m40 Service Manuel

M40SM Colortrac Ltd Page 1 of 129
Issue 2 M Series Service Manual Date: 20/12/12

This is a confidential controlled document and is the property of Colortrac Ltd.
It is not to be copied or reproduced in part or whole. It is intended for staff to read.
Colortrac M Series
Service Manual
M Series Service Manual
M Series
M25e
M40e
Service Manual
Issue 2
©Colortrac Ltd 2012
No part of this product or publication may be reproduced,

copied or transmitted in any form or by any means without
permission from:
Colortrac Ltd.
Units 3 – 5 Brunel Court.
Burrel Road.
St Ives,
Huntingdon,
Cambridgeshire,
PE27 3LW.
United Kingdom.
Tel: +44 (0)1480 464618

Fax: +44 (0)1480 464620
www.colortrac.com
 The product and the contents of this publication may be changed without prior notification.
 Colortrac Ltd makes every effort to ensure this publication is free from error. Misprints, errors
or quality observations should be reported to Technical Support, Colortrac Ltd.
 Colortrac Ltd shall not be liable for any damages, errors, issues or events that result from the
use of the equipment or this manual.
Page 2 of 129

CONTENTS
1 Introduction ............................................................................................................................... 5
1.1 Scanner Models ............................................................................................................... 5
2 Tools Required ......................................................................................................................... 6
3 Obtaining Technical Support from Colortrac ............................................................................ 7
3.1 Creating an Account ........................................................................................................ 7
3.2 User Profiles .................................................................................................................... 7
3.3 Submitting Requests for Support ..................................................................................... 7
3.4 Asset Selection ................................................................................................................ 7
3.5 Support Ticket Information ............................................................................................... 7
4 How to Contact Technical Support ........................................................................................... 8
5 Safety........................................................................................................................................ 8
5.1 Safety Warnings ............................................................................................................... 8
5.2 EMC Testing .................................................................................................................... 8
6 Scanner Cautions ..................................................................................................................... 9
7 Photos Information ................................................................................................................... 9
8 Warranty ................................................................................................................................. 10
8.1 Warranty Period ............................................................................................................. 10
8.2 Consumables ................................................................................................................. 10
9 Control Board Replacement Statement .................................................................................. 10
10 CIS Technology ................................................................................................................. 11
11 Scanner Accessories ......................................................................................................... 12
11.1 USB Cable Type A and B .............................................................................................. 12
11.2 External Power Supply................................................................................................... 13
12 Scanner Information........................................................................................................... 14
12.1 Block Diagram ................................................................................................................ 14
12.2 Scanner Operation ......................................................................................................... 15
13 Removing and Replacing Panelling ................................................................................... 17
13.1 Lid Assembly Maintenance Position .............................................................................. 17
13.2 Left End Cover ............................................................................................................... 20
13.3 Right End Cover ............................................................................................................. 22
13.4 Top Lid Cover ................................................................................................................ 24
13.5 Paper Tray Unit .............................................................................................................. 27
13.6 Lower Covers ................................................................................................................. 31
13.7 Upper Covers ................................................................................................................. 35
13.8 Lid Assembly.................................................................................................................. 37
14 Removing and Replacing Components ............................................................................. 45
14.1 Main Board ..................................................................................................................... 45
14.2 Control Board ................................................................................................................. 53
Page 3 of 129
14.3 SingleSensor Glass Sub-Assy ....................................................................................... 60

14.4 SingleSensor CIS Assy .................................................................................................. 63
14.5 Drive Roller Unit ............................................................................................................. 70
14.6 Hold Up Roller Unit ........................................................................................................ 75
14.7 Hold Up Roller Unit Support Bar .................................................................................... 82
14.8 Main Timing Belt ............................................................................................................ 84
14.9 Drive Roller Timing Belt ................................................................................................. 88
14.10 Paper Sensor ................................................................................................................. 91
14.11 Pinch Roller Assembly ................................................................................................... 94
14.12 Power Switch ................................................................................................................. 97
14.13 Power Socket ............................................................................................................... 100
14.14 Microswitch .................................................................................................................. 103
14.15 Motor ............................................................................................................................ 107
15 Utilities Program ............................................................................................................... 111
15.1 Installation .................................................................................................................... 111
15.2 Calibration .................................................................................................................... 112
15.3 Power Saving ............................................................................................................... 114
15.4 Auto width .................................................................................................................... 114
15.5 Second Level Utilities................................................................................................... 115
15.6 Scanner Upgrade ......................................................................................................... 115
15.7 Automatic Updates ....................................................................................................... 116
15.8 Firmware Installation .................................................................................................... 116
15.9 Auto-stitch .................................................................................................................... 118
15.10 Run Diagnostics ........................................................................................................... 119
16 Distributor’s Utilities ......................................................................................................... 120
16.1 Engineering Utilities ..................................................................................................... 120
16.2 Manual Stitch ............................................................................................................... 121
16.3 Motor Speed ................................................................................................................ 122
16.4 Load Delay ................................................................................................................... 123
16.5 Paper Staging .............................................................................................................. 124
17 Help Desk ........................................................................................................................ 125
17.1 Extending Warranty ..................................................................................................... 125
18 Glossary ........................................................................................................................... 127
19 Service Manual Release Notes ....................................................................................... 129
20 Features Not Included...................................................................................................... 129
Page 4 of 129
11
1 Introduction
1.1 Scanner Models
This manual contains information for reference by qualified service engineers, trained in
the repair of the SmartLF M Series.
There are 2 x M series Models:
SmartLF M25e  Scan width of 25 inches

 Handles 27 inch media
 Optical resolution of 1200 dpi
 16.7 million colour RGB (24-bit)
 256 colour RGB adapted indexed colour palette (8-bit)
 256 level Greyscale (8-bit)
 Black & White (1-bit)
 Speed: Enhanced
 Contains 1 x SingleSensor CIS Assy (with 30,000
pixels)
SmartLF M40e  Scan width of 42 inches

 Handles 44 inch media
 Optical resolution of 1200 dpi
 16.7 million colour RGB (24-bit)
 256 colour RGB adapted indexed colour palette (8-bit)
 256 level Greyscale (8-bit)
 Black & White (1-bit)
 Speed: Enhanced
 Contains 1 x SingleSensor CIS Assy (with 50,400
pixels)
Page 5 of 129
2 Tools Required
To maintain the M Series the tools listed below are required. The tools are generally available;
they are not the responsibility of Colortrac to supply.
1. Wristband 2. Pencil
 Anti-static and cable.  HB Lead
3. 7mm Nutdriver. 4. 1.5mm Allen Key

 To remove and fit M5 nuts.  or 1.5mm Hex Key
5. Medium Pozi-drive screwdriver. 6. Small Pozi-drive screwdriver.

 PZ1 x 80mm length.  PZ0 x 60mm length.
7. Small Flat Screwdriver 8. Medium Flat Screwdriver.

 3mm blade x 65mm length (approx.)  6mm blade (approx.)
9. Pliers.
 Flat nosed pliers, short serrated.
Page 6 of 129
3 Obtaining Technical Support from Colortrac
Colortrac uses an online service desk facility called the Colortrac Global Help Desk to
manage requests for technical support for the M Series. The URL for the Help Desk is
www.colortrac-helpdesk.com. All requests for support for the M Series must be
registered via the Help Desk. By using the Help Desk, Colortrac may better manage
support calls to provide customers a better service.
For each support call, the Help Desk automatically raises a ticket. The ticket is the
means to communicate the progress and status of the support call, and other information.
Users may access and update ticket information through their User accounts at the Help
Desk URL.
3.1 Creating an Account
Distributors do not need to contact Colortrac to raise a Help Desk User account. The
Help Desk is programmed to accept new accounts that use specific email domains. But,
Distributors who find they cannot create a User Account should contact Colortrac
Technical Support.
3.2 User Profiles
We ask Users who log in for the first time to update their profile. Some information we
require and some we leave to the Users discretion to provide. But the more complete the
information provided the better Colortrac can provide support.
3.3 Submitting Requests for Support
To submit a request for support, Users must logon to the Help Desk and select the
'Request' icon. Dependant on the request type, Users will be asked to provide the
additional information Colortrac needs to progress the request quickly.
3.4 Asset Selection
Colortrac uses the Help Desk to associate support calls with scanner assets. For this
reason Distributors are requested to select the scanner associated with their request for
support. Those scanners a Distributor has received from Colortrac are listed at the
bottom of the page. Distributors may select the scanner the call is related to. If the
scanner is not listed please enter the serial number in the box provided.
3.5 Support Ticket Information
In the detail of each ticket Users can expect to see:
 All pertinent information to the investigation

 Regular updates on progress.
 Requests for further information or activity.
 The solution or outcome.
 Closure agreement.
The notes facility can be used to provide further information.
Page 7 of 129
4 How to Contact Technical Support
Contact Numbers  Support Direct Line: +44 (0) 1480 409997

 Company Tel No: +44 (0) 1480 464618
 Company Fax No: +44 (0) 1480 464620
Helpdesk  www.colortrac-helpdesk.com
Technical Downloads  http://www.colortrac.com/support/software-downloads/

(software, firmware, drivers)
Technical Support Website  www.mseries.colortrac.com

(manuals, catalogues, price  User name: colortrac
lists)  Password: available on request.
5 Safety
5.1 Safety Warnings
5.1.1 Electrical
Do NOT remove any covers from the scanner while the power is on or allow an end user
to operate the scanner with ANY covers removed. Engineers must exercise extreme
caution while working on any scanner.
It is advisable to allow the scanner 5 minutes to discharge before removing covers and
any of the boards. The boards may hold a charge and may give a shock if touched.
Please observe anti-static precaution when handling any

electrical boards from the scanner.
5.1.2 Mechanical
The mechanism that operates the lid and the paper handling assembly can trap fingers
when closing. Please handle with care.
5.1.3 Weight
Because the weight of the scanner is approximately 27Kg, 2 people are required to lift the
scanner.
5.1.4 Rotating Rollers

The scanner operates a roller to move the image across the scanner. These rollers may
grip ties and any other similar articles of clothing, as well as long hair if put near the
rollers during operation.
5.2 EMC Testing
The SmartLF model conforms to EMC and FCC (Part B). EMC testing is carried out to
ensure the M Series does not emit signals that can interfere with other devices, and that
no external interference signals will interfere with it.
Page 8 of 129
6 Scanner Cautions
Do:  Have 2 people to lift the scanner.

 Keep the packaging for continued shipment of the scanner.
 Calibrate the scanner on first installation.
 Keep the Calibration target in a safe place for regular use.
 Use the approved and supplied cables for the scanner.
 Read the operator and installation manual before installation.
 Fill out and return the installation form as soon as possible.
Do not’s:  Do not scan paper with any form of metal fastener or post-it notes
attached.
 Do not allow the scanner to get wet.
 Do not drop the scanner.
 Do not stand the scanner on its end (packaged or un-packed).
 Do not leave the scanner open for any length of time.
 Do not stand on the scanner.
 Do not balance the scanner on an unsafe surface.
 Do not scan thick media that is beyond its maximum limit.
 Do not unplug the scanner during a scan sequence.
 Do not let an end user remove any panels from the scanner.
 Do not use any other power supply other than the approved one
supplied with the scanner.
 Do not install the scanner on an un-even surface.
 Do not install in a dusty or dirty environment.
 Do not allow the USB cable to be pulled forcefully out of the scanner.
NOTE: Before work is carried out on the

scanner the power MUST be switched
off and the power lead removed from the
scanner.
7 Photos Information
Some photos in this manual were taken during pre-production, and various stages of the
M Series development. Some colours / backgrounds / designs shown may vary from the
actual scanner being worked on. Some background panels may be shown in the photo to
be removed when they actually don’t need to be; however the instructions are still correct
and should be followed as described.
Page 9 of 129
8 Warranty
Each Colortrac Scanner starts its warranty period when first shipped from Colortrac to the
purchasing Distributor. Non-consumable parts that fail within the warranty period without
inappropriate influence or action will be replaced free of charge.
Distributors are required to identify faulty parts. To help identify faults quickly it is
recommended that Distributors hold spare parts. Parts that are replaced under warranty
must be returned to Colortrac using the address at the front of this manual.
When a Distributor requests a warranty replacement, Colortrac Technical Support will

issue them an RMA reference number. The warranty replacement is dispatched once
Colortrac receives the defective part. In exceptional cases, Colortrac may agree to send
a warranty replacement before the defective part has been received.
8.1 Warranty Period
The Colortrac warranty period is 2-years. The warranty period starts on the date the
product is handed to the carrier for delivery. The start of the warranty period may be
delayed by 3-months to coincide with its installation at a customer’s site. To request a
deferment to the start of the warranty period follow the procedure on ‘How to extend
warranty’ at Chapter 15.1.
8.2 Consumables
Parts that wear according to operator usage are deemed consumables and not replaced
under warranty. Consumables can be purchased from Colortrac. Those M Series parts
considered to be consumables are:
 SingleSensor Glass Sub-Assy
 Hold Up Roller Unit
 Hold Up Roller Unit Support Bar
 Lower Covers and Upper Covers
 Calibration Target
 Timing Belts
9 Control Board Replacement Statement
In Warranty: M Series Control Boards that fail within the warranty period will be replaced
free of charge. If the Control Board is to be fitted in a scanner that has been upgraded,
Colortrac will also provide a free upgrade to configure the Control Board. As part of
standard warranty procedures, Colortrac will require that the defective Control Board is
returned within 28 days.
Out of Warranty: A new M Series Control Board used from stock or is a direct purchase
from Colortrac, may need to be upgraded. Colortrac will provide a free upgrade for the
new Control Board on condition that the defective Control Board is returned to Colortrac
within 28 days.
Page 10 of 129
10 CIS Technology
A Contact Image Sensor (CIS) is an integrated module that comprises an illumination system, an
optical system and a light-sensing system - all within a single compact component.
The light-sensing system is the silicon surface which is

divided up into (e.g. 5000) discrete square cells, the
size of each being a fraction of an inch depending upon
the required scanning resolution (a 600 dpi scanner will
use a CIS whose cells are 1/600" across). The optical
system is a rod lens array that directs light from the
document surface onto the silicon surface. Such an
optical system is 1:1; i.e. there is no reduction or
enlargement; and this results in a scanner offering the
best performance in terms of resolving power and
geometric accuracy.
Cross-section of a CIS scanner sensor.
The illumination is provided by Light Emitting Diodes

(LED’s) shining down a light guide, which in turn
directs the light onto the document. There are three
LED’s (Red, Green, and Blue) which strobe rapidly,
thereby providing the colour content in the scan. Note
that there are no colour filters in the optical or light-
sensing system. The colour gamut of a CIS scanner
is therefore determined by the spectrum of each of M Series SingleSensor CIS Assy
the LED’s, rather than by colour filters as is the case
with CCDs. Because colour filter technology is more developed than LED spectrum technology, a
CIS scanner will not provide as wide a colour gamut as a CCD scanner.
However, rapidly strobed LED’s require no warm-up period. Therefore, a CIS scanner can be
switched on and used immediately. Furthermore, LED’s are very stable which means that a CIS
scanner does not require frequent re-calibration.
Page 11 of 129
11 Scanner Accessories
11.1 USB Cable Type A and B
Length: 3 meter max.

Speed: 5Gbps
This high quality USB cable complies fully with

the USB 3.0 specification.
 Transfer Speed ~ a new transfer type

called ‘Super Speed’ or SS – 5Gbps
 More Bandwidth ~ uses 2
unidirectional data paths; one to
receive, one to transmit
 Power Management ~ U0 through U3
link power management states are
defined.
 Support to rotating media ~ Bulk
protocol is undated with a new feature
called Stream Protocol that allows a
large number of logical stream within
an Endpoint.
USB 3.0 has transmission speeds of up to 5 Gbps, which is 10 times faster than USB 2.0 (480
Mbps). USB 3.0 significantly reduces the time required for data transmission, reduces power
consumption, and is backwards compatible with USB 2.0.
USB 3.0 support can be added to existing laptop computers with only USB 2.0 and Expresscard
support by using an Expresscard-to-USB 3.0 adapter to supply USB 3.0 signal support. Although
the PCI Express port that the Express card connects cannot supply power of itself, the Express
card and hence the USB 3 ports nevertheless derive power from the USB 2 port that it
additionally connects to as part of the interface. If the
express card has more than one USB 3 port then only
100mA is available from each port. Additional power for
multiple ports may be derived in the following ways:
There have been some issues of USB 3.0 equipment only

transferring data at USB 2.0 speed, usually with a message
"This USB Mass Storage Device can transfer information
faster if you connect it to a Super-Speed USB 3.0 port".
This has been due to several causes, including drivers,
certain cables specified as USB 3.0 (problems disappeared
when a different cable was used), order of starting
equipment, equipment needing to be disconnected and
reconnected, and over clocked computers
NOTE:
Colortrac provides a USB 3.0 cable with each M Series. The use of a cable longer than 3m is at
the customer’s discretion. Colortrac is not responsible for errors that may occur as a result.
Page 12 of 129
11.2 External Power Supply
AC I/P 100 – 240V ~ 1.5A 50 – 60 Hz
DC O/P 19V 9.47A
NOTE:
ONLY USE THE CORRECT COLORTRAC
SUPPLIED POWER SUPPLY WITH THE M
SCANNER.
Page 13 of 129
12 Scanner Information
12.1 Block Diagram
Consists of:
1 x SingleSensor CIS Assy

4 x Paper Sensor
1 x Motor
1 x Power Socket
1 x Power Switch
1 x Main Board
1 x Microswitch
1 x Control Board
Page 14 of 129
12.2 Scanner Operation
Left Hand Back

End
Front
Right Hand
End
The diagram above shows the orientation of the scanner referred to in this manual.
Centre Justified
Side Justified
The scanner has two justification options for scanning media: side justified and centre justified.
Before scanning ensure the software is set to the correct preference and the media is inserted at
the correct position as indicated on the Paper Tray Unit
Page 15 of 129
Insert Media FACE UP into the scanner.
Page 16 of 129
13 Removing and Replacing Panelling
13.1 Lid Assembly Maintenance Position
13.1.1 Introduction
 The Lid Assembly can be fixed into a maintainence position which is upright at 90 degrees to
the chassis. When in this position all parts of the Lid and the SingleSensor housing can be
accessed.
13.1.2 Safety Precautions

 Ensure that the power and USB cables are completely disconnected from the scanner unit.
 Ensure the scanner is positioned on a stable maintenance platform.
13.1.3 Tools
 Medium Pozi-drive screwdriver.
13.1.4 Associated Part Numbers

 n/a
13.1.5 Important Information
 For all photos, please refer to chapter “7 Photos Information” on page 9.
13.1.6 Procedure
1. To raise the lid, remove the 3

x M5 screws holding the left
end Gas Piston Bracket to
the Lid Assembly, making
sure not to drop them into the
scanner.
Note: This can be carried out with or without

the Top Lid Cover fitted. To remove the lid ,
follow the instructions in chapter “13.4 Top
Lid Cover” page 24.
2. Remove the 3 x M5 screws

holding the right end Gas
Piston Bracket to the Lid
Assembly making sure not to
drop them into the scanner.
Page 17 of 129
3. While removing the screws

from the Gas Pistons at both
ends of the Lid Assembly,
make sure your free hand is
holding the Lid Assembly to
prevent it dropping down.
Once free lift the Lid to the
90deg position.
4. Tighten the locking screws in

the Hinge Bracket at the left
end of the Lid Assembly. The
Lid may need to be moved
slightly to allow the screws
access.
5. Tighten the locking screws in

the Hinge Bracket at the right
end of the Lid Assembly. The
Lid Assembly will now stay in
o
the 90 position while work is
carried out on the underside
of the Lid Assembly or the
Lower Scanner area.
Page 18 of 129
6. To lower the Lid Assembly,

loosen off the screws in the
Hinge Brackets, at both ends,
while holding the Lid
Assembly, until the lid can
move freely.
7. Lower the Lid Assembly to

the correct position to
reattach the 3 x M4 screws of
the Right Gas Piston. Make
sure not to drop the screws
into the scanner.
8. Similarly, reattach the Left

Gas Piston with the 3 x M4
screws. Make sure not to
drop the screws into the
scanner.
9. Close the Lid Assembly.
Page 19 of 129
13.2 Left End Cover

13.2.2 Tools
 Small flat bladed screwdriver.

 10H133 : Left End Cover Sub-Assy
13.2.5 Procedure
1. To remove the Left End

Cover, use a flat Screwdriver
and cloth to lever off the Left
End Cover Plate.
2. Lift the Left End Cover Plate

away from the Left End
Cover, and store in a safe
place.
Page 20 of 129
3. Use a Medium Pozi-drive

screwdriver to remove the 4 x
M5 screws from the Left End
Cover.
4. Remove the Left End Cover

and store in a safe place.
5. Replace the Left End Cover

in reverse order, making sure
the Left End Cover Plate is
pushed securely on when all
the screws are tightened.
Page 21 of 129
13.3 Right End Cover

13.3.2 Tools
 Small flat bladed screwdriver

 10H134 : Right End Cover Sub Assy
13.3.5 Procedure
1. To remove the Right End

Cover , use a flat Screwdriver
and cloth to lever off the
Right End Cover Plate.
2. Lift the Right End Cover Plate

away from the Right End
Cover and store in a safe
place.
Page 22 of 129
3. Use a Medium Pozi-drive

screwdriver to remove the 4 x
M5 screws from the Right
End Cover.
4. Remove the Right End Cover

and store in a safe place.
5. Replace the Right End Cover

in reverse order, making sure
the Right End Cover Plate is
pushed securely on when all
the screws are tightened.
Page 23 of 129
13.4 Top Lid Cover

13.4.2 Tools

 10H124 : M40 Top Lid Cover
 10H079 : M25 Top Lid Cover
13.4.5 Procedure
1. To remove the Top Lid

Cover, first depress the Lid
Latches at either end of the
Lid Assembly.
2. Allow the Lid Assembly to

gently open.
Page 24 of 129
3. Carefully remove the 2 x M4

screws holding the left end of
the Top Lid Cover. Take care
not to drop the screws while
removing them.
4. Carefully remove the 2 x M4

screws holding the right end
of the Top Lid Cover. Take
care not to drop the screws
while removing them.
5. Close the Lid Assembly

making sure both Lid Latches
lock securely.
6. Carefully lift the Top Lid

Cover off from the Lid
Assembly.
Page 25 of 129
7. Replace the Top Lid Cover in

the reverse order making
sure the Control Board
Bracket and the Main Board
Cover is located in the
appropriate cut-outs before
lowering the Top Lid Cover
completely and replacing the
2 x M4 screws at either end.
Page 26 of 129
13.5 Paper Tray Unit

13.5.2 Tools

 10H132 : M40 Paper Tray Unit
 10H080 : M25 Paper Tray Unit
13.5.5 Procedure
1. To remove the Paper Tray

Unit , first remove the
Magnetic Paper Guide from
the Paper Tray Unit and store
in a safe place.

as described in chapter “13.2
Left End Cover” on page 20.
Page 27 of 129

Right End Cover” on page
22.

holding the left end of the
Paper Tray Unit to the
scanner.

holding the right end of the
Paper Tray Unit to the
scanner.
Page 28 of 129
6. Remove the M4 screws from

the 3 x support brackets
underneath the Paper Tray
Unit.
7. Gently lift the Paper Tray Unit

up and away from the
scanner.
8. Replace the Paper Tray Unit

in the reverse order, making
sure the Paper Tray Unit is
located at the back of the
Paper Tray Unit area before
lowering into place.
9. When tightening the rear

screws at either end of the
Paper Tray Unit, make sure
the rear of the Paper Tray
Unit is level with the Lower
Covers.
Page 29 of 129
10. When tightening the front

screws at either end of the
Paper Tray Unit, make sure
the front of the Paper Tray
Unit is up so it is level with
the End Covers when it is
fitted.
11. Refit the M4 screws into the 3

x support brackets.
Page 30 of 129
13.6 Lower Covers

13.6.2 Tools
 Small Flat screwdriver.

 10H130 : M40 Lower Covers Pack
 10H081 : M25 Lower Covers Pack
13.6.5 Procedure
1. To remove the Lower Covers,

open the Lid Assembly by
depressing the Lid Latches at
either end.
2. At the left most Lower Covers

insert a small flat screwdriver
into a locking access hole.
NOTE: The method is the same for both front

and rear sets.
Page 31 of 129
3. Gently lever the screw driver

by nudging it back at its top
to release the latch.
NOTE: When removing the cover be

extremely careful not to apply to much force.
4. Gently pull the whole cover

up, freeing it from the
extrusion.
5. Take care to avoid the Latch

Pin and Hold Up Roller Unit
while removing the cover.
6. Gently pull all the remaining

Lower Covers from the
extrusion.
Page 32 of 129
7. Finally remove the opposite

end Lower Covers.
8. To refit the Lower Covers,

starting at one end, make
sure the end cover goes
under the Latch Pin in the
Side Plate.
9. Ensure the earthing brush at

the rear is not trapped under
the cover.
Page 33 of 129
10. Refit the remaining Lower

Covers, remembering to
position those with cut-outs
for the Paper Sensor is in the
correct position.
11. Fit the other End Lower

Covers
Page 34 of 129
13.7 Upper Covers

13.7.2 Tools
 Small Flat Screwdriver

 10H129 : M40 Upper Covers Pack
 10H082: M25 Upper Covers Pack
13.7.5 Procedure
1. At one end of the Upper

Covers, insert a small flat
screwdriver into a locking
access hole. Gently lever the
screw driver by nudging it at
its top to release the latch.
NOTE: When removing the cover, be

extremely careful not to apply too much force.
2. Remove the covers, gently

pulling each from of the Lid
Assembly.
Page 35 of 129
3. To refit, position the Upper

Covers centrally along the Lid
Assembly recess, making
sure to align the Paper
Sensor cut outs where
necessary. Press the Upper
Covers until they click into
place.
Page 36 of 129
13.8 Lid Assembly

13.8.2 Tools
 Pencil

 n/a
13.8.5 Procedure
1. To remove the Lid Assembly,

first remove the Left End
Cover as described in
chapter “13.2 Left End
Cover” on page 20.

Right End Cover” on page
22.
Page 37 of 129
3. Remove the Top Lid Cover

Top Lid Cover” page 24.
4. Remove the 3 x M5 screws to

detach the Right Gas Piston
from the Lid Assembly.
5. Remove the 3 x M5 screws to

detach the Left Gas Piston
from the Lid Assembly. Hold
the Lid Assembly securely
with your free hand while
removing these screws. Allow
the Lid Assembly to gently
close down.
6. Use a medium flat

screwdriver to release the
lugs on the Plastic Screw
Cover from the retaining
holes on either side of the
Outer Hinge Bracket.
Page 38 of 129
7. Remove the screw covers at

both ends and store in a safe
place to prevent damage.
8. Remove the Maintenance

Position Locking Screws and
Springs at both ends of the
Lid Assembly.
9. Release the Motor Control

Cable from the cable clip and
disconnect.
10. Disconnect the Microswitch

Cable.
Page 39 of 129
11. Use a pencil to mark the

position of the Righ Hinge
Bracket before removing it.

holding the Right Hinge
Bracket in place.
13. Pull the Right Outer Hinge

Bracket out from the Side
Plate, making sure not to
catch the cable or connector.
14. Use a pencil to mark the

position of the Left Hinge
Bracket before removing it.
Page 40 of 129

holding the Left Hinge
Bracket in place.
16. Pull the Right Outer Hinge

Bracket out from the Side
Plate, making sure not to
catch the cable or connector.
17. Gently lift the whole Lid

Assembly up and away from
the scanner. Make sure the
cables and connectors do not
catch on the end plates.
Page 41 of 129
18. To refit the Lid Assembly,

lower one end into place;
making sure the cable from
the Inner Hinge Bracket goes
through the appropriate hole
in the End Plate.
19. Lower the other end down

and feed the cable through
the appropriate hole in the
End Plate before allowing the
Lid Assembly lower
completely.
NOTE: Both Inner Hinge Brackets have nylon

washers fitted to centralise the Lid Assembly,
make sure these are still in place before
lowering the Lid Assembly.
20. Refit the Outer Hinge

Brackets at either end of the
Lid Assembly using the 3 x
M5 screws, but do not
tighten.
Page 42 of 129
21. Move the Hinge Bracket at

either end to the reference
line previously marked, and
tighten the 3 x M5 screws
22. Replace the 2 Maintenance

Position Locking Screws and
springs, turning the screws
until they touch the Inner
Hinge Bracket.
23. Make sure the plastic screw

cover is the correct way
round and click back into
place. Back-off each screw
slightly.
24. Re-connect both the Motor

Control Cable and the
Microswitch cable and secure
them in their relative cable
clips.
Page 43 of 129
25. Refit the Top Lid Cover as

described in chapter “13.4
26. Refit the Left End Cover as

Left End Cover” page 20.
27. Refit the Right End Cover as

Right End Cover” page 22.
Page 44 of 129
14 Removing and Replacing Components
14.1 Main Board

14.1.2 Tools
 Small Pozi-drive screwdriver.

 10H005 : Main Board
 10H035 : M40 Cover Main Board
 10H087 : M25 Cover Main Board
 Before removing the Main Board, following the instructions to retrieve the Motor Speed using
the Motor Speed area on page 122.
14.1.5 Procedure

2. Close the Lid Assembly back

down.
Page 45 of 129
3. For the M40, remove the

Aluminium EMC Tape
covering the cables to the
Main Board.

holding the Main Board
Cover to the Lid Assembly.
5. WARNING: Gently lift the

Main Board Cover to reveal
the Mains Connector.
Release the Mains Connector
from the Main Board.
NOTE: Care needs to be taken with the

Suppressor leads on the Main Board cover as
they can be broken with repeated or excessive
movement.
6. For the M25, the Main Board

Cover extends over the
Control Board Bracket
Assembly. The method for
removal is exactly the same
as shown here.
Page 46 of 129
7. Remove the Main Board

Cover and store in a safe
place.
8. Gently lift the locking bar on

each ribbon cable connector.
Don’t use too much force,
which could break the
connector.
9. Gently pull the ribbon cable

from the connector.

cable.
Page 47 of 129
11. Disconnect the Mains Cable,

Motor Control Cable and the
4 x LED Control Cables.
12. Disconnect the Control Board

Cable.

holding the Main Board to the
Lid Assembly.
Page 48 of 129

using anti-static precautions.
15. To refit the Main Board,

position onto the 6 spacers,
making sure no cables are
trapped under the board.
16. Replace the 6 x M3 screws.
17. Reconnect the Microswitch

cable.
Page 49 of 129
18. Reconnect the Control Board

Cable at J9, as well as the
Motor Control Cable.
19. Re-insert the CIS Ribbon

cables into J1 - J3, making
sure the locking plate is up
before inserting them.
20. When the CIS Ribbon cable

is fully in place, secure it by
pressing down both sides of
the locking plate.
21. Reconnect the 4 x LED

cables, ensuring the correct
cable is inserted in the
correct plug.
Page 50 of 129
22. Make sure all the cables are

in their correct locations.
23. Reconnect the Power

Connector. Then lower the
Main Board Cover into place.
24. For the M40, make sure all

the cables are in their
appropriate cutout, and the
USB connector is also in it’s
cutout in the cover, fit 4 x M3
screws to hold the Main
Board Cover in place.
25. Refit the Aluminium EMC

tape over the cables that go
from the Main Board to the
Control Board. Replace the
tape if unusable.
Page 51 of 129
26. For the M25, the Main Board

Cover sits back over both the
Main Board and the Control
Board Bracket Assembly.
27. Replace the Top Lid Cover

28. Power up the PC and

scanner and download the
Configuration program from
www.mseries.colortrac.com/
Mconfiguration.zip and
configure to the correct
scanner model length.
Note: This is the same program as used for

the ordinary Colortrac SC scanners, and only
the 40 and 25 will allow the scanners to work
with the software.
29. Reconnect the Power and USB cables to the Scanner and power up the scanner and
Utilities Program on a PC.
30. Set the Motor Speed as described in chapter “16.3 Motor Speed” page 122.
31. Re-cycle the power for the scanner and re-cycle the utilities program.
32. Download the latest firmware as described in chapter “15.8 Firmware Installation” page
116.
33. Re-cycle the power to the scanner and re-cyle the utilities program.
34. Run the Calibration as described in chapter “15.2 Calibration” page 112.
35. Run the Auto-stitch as described in chapter “15.9 Auto-stitch” page 118.
36. Re-cyle the power to the scanner.
Page 52 of 129
14.2 Control Board

14.2.2 Tools
 Small Pozi-drive screwdriver.
 Pencil

 10H004 : Control Board
 10H125 : M40 Control Board Bracket Assembly
 10H086 : M25 Control Board Bracket Assembly
 10H075 : M40 Control Board Bracket Cover
14.2.5 Procedure


Main Board Cover as shown
in chapter “14.1 Main Board”
page 45, then go to
instruction 6 in this chapter.
Page 53 of 129

aluminium EMC Tape and
keep it in a safe place to be
refit later.

holding the Control Board
Bracket Cover.
5. Remove the Control Board

Bracket Cover.
6. Before removing the Control

Board Bracket Assembly, use
a pencil to mark its position.
Page 54 of 129

holding the Control Board
Bracket Assembly to the Lid
Assembly.
8. Rotate the Control Board

Bracket Assembly to gain
access to the Control Board
and cables.
9. Disconnect the Key Pad

Ribbon Cable from the
Control Board.
NOTE: This only needs to be done if the

Control Board is being removed from the
bracket.
10. Disconnect the 4 x Paper

Sensor Cables and the
Control Board Cables from
the Main Board.
Page 55 of 129

holding the Control Board to
the Control Board Bracket
Assembly.
12. Remove the Control Board,

using anti-static precautions.
13. To refit, use the 4 x M3

screws that hold the Control
Board to the Control Board
Bracket Assembly.
14. Reconnect the 4 x Paper

Sensor Cables, making sure
the correct cable is in its
referenced socket.
Page 56 of 129
15. Make sure all the cables are

in their correct location on the
Control Board.
16. Reconnect the Key Pad

Ribbon Cable to the Control
Board.
17. Rotate and locate the Control

Board Bracket Assembly to
the pencil lines marked out
before, then refit the 4 x M3
screws to hold the Control
Board Bracket Assembly to
the Lid Assembly.
18. For the M25, refit the Main

Board Cover as described in
chapter “14.1 Main Board”
page 45.
Page 57 of 129
19. For the M40, fit the Control

Board Bracket Cover and
make sure all the cables are
in the cut out.
20. Refit the 4 x M3 screws to

hold the Control Board
Bracket Cover to the Lid
Assembly.
21. Re-apply the Aluminium EMC

Tape over exposed cables.
Page 58 of 129

23. Be aware that after fitting a replacement Control Board, the scanner may be seen as an
‘M’ model. If the scanner had ready been upgraded to / purchased as a ‘C’ or an ‘E’, then
a new upgrade will need to be run.
Please read the “Control Board Replacement Statement” on page 10 for more details.
Page 59 of 129
14.3 SingleSensor Glass Sub-Assy

14.3.2 Tools

 10H128 : M40 SingleSensor Glass Sub-Assy
 10H083 : M25 SingleSensor Glass Sub-Assy
14.3.5 Procedure
1. To Remove, Open the Lid

Assembly and using a Small
Flat Screwdriver and a clean
cloth, insert the screwdriver
into the recess at the left end.
2. Gentle lever back the

screwdriver to prise the
SingleSensor Glass Sub-
Assy away from the
SingleSensor CIS Assy.
Page 60 of 129
3. Continue to gently pull the

whole SingleSensor Glass
Sub-Assy away from the Lid
Assembly.
4. Remove the SingleSensor

Glass Sub-Assy
5. When refitting the

Assy, make sure the right
end is against the End Plate.
6. Position the SingleSensor

Glass Sub-Assy over the
SingleSensor CIS Assy and
make sure it is central all the
way along.
NOTE: Before fitting the SingleSensor Glass

Sub-Assy, clean both sides with a lint free
cloth to remove any dust, dirt or fingerprints.
Page 61 of 129
7. Press firmly all along the

Assy until all the latches are
locked in place.
8. Clean the surface to remove

any fingerprints or dirt.
Utilities Program.
12. Re-cycle the scanner and software.
Page 62 of 129
14.4 SingleSensor CIS Assy

14.4.2 Tools
 Small Pozi-drive Screwdriver
 Medium Flat Screwdriver

 10H127 : M40 SingleSensor CIS Assy
 10H084 : M25 SingleSensor CIS Assy
14.4.5 Procedure

2. Disconnect the 4 x LED

cables as described in
page 45. Do not remove the
Main Board, just disconnect.
Page 63 of 129

Bracket as described in
chapter “14.2 Control Board”
page 53.
4. Gently lift the locking bar on

the ribbon cable connector,
make sure not to use
extreme force which could
break the connector.
5. Gently pull the ribbon cables

from the 3 (M40) or 2 (M25) x
connectors.
6. Fix the Lid Assembly into the

maintenance position as
Lid Assembly Maintenance
Position” on page 17.
Page 64 of 129

from the left end of the

from the right end of the
NOTE: With your free hand, hold the

SingleSensor CIS Assy in place to prevent it
dropping and being damaged.
9. Use the small screw to gently

push the SingleSensor CIS
Assy from the Lid Assembly.
10. Gently remove the

SingleSensor CIS Assy from
the Lid Assembly.
Page 65 of 129
11. Allow the CIS ribbon cables

to pull through the Lid
Assembly. Gently assist if
necessary.
12. Gently pull the remaining

length of the LED cables
through from the Lid
Assembly.
13. Gently lift the SingleSensor

CIS Assy away from the Lid
Assembly.
14. To refit, feed the LED cables

through the Lid Assembly
before lifting the
SingleSensor CIS Assy into
place, continuing to pull the
cables through the Lid
Assembly as the
SingleSensor CIS Assy is
lifted into place.
Page 66 of 129
15. Feed the CIS Cables through

the Lid Assembly before fully
inserting the SingleSensor
CIS Assy in place.
16. While holding the

SingleSensor CIS Assy flat in
place, refit the 2 x M3 screws
into the right end, but do not
tighten at this stage.
17. Refit the 2 x M3 screws into

the left end, but do not
tighten at this stage.
18. Before fully tightening the 4 x

M3 screws, apply slight
pressure in the centre of the
SingleSensor CIS Assy to
hold in place, and then
tighten the screws.
19. Make sure the LED cables

are through the Lid Assembly
and refit the Control Board
Bracket and Cover as
Control Board” page 53.
Page 67 of 129
20. Reconnect the 4 x LED

cables into their reference
position on the Main Board.
21. Re-insert the CIS Ribbon

cables into J1 - J3 (model
dependent). Make sure the
locking plate is up before
inserting the ribbon.
22. When the CIS Ribbon cable

is fully in place, press both
side of the locking plate down
to make connection
23. Refit the Main Board Cover

Main Board” page 45.
Page 68 of 129
24. Lower the Lid Assembly out

of the maintenance position
as described in chapter “Lid
Assembly Maintenance
Position” page 17.
Utilities Program.
28. Re-cycle the scanner and Utilities.
29. Run the Auto-stitch as described in chapter “15.9 Auto-stitch” page 118.
30. Re-cycle scanner.
Page 69 of 129
14.5 Drive Roller Unit

14.5.2 Tools
 Pliers

 10H071 : M40 Drive Roller Unit
 10H048 : M25 Drive Roller Unit
14.5.5 Procedure
1. Remove the appropriate

Lower Covers as described in
chapter “13.6 Lower Covers”
page 31.
NOTE: Use the same method for both front

and rear rollers, but remove the Lid Assembly
as described in chaper “13.8 Lid Assembly”
page 37” for the rear roller removal.
2. Remove the Main Timing Belt

Main Timing Belt” page 84.
NOTE: When removing the Rear Drive Roller

Unit, also remove the Drive Roller Timing Belt
as described in chapter “14.9 Drive Roller
Timing Belt” page 88.
Page 70 of 129
3. Remove the E Clip from the

Drive Roller Unit Shaft by
pushing on the open end of
the E Clip to slide off.
4. Pull the Drive Roller Unit

Pulley off from the Drive
Roller Unit Shaft.
NOTE: The Pulley can be difficult to remove.

Pull the pulley away from the scanner evenly
either side of the shaft.
5. Remove the 2 x M3 locking

screws and washers holding
the bearing into the Left End
Plate.
Page 71 of 129
6. Push the Drive Roller Unit so

the bearing moves out of the
Left End Plate.
NOTE: Only the Left End Bearing needs to be

removed during this procedure.
7. Remove the bearing, and

spring washer from the Drive
Roller Unit Shaft.
8. Lift and remove the Drive

Roller Unit out from the
recess.
9. To refit the Drive Roller Unit ,

first fit the Bearing and spring
washer onto the right end of
the Drive Roller Unit.
Page 72 of 129
10. Feed the Left end of the

Drive Roller Unit Shaft into
the hole in the Left End Plate,
and lower the Drive Roller
Unit into the recess.
11. Insert the right end of the

Drive Roller Unit Shaft into
the appropriate hole in the
Right End Plate against the
locking washers.
12. Refit the bearing and spring

washer and press into the
hole in the Left End Plate.
13. Refit the 2 x M3 locking

screws and washers.
Page 73 of 129
14. Line up the flat of the Drive

Roller Unit Shaft and the
Drive Pulley keyway and
push completely on.
15. Using pliers, refit the E Clip

onto the Drive Roller Unit
Shaft to hold the Pulley in
place.
16. Refit the Main Timing Belt as

NOTE: When fitting the Rear Drive Roller Unit,

also refit the Drive Roller Timing Belt as
described in chapter “14.9 Drive Roller Timing
Belt” page 88.
17. Refit the appropriate Lower

Covers as described in
chapter “13.6 Lower Covers”
page 31.
NOTE: For the Rear Drive Roller Unit, refit the

Lid Assembly as described in chaper “13.8 Lid
Assembly” page 37”.
Page 74 of 129
14.6 Hold Up Roller Unit

14.6.2 Tools

 10H070 : M40 Hold Up Roller Unit
 10H049 : M25 Hold Up Roller Unit
14.6.5 Procedure
1. Remove the Lower Covers as

Lower Covers” page 31.
2. Rotate the Hold Up Roller

Unit until the screw nearest
the End Plate is accessible.
NOTE: This can be hard to rotate due to the

belt connection to the Motor Drive. Rotating
the Drive Roller Unit at this point will also
rotate the Hold Up Roller Unit.
Page 75 of 129
3. Remove the M3 CSK Screw

from the Hold Up Roller Unit
Collar Assembly.

Unit again until the other
screw, nearest the Roller, is
accessible.
5. Remove the M3 CSK screw

from the Hold Up Roller Unit
Collar Assembly.
Page 76 of 129
6. Use the Screwdriver to assist

sliding the Hold Up Roller
Unit Collar Assembly across
towards the Left End Plate.
7. Use the Screwdriver to lift the

Hold Up Roller Unit.
8. Gently lift the Hold Up Roller

Unit out of the scanner.
9. Remove the bearing from the

Hold Up Roller Unit.
Page 77 of 129
10. When replacing, make sure

the Hold Up Spring is present
and the curvature of the
Spring Cap is aligned ready
for the bearing.
11. Insert the Bearing into the

hole on top of the Hold Up
Spring Cap.
12. Fit the Hold Up Roller Unit

Shaft into the bearing in the
Right End Plate.
13. Gently lower the Hold Up

Roller Unit into place, making
sure not to damage its
sleaving.
Page 78 of 129

Unit until the threaded hole is
accessible.

Unit Collar Assembly until it
lines up with the threaded
hole in the Hold Up Roller
Unit.
16. Slide the Hold Up Roller Unit

Collar Assembly across until
the 2 x holes line up.
Page 79 of 129
17. Refit the M3 CSK screw to

hold the Hold Up Roller Unit
Collar Assembly to the Hold
Up Roller Unit.

Unit until the hole at the left
end of the Collar is level with
the threaded hole in the Drive
Shaft.
NOTE: If necessary, rotate the Drive Roller to

align the two holes.
19. Refit the M3 CSK Screw to

hold the Hold Up Roller Unit
Collar Assembly to the Motor
Drive Shaft.
Page 80 of 129
20. Refit the Lower Covers as

Utilities Program.
24. Re-cycle scanner and software
Page 81 of 129
14.7 Hold Up Roller Unit Support Bar

14.7.2 Tools

 10H135 : M40 Hold Up Roller Unit Support Bar
 10H050 : M25 Hold Up Roller Unit Support Bar
14.7.5 Procedure
1. Remove the Hold Up Roller

Unit as described in chapter
“14.6 Hold Up Roller Unit”
page 75.
2. Use the Small Flat

Screwdriver to lift the right
end of the Hold Up Roller
Unit Support Bar.
Page 82 of 129
3. Lift the Hold Up Roller Unit

Support Bar up and out of the
recess.
4. To refit the Hold Up Roller

Unit Support Bar, position the
left end under the Drive shaft
at the lift end of the recess.
NOTE: It may be easier to fit with the Hold Up

Roller Unit Collar Assembly removed, but
remember to return it before refitting the Hold
Up Roller Unit.
5. Lower the Hold Up Roller

Unit Support Bar into the
recess and make sure it sits
level.
6. Refit the Hold Up Roller Unit

Hold Up Roller Unit” page 75.
Page 83 of 129
14.8 Main Timing Belt

14.8.2 Tools
 M7 Nutspinner

 51H001 : Main Timing Belt (part of 10H030 : Timing Belts Kit)
14.8.5 Procedure

2. Loosen the Main Timing Belt

Tension Bar. Making sure not
to release the nut fully from
the bolt. Slide the Tension
Bar up and re-tighten to hold
the bar out of the way.
NOTE: The Drive Roller Timing Belt does not

need to be removed as shown in these
photos.
Drive Roller Timing Belt Main Timing Belt
Page 84 of 129
3. Pull the Main Timing Belt off

from the Drive Roller Pulley.

by lifting off from the Motor
Pulley.
5. To refit the Main Timing Belt

loop the belt and feed up
through the Motor Bracket.
6. Fit the Main Timing Belt over

the Motor Pulley.
Page 85 of 129
7. Make sure the Main Timing

Belt goes around the
secondary Tension Bar.
8. Position the Main Timing Belt

over the Front Drive Roller
Pulley.
9. Position the Main Timing Belt

over the Rear Driver Roller
Pulley and rotate the pulley if
necessary to get the Main
Timing Belt completely on.
10. Make sure the Main Timing

Belt follows the correct path
as shown.
Page 86 of 129
11. Loosen the M3 nut so the

Tension Bar can drop down,
then apply very slight finger
pressure downwards to
remove excess movement
from the Main Timing Belt.
Tighten the M3 nut; but do
not over tighten.
12. Refit the Left End Cover as

Page 87 of 129
14.9 Drive Roller Timing Belt

14.9.2 Tools
 M7 Nutspinner.

 51H002 : Drive Roller Timing Belt (part of 10H030 : Timing Belts Kit)
14.9.5 Procedure
1. To remove the Drive Roller

Timing Belt, first loosen the
Main Timing Belt from the
Rear Drive Roller Pulley, as
2. Loosen the Drive Roller

Timing Belt Tension Bar.
Making sure not to release
the nut fully from the bolt.
Slide the Tension Bar down
out of the way.
Page 88 of 129
3. Remove the Drive Roller

Timing Belt from around the 2
pulleys.
4. To replace the Drive Roller

Timing Belt, position around
the Rear Drive Roller Pulley
and then the Hold Up Roller
Unit Pulley.
5. Make sure the Drive Roller

Timing Belt goes around the
part of the Rear Drive Roller
Pulley nearest the End Plate.
6. Make sure the Drive Roller

Timing Belt goes over the 2
larger pulleys, and over the
top of the Drive Roller Timing
Belt Tension Bar.
Page 89 of 129
7. Apply very slight pressure

upwards to remove excess
movement from the Drive
Roller Timing Belt. The belt
must not be too tight as this
will cause the motor to lock
up during operation. The
bearings should only touch
the belts enough to hold the
belt in place, not apply
pressure.Do not over tighten
the M4 Nut.

Page 90 of 129
14.10 Paper Sensor

14.10.2 Tools

 71H001 : Paper Sensor Assembly (part of 10H078 : M40 Paper Sensor Pack)
 71H001 : Paper Sensor Assembly (part of 10H051 : M25 Paper Sensor Pack)
14.10.5 Procedure

page 53.
NOTE: It is not necessary to remove the

Control Board from the Control Board Bracket
for this procedure.
2. Release the Paper Sensor

Cables from the Lid
Assembly Cable Clips.
Page 91 of 129
3. Remove the Upper Covers as

Upper Covers” page 35.
NOTE: Only the Upper Covers associated with

the Paper Sensor needs to be removed.
4. Gently pull the Paper Sensor

until it is free from the
bracket.
5. Gently pull the Paper Sensor

Cable free from the Lid
Assembly.
6. To refit the Paper Sensor

Cable, insert back through
the hole in the Lid Assembly.
NOTE: Each Paper Sensor has an individual

reference number. Match the numbers on the
Sensor and Cable.
7. Make sure the Paper Sensor

layout is as shown.
Page 92 of 129
8. Refit the Upper Covers as

9. Re-insert the Paper Sensor

Cables into the Cable Clips.
10. Refit the Control Board

page 53.
Page 93 of 129
14.11 Pinch Roller Assembly

14.11.2 Tools
 Pliers

 10H008 : Pinch Roller Assembly (Pack of 4)
14.11.5 Procedure

2. Remove the Upper Covers as

NOTE: Only the Upper Covers associated with

the particular Pinch Roller Assembly need to
be removed.
Page 94 of 129
3. Use the Small Flat

Screwdriver to prise the E
Clip from the Pinch Roller
Assembly Shaft needing
removal.
4. While removing the E Clip,

keep hold of the Pinch Roller
Assembly and gently remove
it.
5. To refit, insert the Pinch

Roller Assembly into the
bracket, making sure the
spring is fitted and it is fully
pressed in the correct
orientation.
NOTE: The spring will push the Pinch Roller

Assembly out if not held.
6. While continuing to press in

the Pinch Roller Assembly,
refit the E Clip in the recess
of the shaft.
Page 95 of 129
7. Refit the Upper Covers as


Page 96 of 129
14.12 Power Switch

14.12.2 Tools
 Pliers

 10H009 : Power Switch
14.12.5 Procedure


page 45.
Page 97 of 129
3. Gently pull each cable off

from the Power Switch
terminals using pliers.
4. Press the latches of the

Power Switch in with the
Small Flat Screwdriver and
push the switch through the
hole.
5. Pull the Power Switch

completely out from the Rear
Panel.
6. Refit the Power Switch by

pushing through the hole in
the Rear Panel until the
latches lock in place.
7. Make sure the ‘1’ position is

towards the End Plate, as
shown.
Page 98 of 129
8. Reconnect the cables to the

Power Switch Terminals
pushing firmly in place with
pliers.
9. Make sure the wires are fitted

in the correct terminals as
shown.


Page 99 of 129
14.13 Power Socket

14.13.2 Tools
 Pliers

 10H010 : Power Socket Assembly
14.13.5 Procedure


page 45.
Page 100 of 129

3. Using pliers, disconnect the 2

x Cables connected to the
Power Switch.
4. Remove the M4 screw

holding the ‘P’ cable clip and
earth tag.
5. Remove 2 x screws holding

the Power Socket to the Main
Board Cover.
6. After disconnecting the

cables from the Cable Clip,
remove the Power Socket
from the Rear Panel.
7. Refit the Power Socket,

making sure the Cables are
inserted into the Cable Clip.
Page 101 of 129

8. Make sure the Power Socket

has the keyway towards the
top, as shown.
9. Refit the M4 screw to hold

the ‘P’ cable clip and Earth
tag to the Main Board Cover.
10. Reconnect the 2 x cables to

the Power Switch, making
sure they are the same
orientation as the existing
wires.


Page 102 of 129

14.14 Microswitch

14.14.2 Tools

 10H024 : Microswitch Unit
14.14.5 Procedure


Cables, and release it from
the Cable Clip on the End
Plate.
Page 103 of 129

3. Remove the Lower Covers as

NOTE: Only the Lower Covers at the right end

need to be removed for this procedure.
4. Remove the 2 x M2.5 screws

holding the Microswitch to the
End Plate.
5. Carefully pull the Microswitch

Cable through the hole in the
End Plate.
6. Refit the Microswitch Cable

by feeding it carefully through
the hole in the End Plate.
7. Make sure the Microswitch is

facing towards the front of the
scanner, as shown.
Page 104 of 129

8. Replace the 2 x M2.5 screws

to hold the Microswitch to the
End Plate.
9. Reconnect the Microswitch

Cables.
10. Insert the Microswitch Cable

into the Cable Clip on the
End Plate.
Page 105 of 129

11. Refit the Lower Covers as

12. Refit the Right End Cover as

13. If the Microswitch does not

activate when the Lid
Assembly is closed, or the
Lid Assembly cannot close
proberly, it may be necessary
to loosen the screw holding
the Microswitch Activation
Bracket and reposition it.
Page 106 of 129

14.15 Motor

14.15.2 Tools
 Medium Pozi-drive Screwdriver
 1.5mm Allen Key
 Pliers

 10H021 : Motor Sub-Assembly
14.15.5 Procedure

2. Disconnect the Motor Control

Cables.
Page 107 of 129


holding the Motor to the
Bracket.
NOTE: Remove the screw at the top last. The

screw will hold the Motor in place while
removing the other 3 screws.
4. Remove the Motor Sub-Assy.
5. Use the Allen Key to loosen,

but not remove, the 2 x grub
screws holding the Motor
Drive Pulley to the Motor
Shaft.
6. Remove the Motor Drive

Pulley, and refit onto the
replacement Motor (if
necessary).
NOTE: When refitting the Motor Pulley Unit,

use a small amount of thread lock on the grub
screw before inserting them, to prevent them
becoming loose again during operation.
Page 108 of 129

7. Refit the Motor Sub-Assy

making sure the cable is at to
the top left corner.
8. Starting at the top of the

Motor, refit the 4 x M4 screws
and nuts, do not tighten until
all 4 are in place.
9. It may be necessary to use

pliers to refit the bottom M4
nut and washers.
10. Lightly tighten the M4 nuts,

see illustration below.
Just tight enough the hold. Too tight as to crush the

Too loose as to not hold at all.
grommet.
Page 109 of 129

11. Reconnect the Motor Cables

together, and fit into the cable
clip.

Page 110 of 129

15 Utilities Program
15.1 Installation
1. If it has not been installed

during the initial setup,
locate the file setup.exe on
the accompanying CD, or
the Website, and run it.
2. Follow the “Next”

commands until the
installation is complete.
3. If the Icon is not displayed

on the desktop, locate the
file “C:\......\ProgramData\
Colortrac\M Series
Utilities\SmartFL M
utilities.exe”, right click it,
and copy a shortcut to the
desktop.
Page 111 of 129

15.2 Calibration

 10H028 : Calibration and Auto-stitch Target
1. Open the Lid Assembly and

clean the SingleSensor
Glass Sub-Assy. Close the
Lid Assembley.
2. Insert the Calibration Target

so that the black part
section is inserted first, face
up.
NOTE: It is necessary to remove the

Magnetic Paper Guide so the target can fit
centrally in scanner.
3. Double click the SmartLF M

Utilities icon.
4. On the front page, click the

‘Calibrate’ button.
Page 112 of 129

5. Click ‘OK’ to except the

message.
6. After approx. 4 minutes, the

‘Calibration’ (or
Normalisation) is complete.
During calibration , the
target will move through the
scanner in stages several
times.
Page 113 of 129

15.3 Power Saving

Utilities icon.
2. Enter the amount of time,

after last use, the scanner
will power off. The Max
Value is 15. Select ‘Apply’.
15.4 Auto width

Utilities icon.
2. Select either mm, inches or

off to display when
autosizing.
Page 114 of 129

15.5 Second Level Utilities

Utilities icon.
2. To enter the second level

utilities Click ‘Utilities’ at the
bottom of the front page.
15.6 Scanner Upgrade
1. Follow the instructions to

the Second Level Utilities in
chapter “15.5 Second
Level Utilities” page 115.
2. If the scanner is an ‘M’ or

‘C’ model, highlight the
appropriate upgrade model,
enter the correct serial
number for the scanner
attached, and select
‘Produce file’. This will
produce a txt file that can
be emailed to:
[email protected]
Page 115 of 129

15.7 Automatic Updates
1. Follow instructions to the

Second Level Utilities in
2. Highlight to request
automatic updates of the
utilities or scanner
information. De-select if the
PC does not have internet
connection.
15.8 Firmware Installation

2. Download the latest

firmware from the download
site:
http://www.colortrac.com/support/drivers
Page 116 of 129

3. Click the browser button to

locate the downloaded
firmware. After selecting the
firmware #########.cab
file, click download.
4. Agree to the warning

message.
NOTE: It is important to allow the firmware

to complete. Although the Main Board now
carries a backup firmware, there is still a
possibility of irreversible corrupting if the
download is disturbed.
5. Once the download has

finished it will request the
scanner and software are
both Re-cycled.
Page 117 of 129

15.9 Auto-stitch

 10H028A : Calibration and Auto-stitch Target

2. Insert the Calibration Target

so that the black section is
in first, and face up.
NOTE: It is necessary to remove the

Magnetic Paper Guide so the target can fit
centrally in the scanner.
3. Click ‘Auto-stitch’ button to

start the process.
4. Click ‘OK’ to except the

message.
Page 118 of 129

5. On completion, click the

‘OK button.
Useful Information:
 FB stitch range: 0 – 32
 LR stitch range: 0 – 88
15.10 Run Diagnostics
Running the Diagnostic will allow the Utilities to compare how the scanner is operating to how it knows
it should, and will offer an automatic fix of each parameter.
Typical error messages include:

 100 – USB (typically caused by Etron USB 3.0 chipset).
 101 – User parameter corruption.
 102 – Factory parameter corruption.

2. Click ‘Run Diagnostics’

button to start the process
and follow any message
that appear.
NOTE: It is still advisable to contact support

before running the diagnostics.
Page 119 of 129

16 Distributor’s Utilities
16.1 Engineering Utilities
1. Double click on the

SmartLF M Utilities icon on
the PC attached to the
scanner.
2. Right mouse click in the

front page to access the
engineering utilities.
Password: p107
NOTE: Do NOT inform end-users of this

password unless deemed absolutely
necessary by a Colortrac Support Engineer
Page 120 of 129

16.2 Manual Stitch
1. Enter the distributor’s

utilities as described in
chapter “16.1 Engineering
Utilities” page 120.
2. Make fine adjustments to

the stitch values of each
section of the SingleSensor
CIS Assy by over writing
the appropriate value and
clicking ‘Set Stitch’
If the image, scanned at 600dpi, needs an adjustment of (for example)1 pixel, change the value at the
CIS area (e.g. CIS1) by 1 count in the same direction that moving the line will solve the problem. The
same is true for both the FB and LR stitch values. If an adjustment is made to any of the inner values,
then all values before that point need to be change by exactly the same amount in the same direction.
Values cannot be negative numbers.
Example: CIS 3 has a step of 2 pixels higher than CIS 4, adjust CIS’s 1, 2 and 3 by -2 counts or CIS 4
and 5 by +2 counts.
It is important to always click ‘Set Stitch’ after making any adjustments, as these new figures are not
sent to the scanner unless it is set.
Useful Information:
 FB stitch range: 0 – 32
 LR stitch range: 0 – 88
Page 121 of 129

16.3 Motor Speed

2. When changing a Main

Board, this values might
need to be recorded prior to
removing the board if the
reference lable is damaged
or missing from under the
scanner. Record this value.
3. After fitting a Main Board,

over write the value at this
point with the recorded
value, and click ‘Set Motor
Speed’
4. Using this equation will help

recalculate a new motor
speed to compensate for
inaccuracies that may
occur:
NOTE: Use a document of known length that

is no shorter than 1m long.
Useful Information:
 Default Motor Speed: 78000
Page 122 of 129

16.4 Load Delay

2. Change the length of delay

before the scanner takes
the media in by over writing
the value and clicking ‘Set
Load Delay’
NOTE: The value is in mSec, so 1000 is

equal to 1 second, 2000 is 2 seconds etc.
Useful Information:
 Default Load Delay: 1000mSec.
Page 123 of 129

16.5 Paper Staging

2. Make a adjustments for the

start and end of media, to
reduce or increase the
‘border’ of the scanned
image, by over writing the
pixel count and clicking the
appropriate ‘Set Paper…’
button.
Page 124 of 129

17 Help Desk
17.1 Extending Warranty
1. Open Helpdesk www.colortrac-helpdesk.com
2. Enter your account details.
3. Create a new ticket
4. Go to the Asset Info tab,

enter the serial number of
the scanner in the
appropriate box, and
search. When the scanner
is highlighted, choose that
scanner.
Page 125 of 129

5. Go to the Ticket Details tab,

and in the request type,
choose ‘Notification of
Installation Date’
6. Enter the serial number of

the scanner
7. Enter the installation date,

making sure that it is within
the 3 month period since it
was shipped out to your
company, if not, the system
will only take the 3 months
date as the installation date.
8. Highlight ‘Client’ and ‘Tech’.
9. Press ‘Save and Email’
Page 126 of 129

18 Glossary
Term Description
Assembly A collection of parts put together to make a specific unit.
Assy Short for Assembly, see Assembly.
Automatic process to make an electronic adjustment by way of delays

Auto-stitch and the use of spare pixels for each CIS that make up the
SingleSensor CIS Assy, so it sees along the same scan line correctly.
The process of setting the black and white levels for each CIS section
Calibration so they all see the same values along the scan line. Formally known
as Normalisation.
Contact Image Sensor. Device used to aquire images by way of colour

CIS sensitive sensor that detect each Red, Green and Blue varients
seperately as it pass over an image at close range.
Countersunk. A type of screw head that will allow the screw to sit in a
CSK recess that is level with, or below, the surface of the material being
screwed into.
Electromagnetic Compatibility. Stray signals nterfe from electronic

EMC
devices that can cause nterference with other equipment.
The plastic cover that goes over the mechanics at the ends of the
End Cover
scanner.
The plastic plate that clips onto the End Covers to hide the screw
End Cover Plate
heads that hold the End Covers to the scanner.
Front / Back. Normally referring to the stitch values on the horizontal

FB
(x) axis of the SingleSensor CIS Assy.
A screwdriver that fits into the screw heads that have a slot cut in
Flat Head Screwdriver
which is used to remove or tighten the screws.
Left / Right. Normally referring to the stitch values from vertical (y) axis
LF
of the SingleSensor CIS Assy.
Also known as the Upper Housing unit, this contains all the electronics
Lid Assembly
that operate the scanner and is located at the top of the scanner.
Another term for ‘Calibration’. Setting the black and white points of the
Normalisation scanner, so that all the CIS see the same value for Black and White all
the way along the scan.
Page 127 of 129

The manual checking of the values and image adjustment created by

Manual Stitch the auto-stitch process. Adjustments are also possible with manual
stitch.
A cross ended screwdriver that fits into the screw heads that have a
Pozi-drive Screwdriver
cross shaped recess in which is used to remove or tighten the screws.
Sometimes referred to as a ‘Cog’, this is a circular, toothed mechanism

Pulley used for turning 2 or more rollers at the same time by way of a toothed
belt.
RGB Red, Green and Blue colours.
Also referred to as the “SingleSensor” in some documentation, the unit

SingleSensor CIS Assy houses the 5 x CIS devices along a single line, instead of staggered as
in previous Colortrac CIS models.
Short for Sub Assembly. A collection of individual parts put together to

Sub-Assy
make a unit that goes towards making up a higher Assembly.
The metal cover plate that goes over the top of the Lid Assembly to
Top Lid Cover
hide and protect the electronics that operate the scanner.
Page 128 of 129

19 Service Manual Release Notes
Issue Number Date of Release Changes to Service Manual
Issue 1 23/10/2012  First issue.
20 Features Not Included
The following information is not included in this Manual:

 Part Prices (please see the ‘Spares Catalogue’ on the Colortrac Support Site)
 Part Assemblies (please see the ‘Parts Catalogue’ on the Colortrac Support Site)
 Parts Weights and Dimensions
 Reliability Data
Page 129 of 129

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M40SM Colortrac Ltd Page 1 of 129

Issue 2 M Series Service Manual Date: 20/12/12

©Colortrac Ltd 2012

No part of this product or publication may be reproduced,

Tel: +44 (0)1480 464618

14.3 SingleSensor Glass Sub-Assy ....................................................................................... 60

1.1 Scanner Models

There are 2 x M series Models:

SmartLF M25e  Scan width of 25 inches

SmartLF M40e  Scan width of 42 inches

3. 7mm Nutdriver. 4. 1.5mm Allen Key

5. Medium Pozi-drive screwdriver. 6. Small Pozi-drive screwdriver.

7. Small Flat Screwdriver 8. Medium Flat Screwdriver.

3 Obtaining Technical Support from Colortrac

3.1 Creating an Account

3.2 User Profiles

3.3 Submitting Requests for Support

3.4 Asset Selection

3.5 Support Ticket Information

In the detail of each ticket Users can expect to see:

 All pertinent information to the investigation

The notes facility can be used to provide further information.

4 How to Contact Technical Support

Contact Numbers  Support Direct Line: +44 (0) 1480 409997

Technical Downloads  http://www.colortrac.com/support/software-downloads/

Technical Support Website  www.mseries.colortrac.com

5.1 Safety Warnings

Please observe anti-static precaution when handling any

5.1.4 Rotating Rollers

5.2 EMC Testing

Do:  Have 2 people to lift the scanner.

NOTE: Before work is carried out on the

When a Distributor requests a warranty replacement, Colortrac Technical Support will

8.1 Warranty Period

9 Control Board Replacement Statement

The light-sensing system is the silicon surface which is

The illumination is provided by Light Emitting Diodes

11.1 USB Cable Type A and B

Length: 3 meter max.

This high quality USB cable complies fully with

 Transfer Speed ~ a new transfer type

There have been some issues of USB 3.0 equipment only

11.2 External Power Supply

AC I/P 100 – 240V ~ 1.5A 50 – 60 Hz

DC O/P 19V 9.47A

12.1 Block Diagram

1 x SingleSensor CIS Assy

12.2 Scanner Operation

Left Hand Back

Insert Media FACE UP into the scanner.

13 Removing and Replacing Panelling

13.1 Lid Assembly Maintenance Position

13.1.2 Safety Precautions

13.1.4 Associated Part Numbers

13.1.5 Important Information

 For all photos, please refer to chapter “7 Photos Information” on page 9.

1. To raise the lid, remove the 3

Note: This can be carried out with or without

2. Remove the 3 x M5 screws

3. While removing the screws