Xerox Documate 6440 User Guide

							Xerox® DocuMate® 6440 Maintenance
36User Guide
2. Open the Automatic Document Feeder cover.
3. Wipe clean the rollers and glass in the scanner body. Rotate the rollers to clean the entire 
surface.
4. Wipe clean the rollers and glass in the underside of the ADF door. Rotate the rollers to clean 
the entire surface.
5. Using a clean, dry cotton swab, brush away any dust on the double feed detection sensors. 
						

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6. Close the scanner when you’re finished.
Replacing the Separation Roller
The roller will wear out and is designed to be a user-replaceable part. A worn roller can cause 
documents to feed in skewed at an angle, or multiple pages to feed at the same time. Before 
replacing the roller you should clean it as excessive dust on the roller will make it appear worn and 
smooth. You cannot properly diagnose a worn roller until you have cleaned it. You should generally 
replace the roller between 80,000 and 100,000 scans. 
Replacement parts can be purchased from the Parts & Accessories page for your scanner at 
www.xeroxscanners.com
.
1. Open the scanner.
2. Locate the roller cover in the ADF door. 
						

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3. Pinch the sides of the roller cover and pull it down to access the roller.
4. Carefully angle the roller up and out of the scanner.
5. Remove the replaceable roller from the bar.
6. Discard the roller, it cannot be repaired or reused.
7. Take the new roller out of its packaging. Clean any dust off the roller before installing it. 
8. Slide the new roller onto the bar. Make sure the struts on the bar line up to the slots in the end 
of the roller.
9. Insert the round end of the roller into the slot in the scanner. Carefully lower the roller into the 
scanner. Make sure the groove on the right side of the roller is aligned so that it slides in place 
into the U-shape of the bracket. 
						

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10. Lift the roller cover and carefully push it closed to lock it in place. Make sure everything is 
aligned properly and the cover is fully closed. If the cover is not fully closed it will break during 
scanning and damage the scanner.
11. Close the scanner when you’re finished.
Replacing the Feed Roller
The roller will wear out and is designed to be a user-replaceable part. A worn roller can cause 
documents to feed in skewed at an angle, or multiple pages to feed at the same time. Before 
replacing the roller you should clean it as excessive dust on the roller will make it appear worn and 
smooth. You cannot properly diagnose a worn roller until you have cleaned it. You should generally 
replace the roller every 160,000 to 200,000 scans.
Replacement parts can be purchased from the Parts & Accessories page for your scanner at 
www.xeroxscanners.com
.
1. Open the Automatic Document Feeder cover. 
						

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2. Locate the roller cover in the body of the scanner.
3. Move the paper guides to the side and then pull the feed roller cover away from the scanner. 
Note: if the paper guides are in front of the roller cover when you open it, they will 
automatically release from the scanner body. If this happens, follow the instructions on 
page 33 for resetting the guides in the scanner.
4. The lower roller is held in place with a lock tab that rotates to lock and unlock it. To unlock the 
tab, rotate it until the small lock flange is completely free. 
						

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5. Carefully angle the roller up and out of the scanner and then discard it, it cannot be repaired.
6. Take the new roller out of its packaging. Clean any dust off the roller before installing it. 
7. Insert the left end of the new roller assembly into the hole in the roller channel. Angle the 
roller module into the roller channel. Align the tab on the lock flange with the slot in the 
scanner. 
Make sure the belt on the roller is facing you and that the gears on the roller module properly 
align to the gears in the scanner. Hold the roller module in the scanner while you lock it in 
place. 
8. Rotate the locking tab into the slot in the scanner. Push on the lever until it clicks in place and 
locks the roller in the scanner. 
The lock will “click” into place when it is secure. However, if it does not rotate easily into the 
housing, make sure the flange is properly seated in its latch.
9. Lift the roller cover and carefully push it closed to lock it in place. Make sure everything is 
aligned properly and the cover is fully closed. If the cover is not fully closed it will break during 
scanning and damage the scanner. 
						

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10. Make sure the paper guides are properly seated in the scanner.
11. Close the scanner when you’re finished.
Troubleshooting
Problem: The scanner won’t scan. What’s wrong? 
Check for one of these possible causes:
•Are the cables loose or not plugged in securely? Inspect the cable connections. Make sure 
the cables are plugged in securely.
•Is the scanner’s status light on? Turn on the scanner’s power. If the status light doesn’t 
come on, plug the power supply into another electrical outlet. If you are using a UPS battery 
back-up or power strip, try plugging the scanner directly to a wall outlet.
•Did you restart the computer and scanner? If the scanner gets a paper jam, or looses 
connection because of an error, try restarting your computer and power cycling the scanner.
•Did you plug the scanner into a USB hub? If you’re using a USB hub to connect the scanner 
try plugging the scanner’s USB cable directly to the back of the computer. It is not 
recommended that you use the scanner with a USB hub, if you are using a hub, the hub must 
have its own power supply.
•Is the USB cable 6’ or less? If you are using a USB cable that is longer than 6’ you may lose 
connection to the scanner. The recommended USB cable length is 6’ or less, the USB cable 
provided with your scanner is within this range.
•Did you select another image source in the scanning software? If you use multiple 
imaging devices with your computer, such as a camera, all-in-one printer, or another scanner, 
you may have selected another source for images. Make sure Xerox
® DocuMate® 6440 is 
selected as the scanner. 
						

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Problem: Why does my scanner not function after performing a system restore on Windows?
The system restore process may have corrupted some of the driver components. It is 
recommended that you reinstall your scanner driver. Please refer to “Uninstalling Your Scanner” on 
page 45 for installation instructions.
Problem: Why won’t my scanner buttons work after scanning with Windows Image Acquisition 
(WIA)?
After performing a scan using the WIA interface you must close the application you were using 
before scanning with the buttons on the scanner. This does not occur when scanning using the 
TWAIN or ISIS interface.
Problem: Why won’t my scanner work after the computer has been sitting idle for several hours?
To resolve the problem, simply turn off the scanner power then turn it back on again.
This may occur after Windows goes into power saving mode to “hibernate” the computer into a 
low power state. When you move your mouse or type on the keyboard it “wakes” the computer 
back up and restores full power to the system. This power fluctuation during the computer’s 
hibernating period may sometimes cause the scanner to lose communication to the computer.
Problem: The installation will not complete successfully. If installation finishes, the scanner’s 
OneTouch options do not seem to work properly.
A likely cause is that some driver programs are already installed on your computer for another 
scanner. They may be interfering with the installation and OneTouch options, and you need to 
remove those other drivers and re-install your Xerox
® scanner. You can remove these programs 
from the Windows Control Panel. Please refer to the user manual provided with your other scanner 
hardware for instructions about removing the driver and software for that unit.
Problem: My computer keeps giving me out of hard drive space error messages.
The minimum requirement of free hard drive space is for the installation of the scanner driver and 
basic, low resolution, scanning. High resolution scans result in files that can be over 1 gigabyte in 
size. Free up some space on your hard drive for the software to be able to save the scanned 
images.
Problem: The paper jams the ADF. 
To reduce the number of paper jams, smooth and straighten the paper before scanning, and 
adjust the guides to the paper size. Paper fed into the ADF at an angle can cause the feed 
mechanism to jam. If paper jams are occurring more frequently, try cleaning the roller with a soft 
cloth dampened with Isopropyl rubbing alcohol. Excessive dust on the roller can make it appear 
worn and will cause issues feeding paper. See “Cleaning Inside the Automatic Document Feeder” 
on page 35 for cleaning instructions. 
Problem: The ADF won’t feed pages properly. 
A dirty or worn roller can cause documents to feed in skewed at an angle, or multiple pages to feed 
at the same time. First, try cleaning the rollers as described in “Cleaning Inside the Automatic 
Document Feeder” on page 35. If the problem persists, the separation and/or feed rollers may 
need to be replaced. Please see “Replacing the Separation Roller” on page 37 and “Replacing the 
Feed Roller” on page 39. 
						

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Problem: If the USB cable is disconnected during a scan, the scanner does not reconnect when 
the USB cable is plugged back in.
Unplug the power cable from the scanner, and then plug it back in.
If the scanner does not reconnect:
1. Unplug the power cable from the scanner.
2. Restart your computer.
3. After the restart is complete, plug the power cable back in.
Problem: The scanner reports a Double Feed error when there is only one page in the scanner.
Try cleaning the double feed detection sensor. Dust on the sensor may prevent the sensor from 
working properly.
Error Light Troubleshooting Codes
Normal Operation
•Steady blue: indicates the scanner is ready to scan.
•Slow flashing blue: indicates the scanner is in low power mode.
•Rapid flashing blue: indicates the scanner is waking up from low power mode.
•Steady red: the scanner is busy or it is not connected to the computer. 
•Flashing red: the scanner is reporting an error.
Error Codes
The status light indicates the current state of the scanner. If your scanner experiences hardware 
problems, the status light turns red and will flash a specific number of times, pause, and then 
repeat the same number of flashes. The number of flashes between pauses indicates the 
hardware error code. The LED display will also flash an “E” then the error code number that 
matches the status light’s blinking pattern.
Descriptions of the most common patterns are listed below. In all cases, you should turn off the 
scanner and check the scanner setup. Make sure the USB cable is plugged into the scanner and 
computer. Make sure the power cord is plugged into the scanner and into a wall outlet. Contact 
Xerox Technical Support if you experience a different blinking pattern.  
						

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Uninstalling Your Scanner
Use the options in the Windows Control Panel to remove the scanner driver and modules, and any 
other software provided with the scanner.
Please leave the scanner’s USB cable plugged into the computer while uninstalling the scanner 
driver. Unplug the USB cable when directed to do so in the instructions below.
Open the list of installed programs in the Windows Control panel.
• Windows XP: Open Add/Remove Programs
• Windows Vista and later: Open Programs and Features
Uninstalling the scanner driver:
1. In the list of installed programs click on Xerox
® DocuMate® 6440 driver.
2. Click the Change/Remove or Uninstall button.
Error 
CodeProblem DescriptionSolution
0 Scanner is not connected to the 
computer
(The LED does not flash “E” and 
the status light remains blue.)A cable may be loose. Check that the scanner’s cables are 
correctly attached to the computer. If the scanner still does 
not connect, re-boot the computer.
4 Paper jam Open the ADF cover and remove the jammed page. See 
“Clearing Paper Jams” on page 35.
5 Multiple paper feed Multiple pages have fed through the scanner at one time. 
Open the ADF door and remove the pages from the 
scanner. Make sure the pages are not stuck or taped 
together before loading them in the ADF. If the problem 
persists, clean the scanner as described in “Cleaning Inside 
the Automatic Document Feeder” on page 35.
6 The scanner’s cover is open The ADF door is not closed all the way. Open the scanner, 
make sure the paper guides are properly seated in the 
scanner and that the roller covers are fully closed, and then 
close the ADF again. Push down on the lid until it locks into 
place.
7, 8 The lamp in the scanner body 
or lid has malfunctionedThis usually occurs if the power was disconnected during a 
scan. Turn the scanner off, then back on again. If the 
problem persists, turn off the scanner, re-start the 
computer, then turn the scanner on. If the problem 
continues, and your scanner’s power is plugged into a 
surge protector or UPS battery backup, try plugging the 
scanner power directly into a wall outlet.
All 
Other 
CodesAn internal part in the scanner 
may have malfunctionedTurn off the power to your scanner, re-boot your computer, 
then turn it back on. If the problem persists, contact Xerox 
Technical Support.