Xerox TS 100 Service Guide

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Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Notes for Serving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SpecificationBasic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Hardware ssemblyMajor Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Basic TroubleshootingFailure Types - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Failure Types - detailed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PCB Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Mechanical Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Imaging Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Physical Damage Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Physical Damage External . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hardware Repair TipsCIS (Contact Imaging Sensor) Module. . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Motor and Gear Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

RM ssembly ProcedureTop Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Bottom Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CIS (Contact Imaging Sensor)/ Motor and Gear Module . . . . . . . . . . . . . . . . . . . . . . . . 17

PCB (Printed Circuit board). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Repaired Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ContentsIntroduction


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IntroductionThis manual is intended to be used by the maintenance/RMA technicians. It describes areas of

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 Xerox Travel Scanner 100 before serving the unit.


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General Notes for Serving

(1) Before trying to disassemble the XEROX TRAVEL SCANNER 100, make sure the USBcable of the XEROX TRAVEL SCANNER 100 is disconnected from the scanner. Serving

scanner unit while connected to a pc may damage scanner and/or computer

(2) When scanner driver and software are loaded, do not unplug the scanner and/or USB cable

from the computer. Doing so could cause a system crash. Always close the scanning

software before disconnecting XEROX TRAVEL SCANNER 100 from computer.

(3) 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.

(4) Keep the Contact Imaging Censor glass surface always clean. If contaminated, use a dry

clean cloth with isopropyl alcohol for cleaning.

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

General Description

The XEROX TRAVEL SCANNER 100 is fully USB powered. This portable scanner is capable to

scan up to 600dpi optical. Scanned size ranges from business cards to legal size

documents.

The XEROX TRAVEL SCANNER 100 sheet fed scanner has a scanning speed of 6 pages per

minute black & white and 3 pages per minute color


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SpecificationBasic Specifications

Product Name: XEROX TRAVEL SCANNER 100

Type: Sheet fed scanner, simplex

Optical Resolution: 600 dpi (optical)

Image Sensor: Linear color CMOS

Scanning Modes:48-bit color (internal),24-bit color (output),8-bit grayscale, 1-bit B&W

Scanning Speed:6ppm B&W,3ppm color

Scan Area:Business card to legal document,A4 format

Paper Thickness: 0.1mm to 0.8mm

Physical Dimension:11.7" x 2" x 1.7" (L x W x H)(296mm x 51mm x 42mm)

Weight: 12 oz. (345 grams)

Paper Sensor: Electro-Mechanical

Interface: USB 2.0 High Speed

Power Source: Fully USB powered

Power Consumption:0.2W (standby),2.0W (during scan)


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Hardware ssemblyMajor Parts

The Xerox Travel Scanner 100 consists of 4 major parts

Top housing

Bottom housing

CIS (Contact Imaging Censor) / Motor and gear module, and

PCB (Printed Circu it Board)


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Basic TroubleshootingFailure Types - General

Before servicing the Xerox Travel Scanner 100, it is important to determine the failure types and

properly categorize all failure units.

All returned scanners are assumed to be properly screened by tech support technicians before

arrival. With proper first-tire tech support, all of the returned scanners should carry a single or

multiple hardware failures. However it is possible that some RMA scanners pass pre-screening

because they carry hard to duplicate or hard to find problems. Sometimes specific computer

software settings cause the scanners to fail and are returned as RMA units even though the

scanner hardware functions properly. When returned scanners appear normal on the initial try,

service technician should instead pay extra attention to scan color, streak lines on scanned

images, scanning noises, paper skewing and etc. Make sure these scanners are calibrated and

test scanned multiple times before it is considered repaired.


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There are five general failure types:

PCB Failure

o Device Not Recognized

o System Freeze or Crash

Mechanical Failure

o Scanner Paper Jam

o Noise

o Unresponsive Paper Sensor

o Lost Gear

Imaging Failure

o Calibration Failure

o Streak Line

o Black Image

o Skewed Image

o Incorrect Coloration

Physical Damage internal

o Loose Parts

o Broken Glass

Physical damage external

o Top Housing

o Bottom Housing

While mechanical failure and external physical damage could be repaired, PCB failure, imaging

failure, and internal physical damage that are difficult to repair should be returned directly to

DCT Service Depotafter screening.


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Failure Types Detailed

In this section, the above mentioned failure types are described in detail.

PCB Failure

The first type of PCB failure is Device Not Recognized. Scanner has a permanent

problem in the PCB that cannot be easily identified and/or repaired. This type of failure

should be separately labeled and returned to DCT Service Depot.

The second type of PCB failure is System Freeze or Crash. While scanner might be

loaded property by the scanning software, the entire computer system could freeze or

crash as soon as scan is activated. This type of error can also be part of permanent PCB

failure and should be separately labeled and returned to DCT Service Depot.

Mechanical Failure

The first type of mechanical failure is that the Scanner Paper Jamand makes a loud

hum. This is usually caused by debris introduced into the scanner to prevent roller, gear,

or motor from normal operation. This type of failure is repairable and will be discussed in

the Hardware Repair Tipssection.

The second type of mechanical failure is Noise. Some scanners, after a period of use,

loses it lubricant or increases in gear friction due to small dust and/or debris that are not

large enough to stop the gear/motor from running. This type of failure is repairable and

will be discussed in the Hardware Repair Tipssection.

The third type of mechanical failure is Unresponsive Paper Sensor. An unresponsive

paper sensor can be caused by a bad paper sensor or a bad PCB. Either way will makethis difficult to repair. This failure and should be separately labeled and returned to DCT

Service Depot.


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The fourth type of mechanical failure is Lost Gear. There is a small, removable gear at

the end of the roller. It is the smallest gear disc in the whole gear set also the only

removable gear piece. Due to excessive impact or improper use, the gear disengages

from the roller and the rest of the gear set, causing the scanner to run with no buzzing

sound but does not grab paper either. This type of failure is repairable and will be

discussed in the Hardware Repair Tipssection.

Imaging Failure

The first type of imaging failure is Calibration Failure. One type of calibration failure

results in total failure. No matter how many tempts, software returns with a calibration

failed message. This type of error can be a part of permanent CIS module failure and


The second type of imaging failure is Streak Lineon image. The streaks are vertically

across the scanned image and can be in any color (black, white, or color) and with any

width (a thin line or a wide band). This type of error can either be CIS module failure or

PCB failure and should be separately labeled and returned to DCT Service Depot.

However CIS module cable connection on both ends (CIS module and PCB) should be

checked prior to returning to DCT Service Depot as this can be a result of loose

connection.

The third type of imaging failure is Black Image. The scanned image is entirely in solid

black with out any other information. Service technician should first calibrate the scanner

and attempt to scan. If black image appears, recalibrate and re-scan to see if this is

reproducible. If service technician is able to reproduce any black scan, the scanner


The fourth type of imaging failure is Skewed Image. One side of the scan target move

faster than the other side to cause an image distortion to scan results. This type of

failure is repairable and will be discussed in the Hardware Repair Tipssection.


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The fifth type of imaging failure is Incorrect Coloration. Typical examples are the entire

scan has too much yellow, green, blue, or purple in it. No matter how many successful

calibrations is performed, the same problem remains. This type of error can either be

CIS module failure or PCB failure and should be separately labeled and returned to DCT

Service Depot.

Physical Damage internal

The first type of internal damage is Loose Parts. Loose parts can be the roller, broken

housing for the CIS module, springs or gear disc; it can also be a motor that broke into

multiple pieces inside the scanner. As long as they are replaceable, these should be

repaired. For anything else that is not replaceable or repairable, the scanner should be

separately labeled and returned to DCT Service Depot.

The second type of internal damage is Broken Glass. If glass is scattered inside the

scanner, stop repairing immediately and carefully warp the scanner with PVC bag or

tape, separately label the scanner and return it to DCT Service Depot. If the CIS has a

crack on the glass but the glass is still intact to the CIS module and spare parts are

available, then the CIS module should be swapped and repaired. Make sure to wear

proper eye protection when repairing scanners with broken parts,

Physical damage external

The first type of external damage is Top Housing. In case of a broken top housing and

spare parts are available, the top housing should be replaced. If replacement is not

available, separately label the scanner and return it to DCT Service Depot.

The second type of external damage is Bottom Housing. In case of a broken bottom

housing and spare parts are available, the bottom housing should be replaced. If

replacement is not available, separately label the scanner and return it to DCT Service

Depot.


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Hardware Repair Tips

CIS (Contact Imaging Censor) / Motor and gear module, and PCB (Printed Circuit Board) are

the main electronic components of Xerox Travel Scanner 100. This is the area where most

repairs will be performed.

CIS (Contact Imaging Censor) Module

The CIS Module is held against the rubber roller. Scan targets passes through the gap

between the rubber roller and the glass surface of the CIS module.

The tension springs play an important role of the contact force between the rubber roller

and the glass surface of the CIS module. A bad scan such as a Skewed Image or other

bad scans can occur if spring tension is not adjusted correctly:

1. When both springs are too tight, it will be more difficult for scan targets to pass

through, therefore causing scanning failure

2. When both springs are too loose, the scanner will not be able to grab on to the

scan target, therefore causing feed failure

3. When spring tension are unequal, the scanner might feed scan targets through,

however the scan targets are likely to warp during scan activity, causing askewed image.

4. Due to excessive impact or improper use, the springs completely disengaged,

causing the scanner to lose its ability to grab onto any scan target.


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When servicing scanners with feeding problems, this could be one of the areas to adjust.

Skewed Imagecan be resolved with equal tension on both springs.

The CIS Module transmits data to the PCB (Printed Circuit Board) via CIS Data Cable. A

common imaging failure could be caused by loose connected CIS Data Cable to either

the CIS module or the PCB. Replacing CIS Data Cable could also solve image related

failure.


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Motor and Gear ModuleMotor and gear module is the most important mechanical part of the scanner. Motor

causes the rubber roller to rotate through the gear set. Motor and gear module failure

usually consist more than 50% of total RMA returns. The motor has a cables attach to it,

where the end connects directly to the PCB via a plastic white/blue connector at the

cable end.

Motor and Gear Set

Motor Connector


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Some common reported problems with the motor and gear module are

o Scanner Paper Jam- Motor remains stationary when scanning, scanner refuses

to take paper, making loud humming noise, solutions are:

Remove debris caught between gear tooth, or

Replace gear set, or

Replace motor unit

o Periodical RattleNoise- Noise introduced during scan activity that is repeated

with patterns. This is usually caused by the gear set. Try to lubricate the gear set

and/or motor should solve the issue. Replace gear set and/or motor unit if

lubrication does not improve in noise reduction.

Images below illustrate the location to apply to the gear set and motor unit for the

purpose of noise reduction. Apply a small amount of 774L Lubrication Greaseto

each of the four gear contact point.

Make sure the scanner is in running mode when applying 774L Lubrication

Greaseas this will help the grease to evenly distribute.


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o Sometimes scanning Noisecan be continuous. When this occurs, make sure

the gear unit is properly lubricated.

o Apply adequate amount (one tiny drop at each end of the motor axle) of DC

Motor Oilto reduce motor Noise. Replace motor unit if DC Motor Oilfails to

reducing noise during scans.

o In case Lost Gear, motor and gear runs smoothly without buzzing sound but the

roller fails to rotate and grab paper. The gear piece can be replaced to the end of

the roller. Match the half-circle pattern on the gear piece and the roller tip. After

gear piece is restored, apply a small amount of 774L Lubrication Grease to the

gear piece to reduce noise.


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RM ssembly ProcedureThis section illustrates where each part is located in the scanner unit as well as the screws,

springs, connectors and any detachable parts.

Top housing

When replacing top housing, be careful not to damage the paper sensor. Do not yank

the wires when disassembling. Pry the paper sensor off carefully with tweezers.

To install the paper sensor: Hold the paper sensor in the correct direction and push it

back to the holder until clicking sounds are heard.

Bottom housing

There are four screws attached to each corner of the bottom housing. The electric screw

driver should be set to no more than 2-lbs of torque to prevent damaging the housing

thread.


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CIS (Contact Imaging Censor) / Motor and gear module

There are a total of five screws, motor connector wire, CIS module cable, and push

button. Make sure no cables are exposed outside the scanner housing before capping

the top housing back. Perform at least one calibration and one scan to ensure all

connections are installed and no wires and cables are in the paper feeding path.

PCB (Printed Circuit Board)

PCB is fixed on to the bottom housing by three short screws. The large spring is to hold

the CIS module in place. Notice that the USB cable stopper is directional.


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Repaired Scanner

Carefully wipe off the grease and dirt off the scanner housing with soft cloth and 70%

Isopropyl alcohol. Apply QC sticker over the top left screw hole. Cover and tape the

scanner inside a PVC bag.

Xerox TS 100 Service Guide

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