Brother PDS-5000 User manual

Confidential
Read 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

Confidential
© Copyright Brother 2015
All rights reserved.
No part of this publication 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.

Confidential
TRADEMARKS
BROTHER is either a trademark or a registered trademark of Brother Industries, Ltd.
Microsoft, Windows, Windows Vista, Windows Server, Outlook and Internet Explorer are either
registered trademarks or trademarks of Microsoft Corporation in the United States and/or other
countries.
Apple, Macintosh, Mac OS and Safari are trademarks of Apple Inc., registered in the United States and
other countries.
Nuance, the Nuance logo, PaperPort and ScanSoft are trademarks or registered trademarks of Nuance
Communications, Inc. or its affiliates in the United States and/or other countries.
PowerPC is a registered trademark of IBM in the United States and/or other countries.
AOSS is a trademark of Buffalo Inc.
WPA, WPA2, Wi-Fi Protected Access and Wi-Fi Protected Setup are marks of the Wi-Fi Alliance.
Wi-Fi and Wi-Fi Alliance are registered marks of the Wi-Fi Alliance.
AMD is a trademark of Advanced 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 trademarks or trademarks of Adobe Systems
Incorporated in the United States and/or other countries.
Each company whose software title is mentioned in this manual has a Software License Agreement
specific to its proprietary programs.
Any trade names and product names of companies appearing on Brother products, related
documents and any other materials are all trademarks or registered trademarks of those
respective companies.
Copyright and License
© 2015 Brother Industries, Ltd. All rights reserved.
This product includes software developed by the following vendors:
© 1983-1998 PACIFIC SOFTWORKS, INC.
© 2008 Devicescape Software, Inc.
This product includes the “KASAGO TCP/IP” software developed by ZUKEN ELMIC,Inc.

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CONTENTS
SAFETY INFORMATION
CHAPTER 1 SPECIFICATIONS LIST
1. GENERAL ................................................................................................................................... 1-1
2. NETWORK CONNECTIVITY ....................................................................................................... 1-3
3. SERVICE INFORMATION ........................................................................................................... 1-3
4. PAPER ........................................................................................................................................ 1-4
4.1 Paper Handling ................................................................................................................... 1-4
4.2 Media Specifications ........................................................................................................... 1-4
5. SCANNER ................................................................................................................................... 1-5
CHAPTER 2 ERROR INDICATIONS & TROUBLESHOOTING
1. INTRODUCTION ......................................................................................................................... 2-1
1.1 Precautions ......................................................................................................................... 2-1
1.2 Checks before Commencing Troubleshooting .................................................................... 2-2
2. OVERVIEW ................................................................................................................................. 2-3
2.1 Cross-section Drawing ........................................................................................................ 2-3
2.2 Document Feed Path .......................................................................................................... 2-4
2.3 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
4.3.2 Troubleshooting according to image defect ......................................................... 2-18
4.4 Troubleshooting for Software Problems ........................................................................... 2-22
4.4.1 Cannot receive data ............................................................................................. 2-22
4.5 Troubleshooting for Control Panel Problems .................................................................... 2-23
4.5.1 Nothing is displayed on the LCD .......................................................................... 2-23

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4.5.2 Control panel is inoperable ................................................................................... 2-23
4.6 Troubleshooting for Other Problems ................................................................................. 2-24
4.6.1 Cannot update firmware ....................................................................................... 2-24
4.6.2 Machine is not turned ON ..................................................................................... 2-24
CHAPTER 3 DISASSEMBLY/REASSEMBLY
1. SAFETY PRECAUTIONS ............................................................................................................ 3-1
2. PACKING .................................................................................................................................... 3-2
3. SCREW CATALOGUE ................................................................................................................ 3-3
4. SCREW TORQUE LIST .............................................................................................................. 3-4
5. LUBRICATION ............................................................................................................................ 3-5
6. OVERVIEW OF GEARS .............................................................................................................. 3-6
7. HARNESS ROUTING .................................................................................................................. 3-7
8. DISASSEMBLY FLOW CHART ................................................................................................ 3-12
9. DISASSEMBLY PROCEDURE ................................................................................................. 3-13
9.1 Preparation ....................................................................................................................... 3-13
9.2
Paper feed roller kit (Reverse roller ASSY / Pick-up roller ASSY / Separation roller ASSY) ... 3-14
9.3 Reverse roller cover ASSY ............................................................................................... 3-16
9.4 Pick-up roller cover ........................................................................................................... 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 roller gear ASSY ................................................................................................. 3-33
9.16 ADF cover hook ................................................................................................................ 3-34
9.17 Cover release lever ........................................................................................................... 3-35
9.18 ADF cover sensor PCB / Sensor PCB flat cable .............................................................. 3-36
9.19 Paper detection sensor ..................................................................................................... 3-38
9.20 Second side CCD unit / Second side CCD flat cable ....................................................... 3-39
9.21 Multi-feed sensor PCB (Transmit) /
Multi-feed sensor PCB flat cable (Transmit) ..................................................................... 3-43
9.22 Main PCB shield ............................................................................................................... 3-46
9.23 Feed drive belt S / Feed drive belt / Feed motor .............................................................. 3-47

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9.24 First side CCD glass ......................................................................................................... 3-48
9.25 Feed roller ASSY / Exit roller ASSY ................................................................................. 3-49
9.26 Pick-up drive belt / Pick-up motor ..................................................................................... 3-50
9.27 First side LED light PCB ASSY ......................................................................................... 3-51
9.28 First side CCD unit / First side CCD flat cable .................................................................. 3-52
9.29 Multi-feed sensor PCB (Receive) /
Multi-feed sensor PCB flat cable (Receive) ...................................................................... 3-55
CHAPTER 4 ADJUSTING AND UPDATING SETTINGS
AS REQUIRED AFTER PARTS REPLACEMENT
1. IF YOU REPLACE THE MAIN PCB ASSY ................................................................................. 4-1
1.1 Installing Firmware (Sub Firmware, Panel Firmware, and Main Firmware) ........................ 4-3
1.1.1 Checking firmware 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 Adjustment (Optical Density Learning) ....................................................................... 4-28
3.2 Checking Operation after Repair ...................................................................................... 4-33
CHAPTER 5 SERVICE FUNCTIONS
CHAPTER 6 WIRING DIAGRAM
1. WIRING DIAGRAM ..................................................................................................................... 6-1
CHAPTER 7 PERIODICAL MAINTENANCE
1. PERIODICAL MAINTENANCE PARTS ...................................................................................... 7-1
APPENDIX 1 SERIAL NUMBERING SYSTEM
APPENDIX 2 INSTALLING ADJUSTMENT TOOLS
(OD LEARNING AND DOUBLE FEEDING)

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SAFETY INFORMATION
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injuries.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injuries.
Important
Important indicates a potentially hazardous situation 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 features.
This icon indicates that flammable sprays may not be used.
This icon indicates that organic solvents such as alcohol and liquids may not be used.

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To use the Machine Safely
Please keep these instructions for later reference and read them before attempting any
maintenance. If you do not follow these safety instructions, there is a possibility of a fire,
electrical shock, burn or suffocation.
WARNING
DO NOT expose the machine to direct sunlight, excessive heat, open flames,
corrosive gasses, moisture or dust.
DO NOT place your machine on a carpet or rug, as this will expose it to dust. Doing
so may create a risk of an electrical short or fire. It may also damage the machine
and/or render it inoperable.
DO NOT place the machine near heaters, air conditioners, electric fans, refrigerators,
radiators, or water. Doing so may create the risk of a electrical short or fire should
water come into contact with the machine (including condensation from heating, air
conditioning, and/or ventilation equipment that may be sufficient to create a electrical
shock, short circuit or fire).
DO NOT place the machine near chemicals or in a place where chemicals could be
spilled on it. Should chemicals come into contact 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 into contact with any wall or other
device. Otherwise, it could create a risk of overheating and/or fire.
Instead:
• Place the machine on a solid surface, never on a bed, sofa, rug, or other similar soft
surface.
• Do not place this machine in a “built-in” installation unless adequate ventilation is
provided.
CAUTION
Avoid placing your machine in a high-traffic area. If you must place it in a high-traffic
area, ensure that the machine is in a safe location where it cannot be accidentally
knocked-over, which could cause injury to you or others and serious damage to the
machine.
Ensure that cables and cords leading to the machine are secured so as not to pose a
tripping hazard.
DO NOT place this machine on an unstable or tilted cart, stand, table or on any tilted/
slanted surface. The machine is heavy and may fall, causing injury to you and serious
damage to the machine.

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Make sure that no part of the machine protrudes from the desk or stand where the
machine is located. In particular, do not leave the output tray open and extended
beyond the edge of a cabinet, table or stand when the machine is located on the edge
of a cabinet, table, stand, etc. As previously cautioned, make sure that the machine is
located on a flat, level, and stable surface free from vibration. Failure to observe these
precautions could cause the machine to fall, causing injury to you or others and
serious damage to the machine.
Important
• DO NOT place your machine next to sources of interference, such as speakers or
the base units of non-Brother cordless telephones. Doing so may interfere with the
operation of the machine's electronic components.
• DO NOT connect your machine to an AC power outlet controlled by wall switches or
automatic timers. Disruption of power can delete information from the machine's
memory, and repeated cycling of the power can damage the machine.
• Always open the paper tray and output tray fully. Failure to do so 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 sure you
have unplugged the power cord from the AC power outlet.
DO NOT push objects of any kind into the machine through slots or openings in the
casing, as they may touch dangerous voltage points or short out parts.
DO NOT continue using the machine if it has been dropped or the cabinet has been
damaged. Instead, unplug the machine from the power outlet and contact Brother
Authorized Service Personnel.
The machine should be connected to an AC power source within the range indicated
on the rating label. DO NOT connect it to a DC power source or inverter. Doing this
might cause an electrical shock. If you are not sure what kind of power source you
have, contact a qualified electrician.
If water, other liquids, or metal objects get inside the machine, immediately unplug the
machine from the AC power outlet and contact Brother Authorized Service Personnel.

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Power Cord Safety:
• Use only the power cord supplied with this product.
• DO NOT allow anything to rest on the power cord.
• DO NOT place the machine where people can walk on the cord.
• DO NOT place the machine in a position where the cord is stretched or strain is
otherwise put on the cord, as it may become worn or frayed.
• DO NOT use the machine or handle the cord if the cord has become worn or frayed.
If unplugging the machine, DO NOT touch the damaged/frayed part.
• Brother strongly recommends that you DO NOT use any type of extension cord.
AC Adapter Safety
Only use the supplied AC adapter with the unit. Only plug the AC adapter into a power
outlet with voltage that is within the range indicated on Specifications in the User's
Guide. Failure to do so may result in injury to yourself or others, or damage to the
machine or other property. Brother does not assume any responsibility 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 adapter is plugged
in. There may be a remote risk of electric shock from lightning when the machine is
used during a thunderstorm.
When disconnecting the AC adapter from the machine or from the power outlet,
always hold the connector, not the cable, and pull firmly. Failure to do so may result in
exposed or broken power cord wires and/or create a risk of fire, or electric shock.
Make sure that one end of the power cord is firmly plugged into a standard power
outlet and the other end is firmly plugged into the adapter block. Do not use an outlet
that is loose. If the power cord is not completely plugged into the power outlet and
adapter block, the adapter may become hot and/or catch fire.