Travel Scanner 100

Service Manual Version 1.0

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Notes for Serving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specification
Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Hardware Assembly
Major Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Basic Troubleshooting
Failure Types - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Failure Types - detailed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PCB Fai l ure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Imaging Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical Damage Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Physical Damage External . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hardware Repair Tips
CIS (Contact Imaging Sensor) Module. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Motor and Gear Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

RMA Assembly Procedure
Top Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bottom Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CIS (Contact Imaging Sensor)/ Motor and Gear Module . . . . . . . . . . . . . . . . . . . . . . . . 17
PCB (Printed Circuit board). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repaired Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Contents
Introduction


2
Introduction
This 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 USB
cable 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







4
Specification
Basic 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 Assembly
Major 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 Circuit Board)






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Basic Troubleshooting
Failure 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 Depot after 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 Jam and 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 Tips section.

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 Tips section.

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 make
this 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 Tips section.

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
should be separately labeled and returned to DCT Service Depot.

The second type of imaging failure is Streak Line on 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
should be separately labeled and returned to DCT Service Depot.

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 Tips section.



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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 a
skewed 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 Image can 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 Module
Motor 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 Rattle Noise - 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 Grease to
each of the four gear contact point.

Make sure the scanner is in running mode when applying 774L Lubrication
Grease as this will help the grease to evenly distribute.



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o Sometimes scanning Noise can 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 Oil to reduce motor Noise. Replace motor unit if DC Motor Oil fails 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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RMA Assembly Procedure

This 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.