Contex COUGAR 36 Operating manual

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Technical Service Manual
COUGAR 25 and COUGAR 36
CHAMELEON 25 and CHAMELEON 36
CHAMELEON PREMIER 36
CHROMA Tx 40 and CRYSTAL Tx 40
COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER Tx
COUGAR Sx 25 and CHAMELEON Sx 25
CHROMA XL 42 and CRYSTAL XL 42
MAGNUM XL 54
FSG/TSM/001 (2.4)
Part Number 6799D129

1 DOCUMENT REVISION RECORD
2 LIST OF DOCUMENTS
3
FSG MAINTENANCE MANUAL
COUGAR 25 and COUGAR 36
CHAMELEON 25 and CHAMELEON 36
CHAMELEON PREMIER 36
CHROMA Tx 40 and CRYSTAL Tx 40
MAGNUM XL 54
COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER Tx 36
4 Addendum to FSG/MTM/001
CHROMA XL 42, CRYSTAL XL 42
COUGAR Sx 25, CAMELEON Sx 2
5
6
7
8
9
SPARE PARTS AND SERVICE ACCESSORIES
COUGAR 25, COUGAR 36, CHAMELEON 25,
CHAMELEON 36, CHAMELEON PREMIER 36
CHROMA Tx 40, CRYSTAL Tx 40
COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36
MAGNUM XL 54
COUGAR Sx 25, CHAMELEON Sx 25
CHROMA XL 42, CRYSTAL XL 42
10 TECHNICAL SERVICE BULLETINS

FSG/TSM/001
Document Revision Record DRR
REV. DATE
CHANGED
BY PAGES
AFFECTED BRIEF DESCRIPTION OF CHANGE
1.0 010919 BN/LM All Original issue of document
1.0a 010927 LM FSG/MTM/001 p.67, Fig. 4-8 corrected
2.0 020808 BN/LM All CHAMELEON PREMIER 36
CHROMA Tx 40, CRYSTAL Tx 40
added
2.0a 021030 LM FSG/MTM/001 p.72, Fig. 4-10 updated
2.1 030507 BN/LM All COUGAR Tx 36, CHAMELEON Tx 36,
PREMIER Tx 36 added
2.2 031031 BN/LM All MAGNUM XL 54 added
2.2a 040107 LM p.4 List of Documents updated
FSG/MTM/001 rev. 2.0 to 2.0a
FSG/TSB/001 Added
2.2b 040427 LM p.4 List of Documents updated
FSG/MTM/001 rev. 2.0a to 2.0b
FSG/TSB/002 Added
2.3 040706 LM FSG/MTM/002 Added (Addendum with Sx 25 and XL 42)
SOG/PLS/013 New spare part list (Sx 25 and XL 42
added)
2.3a 050614 LM FSG/TSB/003 Added
2.4 060511 LM All FSG/MTM/001 (2.3)
FSG/MTM/002 (1.1)
SOG/PLS/013 (1.8)
FSG/TSB/004 added

FSG/TSM/001 060511
List of Documents:
FSG/MTM/001 (2.3) FSG Maintenance Manual
COUGAR 25 and COUGAR 36
CHAMELEON 25 and CHAMELEON 36
CHAMELEON PREMIER 36
CHROMA Tx 40 and CRYSTAL Tx 40
MAGNUM XL 54
COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER Tx 36
FSG/MTM/002 (1.1) Addendum to FSG/MTM/001
CHROMA XL 42, CRYSTAL XL 42
COUGAR Sx 25, CAMELEON Sx 2
SOG/PLS/013 (1.8) Spare Part and Service Accessories
COUGAR 25, COUGAR 36, CHAMELEON 25,
CHAMELEON 36, CHAMELEON PREMIER 36
CHROMA Tx 40, CRYSTAL Tx 40
COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36
MAGNUM XL 54
COUGAR Sx 25, CHAMELEON Sx 25
FSG/TSB/001 (1.0) Camera Alignment (Camera Motor Drive Belt)
FSG/TSB/002 (1.0) Lamp Driver Adjustment
FSG/TSB/003 (1.0) ATAC Calibration on XL 42
FSG/TSB/004 (1.0) Camera Spare Part Board 6735D001R01

TITLE: FSG MAINTENANCE MANUAL
COUGAR 25 and COUGAR 36
CHAMELEON 25 and CHAMELEON 36
CHAMELEON PREMIER 36
CHROMA Tx 40 and CRYSTAL Tx 40
MAGNUM XL 54
COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER Tx 36
DOC. NO.: FSG/MTM/001
PREPARED BY: BN/LM
AUTHORIZED: JR
DISTRIBUTION: Tegningsarkiv, Svendborg (1)
PT, Svendborg (1)
DD (1)
ISSUE REVISION: 2.3
DATE: 2006-05-11
This document is the property of Contex A/S. The data contained herein, in whole or in part,
may not be duplicated, used or disclosed outside the Recipient for any purpose other than to
conduct technical evaluation. This restriction does not limit the Recipients right to use
information contained in the data if it is obtained from another source without restriction.

FSG/MTM/001
2
Document Revision Record DRR
REV. DATE
CHANGED
BY PAGES
AFFECTED BRIEF DESCRIPTION OF CHANGE
1.0 010919 BN/LM All Original issue of document
010927 LM p. 67 Fig. 4-8 corrected
2.0 020808 BN/LM All CHAMELEON PREMIER 36
CHROMA Tx 40, CRYSTAL Tx 40 added
Manual restructured.
2.1 030507 BN/LM All COUGAR Tx 36, CHAMELEON Tx 36,
PREMIER Tx 36 added
2.2 031031 BN/LM All MAGNUM XL 54 added
2.2a 040107 LM p.31 1st line: TP4/TP5 to TP7 and P1/P2 to P2
p.33 Fig. 3-3: Voltages for TP3/4/5 added
2.2b 040427 LM p.29 Fig. 3.1, CN2, pin2: -12V til +12V
p.30-32 Lamp Driver adjustment changed
2.3 060511 LM All Fig. 3-2, LME: J10 pin 5: Tolerances corrected
3.4.3: Added that LED3 might be off when lamp
has been replaced
Fig. 3-4, CBE: C32, right: Tolerances corrected
Fig. 3-14, SKD: SW1 and SW8 interchanged
3.16, Adj. of Original Sensors: Description updated
54” Scan-Width (page 99) corrected
New error codes added (70-219, 70-221, 08-220,
10-159
Replacing Guide Plate Gas Spring added
Description of Test 30 added

FSG/MTM/001 060511
3
Table of Contents
1. Introduction...........................................................................................................................................10
2. General Description..............................................................................................................................11
2.1 COUGAR 25 AND CHAMELEON 25..................................................................................................... 11
2.2 COUGAR 36, CHAMELEON 36 AND CHAMELEON PREMIER 36................................................... 12
2.2.1 COUGAR 36 and CHAMELEON 36..................................................................................................12
2.2.2 CHAMELEON PREMIER 36............................................................................................................. 13
2.3 CHROMA TX 40 AND CRYSTAL TX 40................................................................................................ 13
2.4 MAGNUM XL 54................................................................................................................................... 15
2.5 COUGAR TX 36, CHAMELEON TX 36, PREMIER TX 36................................................................... 16
3. Electrical Check and Adjustments......................................................................................................25
3.1 MARKING CODES FOR CIRCUIT BOARDS AND PROGRAMMED DEVICES.................................................... 25
3.2 DOWNLOADING SCANNER FIRMWARE ..................................................................................................... 26
3.2.1 Erase and Restore Parameter Blocks................................................................................................. 26
3.3 CHECK AND ADJUSTMENT OF THE SWITCH MODE POWER SUPPLY,SMPS .............................................. 27
3.3.1 AC Voltages........................................................................................................................................ 27
3.3.2 DC Voltages ....................................................................................................................................... 27
3.3.3 Adjustments ........................................................................................................................................ 27
3.3.4 Fuses .................................................................................................................................................. 27
3.3.5 Markings ............................................................................................................................................ 27
3.3.6 Jumper Settings.................................................................................................................................. 27
3.3.7 Hints................................................................................................................................................... 28
3.4 CHECK AND ADJUSTMENT OF LAMP AND MOTOR DRIVER BOARD,LME ................................................ 30
3.4.1 DC Voltages ....................................................................................................................................... 30
3.4.2 Lamp-Driver Adjustment.................................................................................................................... 30
3.4.3 Signal LEDs on the LME-Board ........................................................................................................ 31
3.4.4 Stepper Motor Reference Voltages..................................................................................................... 31
3.4.5 Functional Test................................................................................................................................... 31
3.4.6 Fuses .................................................................................................................................................. 32
3.4.7 Markings ............................................................................................................................................ 32
3.4.8 Jumper Settings.................................................................................................................................. 32
3.4.9 Hints................................................................................................................................................... 32
3.5 CHECK AND ADJUSTMENT OF CAMERA BOARD,CBE (NON TX AND XL MODELS)................................... 35
3.5.1 DC Voltages ....................................................................................................................................... 35
3.5.2 Adjustments ........................................................................................................................................ 35
3.5.3 Functional Test................................................................................................................................... 35
3.5.4 Markings ............................................................................................................................................ 35
3.5.5 Jumper Settings.................................................................................................................................. 35
3.5.6 Hints................................................................................................................................................... 35
3.6 CHECK AND ADJUSTMENT OF CAMERA BOARD,CBF (TX AND XL MODELS) .......................................... 39
3.6.1 DC Voltages ....................................................................................................................................... 39
3.6.2 Adjustments ........................................................................................................................................ 39
3.6.3 Functional Test................................................................................................................................... 39
3.6.4 Markings ............................................................................................................................................ 39
3.6.5 Jumper Settings.................................................................................................................................. 39
3.6.6 Hints................................................................................................................................................... 39
3.7 CHECK OF CONTROLLER BOARD,SUC.................................................................................................... 43
3.7.1 DC Voltages ....................................................................................................................................... 43
3.7.2 Adjustments ........................................................................................................................................ 43
3.7.3 Functional Test................................................................................................................................... 43
3.7.4 Markings ............................................................................................................................................ 43
3.7.5 Switch Settings (Download Control Switches)................................................................................... 43
3.7.6 Jumper Settings.................................................................................................................................. 44
3.7.7 Signal LEDs on the SUC-Board......................................................................................................... 44
3.7.8 Hints................................................................................................................................................... 44
3.8 CHECK OF INTERFACE MODULE,IMB (NON TX AND XL MODELS) .......................................................... 47

FSG/MTM/001 060511
4
3.8.1 DC Voltages ....................................................................................................................................... 47
3.8.2 Adjustments ........................................................................................................................................ 47
3.8.3 Functional Test................................................................................................................................... 47
3.8.4 Markings ............................................................................................................................................ 47
3.8.5 Jumper Settings.................................................................................................................................. 47
3.8.6 Hints................................................................................................................................................... 48
3.9 CHECK OF INTERFACE MODULE,IMD (TX AND XL MODELS).................................................................. 51
3.9.1 DC Voltages ....................................................................................................................................... 51
3.9.2 Adjustments ........................................................................................................................................ 51
3.9.3 Functional Test................................................................................................................................... 51
3.9.4 Markings ............................................................................................................................................ 51
3.9.5 Jumper Settings.................................................................................................................................. 51
3.9.6 Hints................................................................................................................................................... 51
3.10 CHECK OF OPERATOR PANEL,SKD......................................................................................................... 54
3.10.1 DC Voltages ....................................................................................................................................... 54
3.10.2 Functional Test................................................................................................................................... 54
3.10.3 Markings ............................................................................................................................................ 54
3.10.4 Switch Setting (Scanner ID)............................................................................................................... 54
3.11 CHECK OF SMART CARD READER,SCR................................................................................................... 60
3.11.1 DC Voltages ....................................................................................................................................... 60
3.11.2 Functional Test................................................................................................................................... 60
3.11.3 Markings ............................................................................................................................................ 60
3.11.4 DIP Switch Setting ............................................................................................................................. 60
3.11.5 Signal LED on the SCR-Board........................................................................................................... 61
3.12 CHECK OF LAMP SENSOR BOARD,OSB................................................................................................... 64
3.12.1 Functional Test................................................................................................................................... 64
3.12.2 Markings ............................................................................................................................................ 64
3.13 CHECK OF OPTOINTERRUPTER BOARD,OIBA ......................................................................................... 64
3.13.1 Functional Test................................................................................................................................... 64
3.13.2 Markings ............................................................................................................................................ 64
3.14 CHECK OF ATAC MOTOR DRIVER BOARD,MDA................................................................................... 66
3.14.1 DC Voltages ....................................................................................................................................... 66
3.14.2 Adjustments ........................................................................................................................................ 66
3.14.3 Functional Test................................................................................................................................... 66
3.14.4 Markings ............................................................................................................................................ 66
3.14.5 Jumper Settings.................................................................................................................................. 66
3.14.6 Hints................................................................................................................................................... 66
3.15 CHECK AND ADJUSTMENT OF ORIGINAL GUIDE SENSORS (ATAC) ......................................................... 69
3.15.1 Adjustment of Roller Sensor............................................................................................................... 69
3.15.2 Adjustment of Top Position Sensor .................................................................................................... 69
3.15.3 Check of ATAC Position Sensors ....................................................................................................... 70
3.16 ADJUSTMENT OF ORIGINAL SENSORS ...................................................................................................... 76
3.16.1 Adjustment of Switch Point ................................................................................................................ 76
3.16.2 Functional Test................................................................................................................................... 76
3.16.3 Hints................................................................................................................................................... 76
3.17 CHECK OF MEDIA THICKNESS DETECTOR (NOT APPLICABLE TO MAGNUM XL 54)............................... 78
3.17.1 Functional Test................................................................................................................................... 78
4. CCD-Cameras.......................................................................................................................................79
4.1 DESCRIPTION OF CCD-CAMERAS ............................................................................................................ 79
4.2 CCD-CAMERA CHECK AND ADJUSTMENT............................................................................................... 86
4.2.1 Check of Light Profiles....................................................................................................................... 87
4.2.2 Hints................................................................................................................................................... 88
4.2.3 Camera Adjustment Wizard ............................................................................................................... 94
4.2.4 Check and Adjustment of Focus......................................................................................................... 94
4.2.5 Check and Adjustment of Scan-Width................................................................................................ 99
4.2.6 Check and Adjustment of CCD-Centering ....................................................................................... 109
4.2.7 Check and Adjustment of Vertical Positioning................................................................................. 110
4.2.8 Final Check...................................................................................................................................... 113

FSG/MTM/001 060511
5
5. Vertical Alignment and Horizontal Stitching...................................................................................130
5.1 PRINCIPLE OF STITCHING ....................................................................................................................... 130
5.2 VERTICAL ALIGNMENT AND HORIZONTAL STITCHING PROCEDURE....................................................... 133
6. General Maintenance..........................................................................................................................141
6.1 STEP BY STEP PROCEDURE FOR GENERAL MAINTENANCE..................................................................... 141
6.1.1 Remove Top Cover........................................................................................................................... 141
6.1.2 Cleaning of the Scanning Area......................................................................................................... 141
6.1.3 Fluorescent Lamp............................................................................................................................. 141
6.1.4 Check Lamp Driver Adjustment....................................................................................................... 141
6.1.5 Check CCD-Camera Adjustment...................................................................................................... 142
6.1.6 Replace Top Cover........................................................................................................................... 142
6.1.7 Run Scanner Maintenance ............................................................................................................... 142
7. Troubleshooting ..................................................................................................................................146
7.1 POWER-ON SELF-TEST .......................................................................................................................... 146
7.2 LED INDICATORS ON OPERATOR PANEL................................................................................................ 147
7.3 ERROR CODES........................................................................................................................................ 147
7.3.1 Error Codes displayed on the Operator Panel ................................................................................147
7.3.2 Error Codes displayed on the PC Screen......................................................................................... 148
7.4 TROUBLESHOOTING HINTS..................................................................................................................... 152
8. Disassembly and Assembly.................................................................................................................156
8.1 TOP COVER WITH FRONT PROFILE ......................................................................................................... 156
8.2 END COVERS.......................................................................................................................................... 156
8.3 REAR COVER ......................................................................................................................................... 156
8.4 BOTTOM PLATE...................................................................................................................................... 156
8.5 TOP PROFILE (LID)................................................................................................................................. 157
8.6 ORIGINAL GUIDE PLATE WITH ATAC.................................................................................................... 157
8.7 GLASS PLATE......................................................................................................................................... 157
8.8 ENTRY ROLLER SHIELD ......................................................................................................................... 157
8.9 EXIT ROLLER SHIELD............................................................................................................................. 158
8.10 MIRROR CHASSIS................................................................................................................................... 159
8.11 REFLECTOR ASSEMBLY.......................................................................................................................... 159
9. Replacement of Parts..........................................................................................................................161
9.1 FEED ROLLER SHAFT ............................................................................................................................. 161
9.2 ORIGINAL SENSOR ACTUATORS............................................................................................................. 162
9.3 STITCHING WIRE.................................................................................................................................... 162
9.4 FLUORESCENT LAMP.............................................................................................................................. 162
9.5 STEPPER MOTOR.................................................................................................................................... 163
9.6 CAMERA MOTOR ................................................................................................................................... 163
9.7 CAMERA BOARD,CBE/CBF.................................................................................................................. 164
9.8 LAMP SENSOR BOARD,OSB.................................................................................................................. 164
9.9 INTERFACE BOARDS,IMB AND IMD..................................................................................................... 165
9.10 DUST FILTER ON FAN............................................................................................................................. 165
9.11 WHITE BACKGROUND PLATE................................................................................................................. 165
9.12 SLIDER FOR MEDIA THICKNESS ADJUSTMENT ....................................................................................... 166
9.13 ELEVATION MOTOR (ATAC)................................................................................................................. 166
9.14 ORIGINAL GUIDE SENSORS (ATAC)...................................................................................................... 166
9.15 GAS SPRING FOR GUIDE PLATE.............................................................................................................. 167
10. SCANtest 6...........................................................................................................................................171
10.1 DESCRIPTION OF SCANTEST 6............................................................................................................... 172
10.1.1 Test 1, Scanner Information............................................................................................................ 172
10.1.2 Test 2, LED Test.............................................................................................................................. 172
10.1.3 Test 3, Key Test ............................................................................................................................... 172
10.1.4 Test 4, Original-Sensor Test............................................................................................................ 172
10.1.5 Test 5, Lamp Test ............................................................................................................................ 173
10.1.6 Test 6, Motor Test............................................................................................................................ 173
10.1.7 Test 7, Complete Hardware Test..................................................................................................... 173
10.1.8 Test 9, Camera Adjustment ............................................................................................................. 173

FSG/MTM/001 060511
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10.1.9 Test 11, Stitching and Vertical Alignment....................................................................................... 173
10.1.10 Test 12, Adjustment of Y-Axis Scaling............................................................................................. 174
10.1.11 Test 13, Switch Scanner to Test Mode............................................................................................. 174
10.1.12 Test 20, Noise Test .......................................................................................................................... 174
10.1.13 Test 21, SCANdump ........................................................................................................................ 177
10.1.14 Test 27, Camera Adjustment Wizard............................................................................................... 177
10.1.15 Test 28, Original Guide Sensor Test............................................................................................... 177
10.1.16 Test 30, Calibrate ATAC.................................................................................................................. 177
11. Wiring Diagrams.................................................................................................................................178
12. Special Service Tools...........................................................................................................................193

FSG/MTM/001 060511
7
List of Figures
Fig. 2-1 COUGAR 25 Block Diagram............................................................................................................... 18
Fig. 2-2 CHAMELEON 25 Block Diagram....................................................................................................... 19
Fig. 2-3 COUGAR 36 Block Diagram............................................................................................................... 20
Fig. 2-4 CHAMELEON 36 and CHAMELEON PREMIER 36 Block Diagram............................................... 21
Fig. 2-5 CHROMA Tx 40 and CRYSTAL Tx 40 Block Diagram.....................................................................22
Fig. 2-6 MAGNUM XL 54 Block Diagram....................................................................................................... 23
Fig. 2-7 COUGAR Tx 36, CHAMELEON Tx 36 and PREMIER Tx 36 Block Diagram................................. 24
Fig. 3-1 SMPS Test Points................................................................................................................................. 29
Fig. 3-2 LME Component Layout...................................................................................................................... 33
Fig. 3-3 LME Block Diagram ............................................................................................................................ 34
Fig. 3-4 CBE Component Layout....................................................................................................................... 37
Fig. 3-5 CBE Block Diagram............................................................................................................................. 38
Fig. 3-6 CBF Component Layout....................................................................................................................... 41
Fig. 3-7 CBF Block Diagram............................................................................................................................. 42
Fig. 3-8 SUC Component Layout....................................................................................................................... 45
Fig. 3-9 SUC Block Diagram............................................................................................................................. 46
Fig. 3-10 IMB Component Layout..................................................................................................................... 49
Fig. 3-11 IMB Block Diagram........................................................................................................................... 50
Fig. 3-12 IMD Component Layout.....................................................................................................................52
Fig. 3-13 IMD Block Diagram........................................................................................................................... 53
Fig. 3-14 SKDA Component Layout ................................................................................................................. 56
Fig. 3-15 SKDA Block Diagram........................................................................................................................ 57
Fig. 3-16 SKDF Component Layout.................................................................................................................. 58
Fig. 3-17 SKDF Block Diagram......................................................................................................................... 59
Fig. 3-18 SCR Component Layout..................................................................................................................... 62
Fig. 3-19 SCR Block Diagram........................................................................................................................... 63
Fig. 3-20 OSB Component Layout.....................................................................................................................65
Fig. 3-21 OIBA Component Layout...................................................................................................................65
Fig. 3-22 MDA Component Layout................................................................................................................... 67
Fig. 3-23 MDA Block Diagram ......................................................................................................................... 68
Fig. 3-24 Adjustment of Roller Sensor ................................................................................................................ 72
Fig. 3-25 Adjustment of Top Position Sensor...................................................................................................... 73
Fig. 3-26 Elevation Motor and Spindle................................................................................................................ 74
Fig. 3-27 Adjustment Tool for Roller Sensor....................................................................................................... 75
Fig. 3-28 Adjustment Tool for Top Position Sensors .......................................................................................... 75
Fig. 3-29 Adjustment of Original-Sensors..........................................................................................................77
Fig. 4-1 Focus Lock Mechanism......................................................................................................................... 82
Fig. 4-2 CCD-Camera, Side View....................................................................................................................... 83
Fig. 4-3 CCD-Camera, Top View....................................................................................................................... 84
Fig. 4-4 Relations between Optical Adjustment Pattern and Screen Images ...................................................... 85
Fig. 4-5 COUGAR 25, CHAMELEON 25, Light Profiles Uncorrected............................................................. 89
Fig. 4-6 COUGAR 25, CHAMELEON 25, Light Profiles Corrected................................................................. 89
Fig. 4-7 COUGAR 36, CHAMELEON 36, PREMIER 36, Light Profiles Uncorrected ..................................... 90
Fig. 4-8 COUGAR 36, CHAMELEON 36, PREMIER 36, Light Profiles Corrected ......................................... 90
Fig. 4-9 CHROMA Tx 40, CRYSTAL Tx 40, Light Profiles Uncorrected........................................................91
Fig. 4-10 CHROMA Tx 40, CRYSTAL Tx 40, Light Profiles Corrected.......................................................... 91
Fig. 4-11 MAGNUM XL 54, Light Profiles Uncorrected................................................................................... 92
Fig. 4-12 MAGNUM XL 54, Light Profiles Corrected....................................................................................... 92
Fig. 4-13 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, Light Profiles Uncorrected.................. 93
Fig. 4-14 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, Light Profiles Corrected...................... 93
Fig. 4-15 COUGAR 25, CHAMELEON 25, Focus Signals............................................................................... 96
Fig. 4-16 COUGAR 36, CHAMELEON 36, PREMIER 36, Focus Signals....................................................... 96
Fig. 4-17 CHROMA Tx 40, CRYSTAL Tx 40, Focus Signals ..........................................................................97
Fig. 4-18 MAGNUM XL 54, Focus Signals....................................................................................................... 97

FSG/MTM/001 060511
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Fig. 4-19 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, Focus Signals....................................... 98
Fig. 4-20 COUGAR 25, CHAMELEON 25, Scan-Width ................................................................................ 102
Fig. 4-21 COUGAR 36, CHAMELEON 36, PREMIER 36, Scan-Width (A).................................................. 103
Fig. 4-22 COUGAR 36, CHAMELEON 36, PREMIER 36, Scan-Width (B).................................................. 103
Fig. 4-23 CHROMA Tx 40, CRYSTAL Tx 40, Scan-Width (A)..................................................................... 104
Fig. 4-24 CHROMA Tx 40, CRYSTAL Tx 40, Scan-Width (B) ..................................................................... 104
Fig. 4-25 CHROMA Tx 40, CRYSTAL Tx 40, Scan-Width (C) ..................................................................... 105
Fig. 4-26 MAGNUM XL 54, Scan-Width (A).................................................................................................. 106
Fig. 4-27 MAGNUM XL 54, Scan-Width (B).................................................................................................. 106
Fig. 4-28 MAGNUM XL 54, Scan-Width (C).................................................................................................. 107
Fig. 4-29 MAGNUM XL 54, Scan-Width (D).................................................................................................. 107
Fig. 4-30 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, Scan-Width (A) ................................. 108
Fig. 4-31 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, Scan-Width (B) .................................108
Fig. 4-32 COUGAR 25, CHAMELEON 25, CCD-Centering and Vertical Positioning .................................. 114
Fig. 4-33 COUGAR 36, CHAMELEON 36, PREMIER 36, CCD-Centering and Vertical Positioning (A).... 115
Fig. 4-34 COUGAR 36, CHAMELEON 36, PREMIER 36, CCD-Centering and Vertical Positioning (B).... 115
Fig. 4-35 CHROMA Tx 40, CRYSTAL Tx 40, CCD-Centering and Vertical Positioning (A)....................... 116
Fig. 4-36 CHROMA Tx 40, CRYSTAL Tx 40, CCD-Centering and Vertical Positioning (B) .......................116
Fig. 4-37 CHROMA Tx 40, CRYSTAL Tx 40, CCD-Centering and Vertical Positioning (C) .......................117
Fig. 4-38 MAGNUM XL 54, CCD-Centering and Vertical Positioning (A).................................................... 118
Fig. 4-39 MAGNUM XL 54, CCD-Centering and Vertical Positioning (B).................................................... 118
Fig. 4-40 MAGNUM XL 54, CCD-Centering and Vertical Positioning (C).................................................... 119
Fig. 4-41 MAGNUM XL 54, CCD-Centering and Vertical Positioning (D).................................................... 119
Fig. 4-42 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, CCD-Centering and Vertical Positioning
(A).............................................................................................................................................................. 120
Fig. 4-43 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, CCD-Centering and Vertical Positioning
(B).............................................................................................................................................................. 120
Fig. 4-44 CCD-Camera Overview (Adjustments)............................................................................................. 121
Fig. 4-45 Optical Adjustment Pattern, 25”........................................................................................................ 122
Fig. 4-46 Optical Adjustment Pattern, 2 Cam., 36” .......................................................................................... 123
Fig. 4-47 Optical Adjustment Pattern, 2 Cam., 40” .......................................................................................... 124
Fig. 4-48 Optical Adjustment Pattern, 3 Cam., 40” .......................................................................................... 125
Fig. 4-49 Optical Adjustment Pattern, 4 Cam., 54” .......................................................................................... 126
Fig. 4-50 Focus Pattern, 25”.............................................................................................................................. 127
Fig. 4-51 Focus Pattern, 40”.............................................................................................................................. 128
Fig. 4-52 Focus Pattern, 54”.............................................................................................................................. 129
Fig. 5-1 Principle of Stitching........................................................................................................................... 131
Fig. 5-2 Stitching Wire Mounting..................................................................................................................... 132
Fig. 5-3 COUGAR 36, CHAMELEON 36, PREMIER 36, Stitching Images.................................................. 134
Fig. 5-4 CHROMA Tx 40, CRYSTAL Tx 40, Stitching Images A/B..............................................................135
Fig. 5-5 CHROMA Tx 40, CRYSTAL Tx 40, Stitching Images B/C ..............................................................136
Fig. 5-6 MAGNUM XL 54, Stitching Images A/B........................................................................................... 137
Fig. 5-7 MAGNUM XL 54, Stitching Images B/C........................................................................................... 138
Fig. 5-8 MAGNUM XL 54, Stitching Images C/D........................................................................................... 139
Fig. 5-9 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, Stitching Images.................................. 140
Fig. 6-1 SM Calibration Sheet, 25”................................................................................................................... 143
Fig. 6-2 SM Calibration Sheet, 40”................................................................................................................... 144
Fig. 6-3 SM Calibration Sheet, 54”................................................................................................................... 145
Fig. 9-1 Gas Sprin for Guide Plate.................................................................................................................... 167
Fig. 9-2 Transmission........................................................................................................................................ 168
Fig. 9-3 Drive-Belt Tightener............................................................................................................................ 169
Fig. 9-4 Scanner Cross Section ......................................................................................................................... 170
Fig. 10-1 Noise Test, Example.......................................................................................................................... 176
Fig. 11-1 COUGAR 25 Primary Wiring......................................................................................................... 179
Fig. 11-2 COUGAR 25, Secondary Wiring ...................................................................................................... 180
Fig. 11-3 CHAMELEON 25, Primary Wiring.................................................................................................. 181
Fig. 11-4 CHAMELEON 25, Secondary Wiring.............................................................................................. 182
Fig. 11-5 COUGAR 36, Primary Wiring.......................................................................................................... 183
Fig. 11-6 COUGAR 36, Secondary Wiring ...................................................................................................... 184

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Fig. 11-7 CHAMELEON 36, PREMIER 36, Primary Wiring.......................................................................... 185
Fig. 11-8 CHAMELEON 36, PREMIER 36, Secondary Wiring...................................................................... 186
Fig. 11-9 CHROMA Tx 40, CRYSTAL Tx 40, Primary Wiring...................................................................... 187
Fig. 11-10 CHROMA Tx 40, CRYSTAL Tx 40, Secondary Wiring................................................................ 188
Fig. 11-11 MAGNUM XL 54, Primary Wiring................................................................................................ 189
Fig. 11-12 MAGNUM XL 54, Secondary Wiring............................................................................................ 190
Fig. 11-13 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, Primary Wiring................................ 191
Fig. 11-14 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36, Secondary Wiring............................ 192

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1. Introduction
The purpose of this Maintenance Manual is to provide technical information to support board-
level troubleshooting and maintenance of the Wide Format Scanners models:
GA67D (COUGAR 25, COUGAR 25 PLUS)
GB67D (COUGAR 36, COUGAR 36 PLUS)
GC67D (CHAMELEON 25, CHAMELEON 25 PLUS)
GD67D (CHAMELEON 36, CHAMELEON 36 PLUS)
GE67D (CHROMA Tx 40, CHROMA Tx 40 PLUS)
GF67D (CRYSTAL Tx 40, CRYSTAL Tx 40 PLUS)
GG67D (CHAMELEON PREMIER 36, CHAMELEON PREMIER 36 PLUS)
GH67D (MAGNUM XL 54)
GK67D (COUGAR Tx 36, COUGAR Tx 36 PLUS)
GL67D (CHAMELEON Tx 36, CHAMELEON Tx 36 PLUS)
GM67D (PREMIER Tx 36, PREMIER Tx 36 PLUS)
Chapter 2 contains a general technical description based on block diagrams.
Chapter 3 describes Electrical Check and Adjustments including jumper and switch settings.
Chapter 4 contains a general description of the Optical System and the CCD-Camera
Adjustments.
Chapter 5 describes Stitching and Vertical Alignment.
Chapter 6 describes General Maintenance.
Chapter 7 contains a list of Error Codes and gives some hints on troubleshooting.
Chapter 8 describes Disassembly and Assembly procedures.
Chapter 9 provides a guide for replacement of parts for which the procedure is not obvious.
Chapter 10 describes the scanner test program, SCANtest 6.
Chapter 11 contains Wiring Diagrams.
Chapter 12 contains a list of Special Service Tools.

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2. General Description
The Wide Format Scanners models:
GA67D (COUGAR 25, COUGAR 25 PLUS)
GB67D (COUGAR 36, COUGAR 36 PLUS)
GC67D (CHAMELEON 25, CHAMELEON 25 PLUS)
GD67D (CHAMELEON 36, CHAMELEON 36 PLUS)
GE67D (CHROMA Tx 40)
GF67D (CRYSTAL Tx 40)
GG67D (CHAMELEON PREMIER 36)
GH67D (MAGNUM XL 54)
GK67D (COUGAR Tx 36)
GL67D (CHAMELEON Tx 36)
GM67D (PREMIER Tx 36)
are described at block-diagram level in Sections 2.1 through 2.5.
2.1 COUGAR 25 and CHAMELEON 25
The Block Diagrams are shown in:
Fig. 2-1 COUGAR 25 Block Diagram, page 18
Fig. 2-2 CHAMELEON 25 Block Diagram, page 19
The COUGAR 25 and CHAMELEON 25 scanner range consists of:
Model: GA67D GC67D
Trade name: COUGAR
25 COUGAR 25 PLUS CHAMELEON 25 CHAMELEON 25 PLUS
No. of cameras: 1 1 1 1
Chassis: 25 inches 25 inches 25 inches 25 inches
Scan width: 25 inches 25 inches 25 inches 25 inches
Computer
interface: USB/SCSI
(IMBA) USB/SCSI (IMBA) USB (IMBB) USB (IMBB)
Scan mode: Color
Monochrome Color Monochrome Monochrome Color Monochrome
Optical resolution: 424 dpi 424 dpi 424 dpi 424 dpi
SmartCard: BASIC PLUS BASIC PLUS
Each of the two models GA67D and GC67D are marketed with two different levels of
functionality, such as image resolution, scanning speed, scanning modes, etc:
Model: GA67D (USB and SCSI interface)
Trade names: COUGAR 25 (basic level of functionality)
COUGAR 25 PLUS (enhanced level of functionality)
Model: GC67D (USB interface only)
Trade names: CHAMELEON 25 (basic level of functionality)
CHAMELEON 25 PLUS (enhanced level of functionality)

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The basic versions of the scanners (COUGAR 25 and CHAMELEON 25) may be field
upgraded to the enhanced versions (COUGAR 25 PLUS and CHAMELEON 25 PLUS) by
replacing the BASIC Smart Card with a PLUS Smart Card.
The scan-area is illuminated by one white fluorescent lamp. The light output from the lamp is
stabilized by feedback to the lamp power supply board (LME).
The CCD-Camera in the scanner contains one 10680 x 3 pixel color CCD. The output signals
from the CCD are Light Profile Corrected at pixel level.
All scanning and image processing functions are contained on only two boards, the Camera
Board (CBE) and the Controller Board (SUC).
The Interface Module (IMB) contains:
USB Controller
SCSI Controller (COUGAR only)
for USB interface respectively SCSI interface. If the computer is connected to both USB and
SCSI interface, the scanner software presents a choice between the two modes to the user.
2.2 COUGAR 36, CHAMELEON 36 and CHAMELEON PREMIER 36
The Block Diagrams are shown in:
Fig. 2-3 COUGAR 36 Block Diagram, page 20
Fig. 2-4 CHAMELEON 36 and CHAMELEON PREMIER 36 Block Diagram, page 21
2.2.1 COUGAR 36 and CHAMELEON 36
The COUGAR 36 and CHAMELEON 36 scanner range consists of:
Model: GB67D GD67D
Trade name: COUGAR
36 COUGAR 36 PLUS CHAMELEON 36 CHAMELEON 36 PLUS
No. of cameras: 2 2 2 2
Chassis: 40 inches 40 inches 40 inches 40 inches
Scan width: 36 inches 36 inches 36 inches 36 inches
Scanner Controller: SUCA SUCA SUCA SUCA
Computer
interface: USB/SCSI
(IMBA) USB/SCSI (IMBA) USB (IMBB) USB (IMBB)
Scan mode: Color
Monochrome Color Monochrome Monochrome Color Monochrome
Optical resolution: 424 dpi 424 dpi 424 dpi 424 dpi
SmartCard: BASIC PLUS BASIC PLUS
Each of the two models GB67D and GD67D are marketed with two different levels of
functionality, such as image resolution, scanning speed, scanning modes, etc:
Model: GB67D (USB and SCSI interface)
Trade names: COUGAR 36 (basic level of functionality)
COUGAR 36 PLUS (enhanced level of functionality)
Model: GD67D (USB interface only)

FSG/MTM/001 060511
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Trade names: CHAMELEON 36 (basic level of functionality)
CHAMELEON 36 PLUS (enhanced level of functionality)
The basic versions of the scanners (COUGAR 36 and CHAMELEON 36) may be field
upgraded to the enhanced versions (COUGAR 36 PLUS and CHAMELEON 36 PLUS) by
replacing the BASIC Smart Card with a PLUS Smart Card.
The scan-area is illuminated by one white fluorescent lamp. The light output from the lamp is
stabilized by feedback to the lamp power supply board (LME).
Each CCD-Camera in the scanner contains one 10680 x 3 pixel color CCD. The output
signals from the CCDs are Light Profile Corrected at pixel level.
All scanning and image processing functions are contained on only two boards, the Camera
Board (CBE) and the Controller Board (SUC).
The computer Interface Module (IMB) contains:
USB Controller
SCSI Controller (COUGAR only)
for USB interface respectively SCSI interface. If the computer is connected to both USB and
SCSI interface, the scanner software presents a choice between the two modes to the user.
In order to stitch (bring together) the scanlines from adjacent cameras, the fields of vision of
the CCD-Cameras overlap slightly and a thin, black wire placed within the overlapped fields
of vision marks the virtual end, respectively start, of adjacent scanlines.
The scanlines from the individual cameras are mechanically aligned (by means of a small
electric motor) in the vertical direction. The Vertical Alignment and the Horizontal Stitching
may be done automatically by means of either SCANtest 6, Test 11 or as part the Scanner
Maintenance calibration procedure.
2.2.2 CHAMELEON PREMIER 36
The CHAMELEON PREMIER 36 is an all monochrome scanner and can not be upgraded to
include color mode.
Model: GG67D (USB interface only)
Trade names: CHAMELEON PREMIER 36 (basic level of functionality)
CHAMELEON PREMIER 36 PLUS (enhanced level of functionality)
Except for the Scanner Controller Board (SUCD) and Scanner ID Switch setting,
CHAMELEON PREMIER 36 is electrically and mechanically identical to CHAMELEON 36.
2.3 CHROMA Tx 40 and CRYSTAL Tx 40
The Block Diagram is shown in:
Fig. 2-5 CHROMA Tx 40 and CRYSTAL Tx 40 Block Diagram, page 22

FSG/MTM/001 060511
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The Tx 40 scanner range consists of:
Model: GE67D GF67D
Trade name: CHROMA Tx 40 CHROMA Tx 40
PLUS CRYSTAL Tx 40 CRYSTAL Tx 40 PLUS
No. of cameras: 3 3 3 3
Chassis: 40 inches 40 inches 40 inches 40 inches
Scan width: 40 inches 40 inches 40 inches 40 inches
Scanner Controller: SUCB SUCB SUCC SUCC
Computer
interface: IEEE 1394/SCSI
(IMDA) IEEE 1394/SCSI (IMDA) IEEE 1394/SCSI (IMDA) IEEE 1394/SCSI (IMDA)
Scan mode: Color
Monochrome Color Monochrome Color Monochrome Color Monochrome
Optical resolution: 508 dpi 508 dpi 508 dpi 508 dpi
SmartCard: BASIC PLUS BASIC PLUS
Each of the two models GE67D and GF67D are marketed with two different levels of
functionality, such as image resolution, scanning speed, scanning modes, etc:
Model: GE67D (IEEE 1394 and SCSI interface)
Trade names: CHROMA Tx 40 (basic level of functionality)
CHROMA Tx 40 PLUS (enhanced level of functionality)
Model: GF67D (IEEE 1394 and SCSI interface)
Trade names: CRYSTAL Tx 40 (basic level of functionality)
CRYSTAL Tx 40 PLUS (enhanced level of functionality)
The basic versions of the scanners (CHROMA Tx 40 and CRYSTAL Tx 40) may be field
upgraded to the enhanced versions (CHROMA Tx 40 PLUS and CRYSTAL Tx 40 PLUS) by
replacing the BASIC Smart Card with a PLUS Smart Card.
The scan-area is illuminated by one white fluorescent lamp. The light output from the lamp is
stabilized by feedback to the lamp power supply board (LME).
Each CCD-Camera in the scanner contains one 7500 x (3+1) pixel (RGB Triplets +
Panchromatic B/W) CCD. The output signals from the CCDs are Light Profile Corrected at
pixel level.
All scanning and image processing functions are contained on only two boards, the Camera
Board (CBF) and the Controller Board (SUC).
The computer Interface Module (IMD) contains:
IEEE 1394 Controller (FireWire)
SCSI Controller
for IEEE 1394 interface respectively SCSI interface.
In order to stitch (bring together) the scanlines from adjacent cameras, the fields of vision of
the CCD-Cameras overlap slightly and a thin, black wire placed within the overlapped fields
of vision marks the virtual end, respectively start, of adjacent scanlines.

FSG/MTM/001 060511
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The scanlines from the individual cameras are mechanically aligned (by means of a small
electric motor) in the vertical direction. The Vertical Alignment and the Horizontal Stitching
may be done automatically by means of either SCANtest 6, Test 11 or as part the Scanner
Maintenance calibration procedure.
2.4 MAGNUM XL 54
The Block Diagram is shown in:
Fig. 2-6 MAGNUM XL 54 Block Diagram, page 23
The XL 54 scanner range consists of:
Model: GH67D
Trade name: MAGNUM XL 54 MAGNUM XL 54
PLUS
No. of cameras: 4 4
Chassis: 54 inches 54 inches
Scan width: 54 inches 54 inches
Scanner Controller: SUCH SUCH
Computer
interface: IEEE 1394/SCSI
(IMDA) IEEE 1394/SCSI (IMDA)
Scan mode: Color
Monochrome Color Monochrome
Optical resolution: 508 dpi 508 dpi
SmartCard: BASIC PLUS
Model GH67D is marketed with two different levels of functionality, such as image
resolution, scanning speed, scanning modes, etc:
Model: GH67D (IEEE 1394 and SCSI interface)
Trade names: MAGNUM XL 54 (basic level of functionality)
MAGNUM XL 54 PLUS (enhanced level of functionality)
The basic version of the scanner (MAGNUM XL 54) may be field upgraded to the enhanced
version (MAGNUM XL 54 PLUS) by replacing the BASIC Smart Card with a PLUS Smart
Card.
The Automatic Thickness Adjustment Control (ATAC) automatically adjusts for media
thickness up to 0.6 inch (15 mm). The motor driver board (MDA) and the motor for the
ATAC system are located in a non-removeable Original Guide Plate.
The scan-area is illuminated by one white fluorescent lamp. The light output from the lamp is
stabilized by feedback to the lamp power supply board (LME).
Each CCD-Camera in the scanner contains one 7500 x (3+1) pixel (RGB Triplets +
Panchromatic B/W) CCD. The output signals from the CCDs are Light Profile Corrected at
pixel level.
All scanning and image processing functions are contained on only two boards, the Camera
Board (CBF) and the Controller Board (SUC).
The computer Interface Module (IMD) contains:

FSG/MTM/001 060511
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IEEE 1394 Controller (FireWire)
SCSI Controller
for IEEE 1394 interface respectively SCSI interface.
In order to stitch (bring together) the scanlines from adjacent cameras, the fields of vision of
the CCD-Cameras overlap slightly and a thin, black wire placed within the overlapped fields
of vision marks the virtual end, respectively start, of adjacent scanlines.
The scanlines from the individual cameras are mechanically aligned (by means of a small
electric motor) in the vertical direction. The Vertical Alignment and the Horizontal Stitching
may be done automatically by means of either SCANtest 6, Test 11 or as part the Scanner
Maintenance calibration procedure.
2.5 COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36
The Block Diagram is shown in:
Fig. 2-7 COUGAR Tx 36, CHAMELEON Tx 36 and PREMIER Tx 36 Block Diagram,
page 24
The Tx 36 scanner range consists of:
Model: GK67D GL67D GM67D
Trade name: COUGAR Tx 36 CHAMELEON Tx 36 PREMIER Tx 36
No. of cameras: 2 2 2
Chassis: 40 inches 40 inches 40 inches
Scan width: 36 inches 36 inches 36 inches
Scanner Controller: SUCB SUCC SUCG
Computer
interface: IEEE 1394/SCSI
(IMDA) IEEE 1394/SCSI (IMDA) IEEE 1394/SCSI (IMDA)
Scan mode: Color
Monochrome Color Monochrome Monochrome
Optical resolution: 400 dpi 400 dpi 400 dpi
Each of the three models GK67D, GL67D, and GM67D are marketed with two different
levels of functionality, such as image resolution, scanning speed, scanning modes, etc:
Model: GK67D (IEEE 1394 and SCSI interface)
Trade names: COUGAR Tx 36 (basic level of functionality)
COUGAR Tx 36 PLUS (enhanced level of functionality)
Model: GL67D (IEEE 1394 and SCSI interface)
Trade names: CHAMELEON Tx 36 (basic level of functionality)
CHAMELEON Tx 36 PLUS (enhanced level of functionality)
Model: GM67D (IEEE 1394 and SCSI interface)
Trade names: PREMIER Tx 36 (basic level of functionality)
PREMIER Tx 36 PLUS (enhanced level of functionality)
The basic versions of the scanners (COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER
Tx 36) may be field upgraded to the enhanced versions (COUGAR Tx 36 PLUS,