmit Taptite cup B M3x8 1 0 6 0 05 6 0 5 Main PCB shield Screw pan S washer M3x10 1 0 6 0 05 6 0 5 Taptite bind B M3x10 black 2 0 8 0 05 8 0 5 Tension pulley holder Taptite cup S M3x6 1 0 6 0 05 6 0 5 Feed motor Taptite cup S M3x6 2 0 6 0 05 6 0 5 Pick u...

Page 48: ...3 5 Confidential 5 LUBRICATION There are no parts that require lubrication ...

Page 49: ...3 6 Confidential 6 OVERVIEW OF GEARS Left side Fig 3 3 Right side Fig 3 4 ...

Page 50: ...n First side LED light PCB harness RD BK Sensor PCB FG harness BK Multi feed sensor PCB flat cable Receive First side CCD flat cable Second side CCD flat cable Sensor PCB flat cable LCD PCB flat cable Feed motor harness RD YW BR BK Pick up motor harness RD YW BR BK Main PCB ASSY Second side CCD flat cable Sensor PCB flat cable ...

Page 51: ...3 8 Confidential 3 Left side of machine 4 LCD PCB ASSY Sensor PCB FG harness BK LCD PCB flat cable LCD PCB flat cable LCD PCB ASSY ...

Page 52: ... light PCB ASSY Second side LED light PCB harness RD BK Upper base ASSY Multi feed sensor PCB flat cable Transmit Multi feed sensor PCB Transmit Anti static brush FG harness BK Sensor PCB flat cable Sensor PCB FG harness BK Paper detection sensor harness RD BL BK Upper base ASSY ADF cover sensor PCB Second side LED light PCB harness RD BK ...

Page 53: ...at cable 8 First side LED light PCB harness Harness colors are subject to change for some reason Second side CCD unit Second side CCD flat cable Upper base ASSY First side LED light PCB harness RD BK First side LED light PCB ASSY Lower base ...

Page 54: ...tial 9 First side CCD flat cable 10 First side CCD flat cable Multi feed sensor PCB flat cable Receive First side CCD flat cable First side CCD unit First side CCD flat cable Multi feed sensor PCB flat cable Receive ...

Page 55: ...i feed sensor PCB flat cable Receive 5 5 9 29 Multi feed sensor PCB Receive 10 15 9 27 First side LED light PCB ASSY 15 20 9 14 Second side CCD glass ASSY 5 5 9 14 Second side LED light PCB ASSY 15 20 9 14 Second side CCD glass spring 5 5 9 24 First side CCD glass 15 15 9 21 Multi feed sensor PCB flat cable Transmit 5 5 9 17 Cover release lever 10 15 9 18 ADF cover sensor PCB 15 25 9 19 Paper dete...

Page 56: ...9 DISASSEMBLY PROCEDURE 9 1 Preparation Disconnecting Cables Prior to proceeding with the disassembly procedure 1 Disconnect the following USB cable if connected AC power cord if connected Fig 3 5 USB cable AC power cord ...

Page 57: ...ase lever to open the upper base ASSY 2 Push the two hooks inward to open the reverse roller cover ASSY 3 Remove the reverse roller ASSY Fig 3 6 4 Pull out the reverse roller ASSY from the shaft Fig 3 7 5 Close the reverse roller cover ASSY Reverse roller ASSY Cover release lever Upper base ASSY Reverse roller cover ASSY Hook Hook Reverse roller ASSY Shaft ...

Page 58: ... left side of pick up roller ASSY to remove it Fig 3 8 9 Turn the lever in the direction of the arrow to remove the separation roller ASSY Fig 3 9 10 Close the pick up roller cover Pick up roller cover Pick up roller ASSY Document guide Document guide Lever Separation roller ASSY Pick up roller cover ...

Page 59: ...sh the right side of reverse roller cover ASSY in the direction of the arrow to remove the boss and remove it Fig 3 10 9 4 Pick up roller cover 1 Open the pick up roller cover 2 Push the left side arm to remove the boss and remove the pick up roller cover Fig 3 11 Hooks Reverse roller cover ASSY Pick up roller cover Arm ...

Page 60: ...ews to remove the shaft mount ASSY Fig 3 12 9 6 Top cover ASSY 1 Push the right side arm to remove the boss and remove the top cover ASSY Fig 3 13 Assembling Note Insert each document guide rib to each groove Shaft mount ASSY Taptite bind B M3x10 black Top cover ASSY Document guides Arm ...

Page 61: ...back cover 1 Push the arm to remove the boss and remove the upper back cover Fig 3 14 Fig 3 15 Assembling Note When attaching the upper back cover insert the spring into the groove two locations Upper back cover Arm Spring Groove ...

Page 62: ...nd B M3x10 black screws from the bottom cover ASSY Release each hook to remove the bottom cover ASSY Fig 3 16 3 Remove the output tray ASSY from the bottom cover ASSY Fig 3 17 Assembling Note When attaching the bottom cover ASSY insert each tab into each groove Taptite bind B M3x10 black Bottom cover ASSY Bottom cover ASSY Output tray ASSY ...

Page 63: ...3 20 Confidential 9 9 Back cover 1 Release the two hooks to remove the back cover Fig 3 18 Back cover Hooks ...

Page 64: ...ever to open the upper base ASSY 2 Release each hook to remove the side cover L Fig 3 19 3 Release each hook Turn the side cover R slightly around the inner boss to remove it from the machine Fig 3 20 4 Close the upper base ASSY Side cover L Upper base ASSY Side cover R Upper base ASSY Boss ...

Page 65: ...M3x6 screws to remove the main PCB shield plate and the sensor PCB FG harness Fig 3 21 Fig 3 22 Assembling Note Secure the sensor PCB FG harness and the main PCB shield plate with the screw A Taptite cup S M3x6 Taptite cup S M3x6 Main PCB shield plate Sensor PCB FG harness Taptite cup S M3x6 A ...

Page 66: ...each lock to disconnect them After disconnecting flat cables check that each cable is not damaged at its end or short circuited When connecting flat cables do not insert them at an angle After insertion check that the cables are not at an angle Note Be sure to replace the double sided tape with a new one after taking off the flat cable from the double sided tape Note Be careful not to damage the f...

Page 67: ... frame as necessary pass it through the flat core B connect it to the main PCB ASSY and attach it to the double sided tape 4 Connect the multi feed sensor PCB flat cable Receive to the main PCB ASSY 5 Attach the double sided tape on the second side CCD flat cable as shown in the figure below Fig 3 25 Double sided tapes Second side CCD flat cable Flat core B Main PCB ASSY Flat core A Multi feed sen...

Page 68: ...e C connect it to the main PCB ASSY and attach it to the double sided tape Fig 3 26 7 Fold the sensor PCB flat cable within the red frame as necessary connect it to the main PCB ASSY and attach it to the double sided tape Fig 3 27 Main PCB ASSY Flat core C LCD PCB flat cable Sensor PCB flat cable Main PCB ASSY ...

Page 69: ...urn over the machine and pull the cover release lever to open the upper base ASSY 2 Pull the left side of upper base ASSY to remove the boss and remove it Fig 3 28 Fig 3 29 Assembling Note When attaching the upper base ASSY to the lower base the rib of upper base ASSY has to be inner than the rib of lower base Upper base ASSY Cover release lever Rib of lower base Rib of Upper base ASSY ...

Page 70: ... taptite bind B M3x10 black screws from the upper base ASSY 2 Release three hooks to remove the panel ASSY from the upper base ASSY Fig 3 30 Fig 3 31 Note Be careful not to snap or bend the anti static brush Hooks Taptite bind B M3x10 black Upper base ASSY Panel ASSY Panel ASSY Upper base ASSY ...

Page 71: ...bling Note When attaching the panel ASSY insert the two tabs of panel ASSY into the two grooves of upper base ASSY When assembling the upper base ASSY do not catch flat cables and the FG harness Grooves Tabs Panel ASSY Upper base ASSY ...

Page 72: ... from the panel ASSY Fig 3 33 Harness routing Refer to 1 Main PCB ASSY and 4 LCD PCB ASSY Note After disconnecting flat cable check that the cable is not damaged at its end or short circuited When connecting flat cable do not insert it at an angle After insertion check that the cable is not at an angle LCD PCB flat cable Taptite cup B M3x8 Panel ASSY LCD PCB ASSY ...

Page 73: ...3 30 Confidential 5 Remove the LCD sheet from the panel ASSY Fig 3 34 Attachment Procedure 1 Fold the LCD PCB flat cable as shown in the figure below Fig 3 35 LCD sheet Panel ASSY LCD PCB flat cable ...

Page 74: ...side CCD glass ASSY Second side CCD glass spring Second side LED light PCB ASSY 1 Push the two hooks outward to remove the second side CCD glass ASSY from the upper base ASSY Fig 3 36 Second side CCD glass ASSY Upper base ASSY Hooks ...

Page 75: ...e second side LED light PCB ASSY Fig 3 37 Harness routing Refer to 5 Second side LED light PCB harness and 6 Upper base ASSY Note Do not touch the LED section of second side LED light PCB ASSY Assembling Note When attaching the second side LED light PCB ASSY insert the tab of second side LED light PCB ASSY into the groove Second side CCD glass springs Tab Groove Second side LED light PCB ASSY Tapt...

Page 76: ...er gear ASSY 1 Release the hook of reverse roller gear S to pull out the reverse roller gear ASSY from the upper base ASSY and remove the reverse roller gear S Fig 3 38 Reverse roller gear ASSY Reverse roller gear S Hook Upper base ASSY ...

Page 77: ... remove the ADF cover hook from the left side of upper base ASSY Fig 3 39 2 Remove the retaining ring to remove the ADF cover hook from the right side of upper base ASSY Fig 3 40 ADF cover hook Retaining ring Upper base ASSY ADF cover hook Retaining ring Upper base ASSY ...

Page 78: ...up S M3x6 screws to remove the cover release lever from the upper base ASSY Fig 3 41 Note Be careful not to snap or bend the anti static brush Assembling Note When attaching the cover release lever hook the spring on the cover release lever Spring Cover release lever Taptite cup S M3x6 Upper base ASSY ...

Page 79: ...and release the sensor PCB flat cable from the securing fixtures Fig 3 42 Harness routing Refer to 1 Main PCB ASSY and 6 Upper base ASSY Note After disconnecting flat cables check that each cable is not damaged at its end or short circuited When connecting flat cables do not insert them at an angle After insertion check that the cables are not at an angle Note Be careful not to bend the FG plate N...

Page 80: ...ttach the double sided tape as shown in the figure below two places Fig 3 43 2 Attach the flat core and the sensor PCB flat cable to the double sided tapes as shown in the figure below Fig 3 44 Double sided tapes Sensor PCB flat cable Flat core ...

Page 81: ...arness from the securing fixtures 2 Turn the paper detection sensor in the direction of the arrow while pushing the hook and remove it from the upper base ASSY Fig 3 45 Harness routing Refer to 6 Upper base ASSY Paper detection sensor Paper detection sensor harness Hook Upper base ASSY ...

Page 82: ...CD unit so that the cut surface of the left shaft and rib of the bushing match and remove it from the upper base ASSY Fig 3 47 Note Be sure to replace the double sided tape with a new one after taking off the flat cable from the double sided tape Note Do not touch the glass surface of second side CCD unit Second side CCD flat cable Second side CCD unit Upper base ASSY Taptite bind B M3x10 black Se...

Page 83: ...econd side CCD flat cable Note Be sure to replace the double sided tape with a new one after taking off the flat cable from the double sided tape After disconnecting flat cable check that the cable is not damaged at its end or short circuited When connecting flat cable do not insert it at an angle After insertion check that the cable is not at an angle Second side CCD flat cable ...

Page 84: ...econd side CCD flat cable through the flat core connect it to the PCB and attach it to the double sided tape Fig 3 49 2 Attach the double sided tape as shown in the figure below two places Fig 3 50 Second side CCD flat cable Flat core Double sided tapes ...

Page 85: ... second side CCD flat cable to the double sided tape as shown in the figure below Fig 3 51 4 Fold the second side CCD flat cable at the position described below Fig 3 52 Second side CCD flat cable Second side CCD flat cable 70 1 mm ...

Page 86: ... multi feed sensor PCB Transmit from the upper base ASSY while lifting the FG plate Fig 3 53 Harness routing Refer to 6 Upper base ASSY Note After disconnecting flat cable check that the cable is not damaged at its end or short circuited When connecting flat cable do not insert it at an angle After insertion check that the cable is not at an angle Taptite cup B M3x8 Multi feed sensor PCB Transmit ...

Page 87: ...ns attach the sponge by following the instruction below Where to attach the sponge on the second side CCD unit side Use the following parts from SPONGE ASSY PDS D00DFL001 Fig 3 54 Assembling Note Attach the sponge on the shield plate along the dotted line Shield plate 1 1 2 Shield plate ...

Page 88: ...ttach the sponge on the upper base ASSY along the dotted line Sponge should be attached so that it is not projected to the outside of the attaching surface If it is projected scanned image may be shaded Sponge attaching surface Upper base ASSY 2 ...

Page 89: ...the main PCB shield Fig 3 57 Assembling Note When attaching the main PCB shield insert the five tabs to each groove Pass the first side CCD flat cable and multi feed sensor PCB flat cable Receive through the two holes of the main PCB shield Screw pan S washer M3x10 Multi feed sensor PCB flat cable Receive Main PCB shield First side CCD flat cable Holes Taptite bind B M3x10 black Tabs ...

Page 90: ...e tension pulley holder in the direction of the arrow 4 Remove the two taptite cup S M3x6 screws to remove the feed motor Fig 3 58 5 Disconnect the feed motor harness from the feed motor 6 Remove the two gaskets from the feed motor Fig 3 59 Feed drive belt S Taptite cup S M3x6 Feed motor Taptite cup S M3x6 Feed drive belt Tension pulley holder Feed motor Feed motor harness Gaskets ...

Page 91: ... First side CCD glass 1 Turn over the lower base 2 Remove the four taptite bind B M3x8 black screws and release the five hooks to remove the first side CCD glass Fig 3 60 Hooks Taptite bind B M3x8 black First side CCD glass ...

Page 92: ... the conductive bushing in the direction of the arrow to remove the feed roller ASSY Fig 3 61 2 Turn the conductive bushing in the direction of the arrow to remove the exit roller ASSY Fig 3 62 Feed roller ASSY Conductive bushing Exit roller ASSY Conductive bushing ...

Page 93: ... remove the gear D and remove the pick up drive belt 2 Remove the two taptite cup S M3x6 screws to remove the pick up motor Fig 3 63 3 Disconnect the pick up motor harness from the pick up motor Fig 3 64 Gear D Retaining ring E3 Gear A Gear B Taptite cup S M3x6 Gear C Pick up motor Pick up drive belt Hook Pick up motor harness Pick up motor ...

Page 94: ...st side LED light PCB ASSY Fig 3 65 Harness routing Refer to 6 Upper base ASSY and 8 First side LED light PCB harness Note Do not touch the LED section of first side LED light PCB ASSY Assembling Note When attaching the first side LED light PCB ASSY insert the tab of first side LED light PCB ASSY into the groove First side LED light PCB ASSY First side LED light PCB harness Taptite bind B M3x10 bl...

Page 95: ...x10 black screw from the upper base ASSY Fig 3 66 3 Turn the first side CCD unit so that the cut surface of the right shaft and rib of the bushing match and remove it Fig 3 67 Note Do not touch the glass surface of first side CCD unit Upper base ASSY Taptite bind B M3x10 black First side CCD unit First side CCD unit Rib Shaft ...

Page 96: ...First side CCD flat cable Note Be sure to replace the double sided tape with a new one after taking off the flat cable from the double sided tape After disconnecting flat cable check that the cable is not damaged at its end or short circuited When connecting flat cable do not insert it at an angle After insertion check that the cable is not at an angle First side CCD flat cable ...

Page 97: ...ure 1 Attach the two double sided tapes as shown in the figure below Fig 3 69 2 Fold the first side CCD flat cable and attach it to the double sided tapes as shown in the figure below Fig 3 70 Double sided tapes First side CCD flat cable ...

Page 98: ... PCB flat cable Receive from the multi feed sensor PCB Receive Fig 3 71 Harness routing Refer to 1 Main PCB ASSY Note After disconnecting flat cable check that the cable is not damaged at its end or short circuited When connecting flat cable do not insert it at an angle After insertion check that the cable is not at an angle Multi feed sensor PCB flat cable Receive Multi feed sensor PCB Receive Ta...

Page 99: ...treaks in Chapter 2 happens attach the sponge by following the instruction below Where to attach the sponge on the first side CCD unit side Use the following parts from SPONGE ASSY PDS D00DFL001 Fig 3 72 2 1 3 Double feeding sensor shield 4 Lower base ASSY B A C ...

Page 100: ...tion 2 Fig 3 74 Assembling Note Stick the sponge 1 and 2 together along with the dotted line Attach the double sided tape on the hook of the lower base ASSY Assembling Note Attach the sponge on the lower base ASSY along the dotted line 1 2 Hook 4 ...

Page 101: ...3 58 Confidential B section Fig 3 75 Assembling Note Attach the sponge on the double feeding sensor shield along the dotted line 3 Double feeding sensor shield ...

Page 102: ...C section 2 Fig 3 77 Assembling Note Attach the sponge on the sponge attaching surface of the lower base ASSY along the dotted line Assembling Note Attach the sponge on the lower base ASSY along the dotted line 2 Sponge attaching surface 4 4 ...

Page 103: ...ration after Repair What you need to prepare 1 One USB cable 2 Create a temporary folder on the C drive of the computer Windows XP or later 3 Service setting tools StdL2Setup exe SetupAddon exe Serial_number exe Pre install them into computer according to APPENDIX 2 4 Product driver Pre install it into computer according to QSG 5 Main firmware Copy this file into the temporary folder created on th...

Page 104: ...4 2 Confidential 6 OD MF Chart ASSY White paper Mech Chart OD Chart White A4 150g paper Crease paper A4 28g paper ...

Page 105: ...s described in 1 1 2 Installing firmware How to check firmware version 1 Check that the product driver is installed in the computer If it is not install it according to QSG 2 Start the computer 3 Connect the machine to your computer using the USB cable and turn the machine ON 4 Click the Start button on the computer and select DS Capture from All Programs 5 The window below appears on the screen S...

Page 106: ...4 4 Confidential 7 The window below appears on the screen Click the Information tab Scroll down and check F W Version ...

Page 107: ...The window below appears on the screen Installation starts 5 Upon completion of the installation the window below appears and the machine turns OFF Click the OK button The window shown below closes Note Do not disconnect the AC cord or USB cable from the machine or computer during installing If the install is failed turn OFF the machine and turn it back on The machine enters the firmware install m...

Page 108: ...window below appears on the screen Click the NVRAM Modify button 3 The window below appears on the screen Enter the serial number described on the label at the back of the machine and press the Reset button 4 The window below appears on the screen Press the OK button Serial number is written into the main PCB ...

Page 109: ...4 7 Confidential 5 Follow the operation procedure 1 to 6 for checking firmware version and check that the serial number written is correct ...

Page 110: ...our computer and click All Programs Click and open Standard Learning Tool II to start Standard Learning Tool II 2 When Please Input ID or Station Name and Please Input Password windows appear enter service Password will be hidden when you enter 3 Select ultrasonic and click the Ok button ...

Page 111: ...ndow below appears on the screen Set the adjustment chart White A4 150g paper shown in the picture to the machine and click the OK button 6 The following window appears after feeding the chart Set the adjustment chart Crease paper shown in the picture to the machine and click the OK button ...

Page 112: ...8 The following window appears after feeding the chart Set the adjustment chart A4 28g shown in the picture to the machine and click the OK button 9 The following window appears after feeding the chart Set the adjustment chart again to the machine and click the OK button 10 The following window appears and the machine turns OFF Click the OK button The window shown below closes ...

Page 113: ...tart button on your computer and click All Programs Click and open Standard Learning Tool II to start Standard Learning Tool II 2 When Please Input ID or Station Name and Please Input Password windows appear enter service Password will be hidden when you enter 3 Select OD and click the Ok button ...

Page 114: ...elow appears on the screen Enter the number ex 47N 1 0195 030 in the picture below on the adjustment chart White paper and click the OK button 6 The window below appears on the screen Enter the number ex 487 1 0000 000 in the picture below on the adjustment chart Mech Chart and click the OK button ...

Page 115: ...Chart and click the OK button 8 The window below appears on the screen after the countdown Set the adjustment chart White paper shown in the picture to the machine and click the OK button 9 The window below appears on the screen Set the adjustment chart Mech Chart shown in the picture so that the A comes at the bottom and click the OK button ...

Page 116: ...ck the OK button 11 The window below appears on the screen Set the adjustment chart OD Chart shown in the picture again so that the A comes at the bottom and click the OK button Same sheet as the procedure 10 Note If you set the OD Chart on the ADF right after the procedure 10 completes the screen below doesn t appear and the adjustment starts immediately ...

Page 117: ...ure again so that the A comes at the bottom and click the OK button Same sheet as the procedure 10 14 The following window appears and the machine turns OFF Click the OK button The window shown below closes Note If you set the OD Chart on the ADF right after the procedure 11 completes the screen below doesn t appear and the adjustment starts immediately Note If you set the OD Chart on the ADF righ...

Page 118: ...e machine is connected to your computer via USB cable 2 Set the test charts density chart TC 027 density chart CTC 001 and density chart TC 023 in the document feeder 3 Start the DS Capture The window below appears on the screen Click the Setup button 4 The window below appears on the screen Check the Front Color box A and uncheck the Front B W box B A B ...

Page 119: ...4 17 Confidential 5 Click the Multi Feed Detection tab C check the Ultrasonic Detection box D and click the OK button E 6 Scanning starts once you click the Scan button D C E ...

Page 120: ...dure 2 again and click the Setup button 8 Uncheck the Front Color box F check the Back Color box G and click the OK button H 9 Scanning starts once you click the Scan button 10 Check the two scanned images for color difference and image distortion F H G ...

Page 121: ...ing Multi feed Function What you need to prepare 1 One USB cable 2 Computer Windows XP or later 3 Service setting tools StdL2Setup exe SetupAddon exe Pre install them into computer according to APPENDIX 2 4 Product driver Pre install it into computer according to QSG 5 OD MF Chart ASSY White A4 150g paper Crease paper A4 28g paper ...

Page 122: ... the Start button on your computer and click All Programs Click and open Standard Learning Tool II to start Standard Learning Tool II 2 When Please Input ID or Station Name and Please Input Password windows appear enter service Password will be hidden when you enter ...

Page 123: ...ic and click the Ok button 4 The window below appears on the screen Click the Start button 5 The window below appears on the screen Set the adjustment chart White A4 150g paper shown in the picture to the machine and click the OK button ...

Page 124: ...s after feeding the chart Set the adjustment chart Crease paper shown in the picture again to the machine and click the OK button 8 The following window appears after feeding the chart Set the adjustment chart A4 28g shown in the picture to the machine and click the OK button 9 The following window appears after feeding the chart Set the adjustment chart again to the machine and click the OK butto...

Page 125: ...ion Perform the steps below to check the machine s condition after repair or adjustment 1 Confirm that the machine is connected to your computer via USB cable 2 Set the test charts density chart TC 027 density chart CTC 001 and density chart TC 023 in the document feeder 3 Start the DS Capture The window below appears on the screen Click the Setup button ...

Page 126: ...ial 4 The window below appears on the screen Check the Front Color box A and uncheck the Front B W box B 5 Click the Multi Feed Detection tab C check the Ultrasonic Detection box D and click the OK button E A B D C E ...

Page 127: ...al 6 Scanning starts once you click the Scan button 7 Set the test chart used in procedure 2 again and click the Setup button 8 Uncheck the Front Color box F check the Back Color box G and click the OK button H F H G ...

Page 128: ...4 26 Confidential 9 Scanning starts once you click the Scan button 10 Check the two scanned images for color difference and image distortion ...

Page 129: ...ing Checking Operation after Repair What you need to prepare 1 One USB cable 2 Computer Windows XP or later 3 Service setting tools StdL2Setup exe SetupAddon exe Pre install them into computer according to APPENDIX 2 4 Product driver Pre install it into computer according to QSG 5 OD MF Chart ASSY White paper Mech Chart OD Chart ...

Page 130: ...n on your computer and click All Programs Click and open Standard Learning Tool II to start Standard Learning Tool II 2 When Please Input ID or Station Name and Please Input Password windows appear enter service Password will be hidden when you enter 3 Select OD and click the Ok button ...

Page 131: ...elow appears on the screen Enter the number ex 47N 1 0195 030 in the picture below on the adjustment chart White paper and click the OK button 6 The window below appears on the screen Enter the number ex 487 1 0000 000 in the picture below on the adjustment chart Mech Chart and click the OK button ...

Page 132: ...Chart and click the OK button 8 The window below appears on the screen after the countdown Set the adjustment chart White paper shown in the picture to the machine and click the OK button 9 The window below appears on the screen Set the adjustment chart Mech Chart shown in the picture so that the A comes at the bottom and click the OK button ...

Page 133: ...ck the OK button 11 The window below appears on the screen Set the adjustment chart OD Chart shown in the picture again so that the A comes at the bottom and click the OK button Same sheet as the procedure 10 Note If you set the OD Chart on the ADF right after the procedure 10 completes the screen below doesn t appear and the adjustment starts immediately ...

Page 134: ...ure again so that the A comes at the bottom and click the OK button Same sheet as the procedure 10 14 The following window appears and the machine turns OFF Click the OK button The window shown below closes Note If you set the OD Chart on the ADF right after the procedure 11 completes the screen below doesn t appear and the adjustment starts immediately Note If you set the OD Chart on the ADF righ...

Page 135: ...e machine is connected to your computer via USB cable 2 Set the test charts density chart TC 027 density chart CTC 001 and density chart TC 023 in the document feeder 3 Start the DS Capture The window below appears on the screen Click the Setup button 4 The window below appears on the screen Check the Front Color box A and uncheck the Front B W box B A B ...

Page 136: ...4 34 Confidential 5 Click the Multi Feed Detection tab C check the Ultrasonic Detection box D and click the OK button E 6 Scanning starts once you click the Scan button D C E ...

Page 137: ...dure 2 again and click the Setup button 8 Uncheck the Front Color box F check the Back Color box G and click the OK button H 9 Scanning starts once you click the Scan button 10 Check the two scanned images for color difference and image distortion F H G ...

Page 138: ...5 1 Confidential CHAPTER 5 SERVICE FUNCTIONS Service mode is not equipped with this product ...

Page 139: ...OWN_TX1_N 8 7 6 5 4 3 DOWN_INCLK_N DOWN_TXCLK_P DGND DOWN_TX2_P DGND 2 1 DGND DOWN_INCLK_P DOWN_TXCLK_N J5 11 10 9 SS_RX_M DGND DGND 8 7 6 5 4 3 SS_DP SS_TX_M DGND SS_RX_P GND_USB 2 1 VBUS30_PWR SS_DM SS_TX_P J8 6 5 4 3 2 1 BOUT2 AOUT2 DGND DGND BOUT1 AOUT1 Pick up motor J1 6 5 4 3 2 1 BOUT2 AOUT2 DGND DGND BOUT1 AOUT1 Feed motor J12 16 15 DGND 14 13 12 11 10 9 UI_LEDG LCM_CD LCM_RST LCM_CS_N 3 3V...

Page 140: ...7 1 Confidential CHAPTER 7 PERIODICAL MAINTENANCE 1 PERIODICAL MAINTENANCE PARTS There are no applicable parts for periodical maintenance ...

Page 141: ...Location Fig App 1 2 A January B February C March D April E May F June G July H August J September K October L November M December L 5 U 1 1 1 1 2 2 Serial number Serial number 6 digit Manufacturing factory No Year of manufacture 5 2015 6 2016 Month of manufacture Product identification code Serial number label ...

Page 142: ...G Installing StdL2Setup tool 1 Double click StdL2Setup exe to start it 2 The window below appears on the screen Select the language to use and click the OK button 3 The opening window below appears on the screen Click the Next button Note Install StdL2Setup exe first and then SetupAddon exe ...

Page 143: ...p 2 2 Confidential 4 The confirmation window below appears on the screen Select I accept the agreement and click the Next button 5 The information window below appears on the screen Click the Next button ...

Page 144: ...ow appears on the screen Select the destination to save the file and click the Next button 7 The window below appears on the screen Do not check the box and click the Next button if you do not want to display the program in the start menu ...

Page 145: ... The window below appears on the screen Do not check the box and click the Next button if you do not want to display the desk top icon 9 The window below appears on the screen If there is no problem click the Install button ...

Page 146: ...App 2 5 Confidential 10 Installation starts 11 The screen below appears when installing is completed If you want to start the program immediately check the box and click the Finish button to complete ...

Page 147: ...ck SetupAddon exe to start it 2 The window below appears on the screen Select the language to use and click the OK button 3 The opening window below appears on the screen Click the Next button 4 The information window below appears on the screen Click the Next button ...

Page 148: ...App 2 7 Confidential 5 The window below appears on the screen Click the Install button 6 The screen below appears when installing is completed Click the Finish button to complete ...

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Brother PDS-5000, Service Manual

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