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01-07-11FL Manual

1. A H i a ell ollo S R 2 se Z z zi Fal E O SS TII A oe Cfo ol N o o A J 4 S SN FUMFL N BILL VALIDATOR REAR VIEW L i TA LI POWER 110 240 V AC 50 60 HZ page 2 4 Part 2 Testing and Repair Rev 05 2003 el J CashCode FrontLoad Bill Validator Series Operation amp Service Manual Step 2 On PC start by clicking on the icon CashCode Service Centre Support Software Under Device or module to test select FLO2 Diagnostics as an assembly Under Unit type select FrontLoad FL or Multi width FrontLoad MFL and an appropriate power interface module Step 3 Click the Run button on the toolbar Wait for test to be completed Review the test results Device ua AA best mymliable Dmt type Cennperct FL te Barvice Stad Wilh tables mi shown on the ptrigre cet dih reitch en the Demniasd baard OH check oll elingi amd preis Eon bahen Actual screen shot from computer using CashCode Service Stand The Failures and Possible causes parts of the screen should help identify any defective module and show possible reasons for failure Click on the Show Picture button for an x ray view of the FrontLoad device which highlights defective modules See picture on the next page R
2. page 2 144 Part2 Testing and Repair Rev 05 2003 CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Bezel FLB 3111 FLB 3131 MFLB 3201 Step 5 Press on latches of the window as shown by arrows Release the latches and remove the window Window 5210021 Panel 5201045 Step 6 Press on the latches of the eye glass as shown by arrows Release the latches and remove the eye glass N Eye glass 5210035 Rev 05 2003 Part2 Testing and Repair PAGE 2 145 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF BEZEL FLB 3311 FLB 3331 MFLB 3401 Tools required Flat screwdriver Philips screwdriver 1 Step 1 Remove one screw Remove display board and cable Disconnect all cables from the display board lt i Washer M3 Plain Zinc Le cane Assy 8203927 G gi Cable Ass y Screw M3x12 Phillips Pan Head Zinc 8201934 Step 2 Remove two screws Remove holder assembly with display 8203927 Tapping Screw Cross Recessed Pan Head Type AB ANSI B18 6 4 4 24 X 3 4 2 pcs 8201A07 page 2 146 Part2 Testing and Repair Rev 05 2003 SlCashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Bezel FLB 3311 FLB 3331 MFLB 3401 Screw M2x8 Phillips Pan Head Zinc 4 pcs 8201A08 Washer M2 Plain Zinc
3. Lock Washer M3 Internal Tooth Zinc nage 2 100 gt Cassete Detector 8203002 0900016 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of HOUSING FLH 0810 Rolled Spacer Bracket Assembly 8208994 0100138 02 gt Lock Washer M3 Internal Tooth Zinc 8203002 2 pes Screw M3x20 Phillips Pan Head Zinc 8201935 Ns Screw M3x20 Phillips Pan Head Zinc 8201935 Lock Washer M3 Internal Tooth Zinc 2 pcs 8203002 Cover Assembly 0100186 _ WA oa Gear i Shaft 5203031 8 5308026 Rolled Spacer a i 8208998 Ba A Connector _ 5202031 Flat Washer 8203999 J Flat Spring i ji 5109015 Spring 2 pes 5409028 Latch 5106010 ag Lever Assembly y 0100148 A SSES Shaft 5308027 Lever 5110048 S Tip _ i 5210015 Spring a Screw M3x6 Phillips Pan Head Zinc 5409008 8201000 Lock Washer M3 Internal Tooth Zinc 8203002 Cassete Detector j 0900016 L Spring 5409630 E Screw M3x6 Phillips Pan Head Zinc 8201000 2 pcs ge ek Switch Assembly Lock Washer M3 Internal Tooth Zinc 4 0900017 8203002 ee 2 pes Rev 05 2003 Part 2 Testing and Repair PAGE 2 101 Co ICashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of HOUSING
4. Press on the walls of the case as shown by arrows Shift housing toward the open cover and remove it Housing Assembly 0100119 Case Assembly 0100123 page 2 162 Part 2 Testing and Repair Rev 05 2003 SI CashCod e FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASSETTE FLC 503 FLC 603 Tools required Flat screwdriver Philips screwdriver 1 Step 1 Follow Step 1 as in Disassembly Of Cassette FLC 103 Step 2 Remove the wood screw Remove parts Wood Screw 2x1 2 8201280 Flat Washer 4 8500000 Cam 5106005 1 Bush 5204009 _ Washer 5110033 Double D Plugs f Part No 2503 Heyco wa 8102973 o Insert 5210005 Handle 5206003 Note Typically one or two 3 4 tubular locks are installed on a cassette Instructions regard ing disassembly and installation of these locks can be found in Part 1 Operation Manual Rev 05 2003 Part 2 Testing and Repair PAGE 2 163 CASSETTE CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of FrontLoad Cassette FLC 603 Step 3 Press on the walls of the case as shown by arrows Shift housing towards the open cover and remove it Housing Assembly 0100119 Case Assembly 0100194
5. 8102339 WA WA 0100123 Ae lt r Se Spo ALE wes 5207017 e A Z Ba e AUA AK AL ob Wood Screw 2x1 2 SAK 8201280 Flat Washer 4 a 8500000 7 a4 J Nie Cam ZA g CS 5106005 LO Bush _ 2 5204009 ii Double D Plugs Part No 2503 Heyco 8102973 Handle 5206003 page 2 152 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Cassette FLC 103 Housing Assembly 0100119 Ki Plate 5101097 Nylon Push Rivet Heyco No 9030 we el Case Assembly 8102339 AA 0100123 Cap 5207017 Wood Screw 2x1 2 8201280 Flat Washer 4 q 8500000 Cam 5106005 CASSETTE Bush 5204009 Double D Plugs Part No 2503 Heyco s 8102973 Washer 5110033 Handle Ba 5206003 Rev 05 2003 Part 2 Testing and Repair PAGE 2 153 4 CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Cassette FLC 503 Housing Assembly 0100119 Nylon Push Rivet Heyco No 9030 8102339 r A 5207017 Wood Screw 2x1 2 8201280 N Bi Flat Washer 4 N gt 8500000 N IAA Ni Ay Cam KS e 5106005 SS a Case Assembly SS e S 0100194 Bush e E i a 5204009 gt NY Ex Double D Plugs
6. page 2 164 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASE ASSEMBLY 0100123 Tools required Tweezers Step 1 Remove holder assembly Holder Assembly et i 0100124 NN Ze e Step 2 Remove springs Spring 5409014 01 KM CASSETTE Rev 05 2003 Part 2 Testing and Repair PAGE 2 165 CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Case Assembly 0100123 Step 3 Remove the spring Shift the plate inside the case Slide the shaft along its axis and remove both the shaft and the rollers from the case 5110041 Shaft Roller page 2 166 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASE ASSEMBLY 0100194 Tools required Tweezers Step 1 Remove holder assembly Holder Assembly 0100124 Spring G 2pcs N a Dech Step 2 l Remove springs CASSETTE Rev 05 2003 Part 2 Testing and Repair PAGE 2 167 4 CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Case Assembly 0100194 Step 4 Remove the spring Shift the plate inside the case and slide the shaft along its axis Remove the shaft and the roll
7. 4 pcs Step 3 4 pes 8203923 Heyco Standard Nylon Washer Part N X050 4 pcs Remove four screws 8203976 Disassemble holder assembly and Holder Ass y display 0100196 Display Ass y 0600014 go a Washer M2 5 Plain Zinc 4 pcs 8203A10 Step 4 Hex Nut M2 Zinc 4 pcs 8202938 Press on two latches inside the bezel Remove the IR port board Disconnect the cable from the board IR Port Board 0404014 Cable Ass y 0500088 Steps 5 6 7 Refer to steps 4 to 6 as described in Disassembly of Bezel FLB 3111 FLB 3131 FLB 3201 Rev 05 2003 Part2 Testing and Repair PAGE 2 147 eh CashCode FrontLoad Bill Validator Series Operation amp Service Manual BEZEL INSTALLATION FLB 1011 FLB 1021 Lock Washer MB Internal Tooth Zinc 2 pcs 8203002 Screw M3x6 Phillips Pan Head Zinc 4 pcs 8201000 Step 1 Open the plastic guide on the validating head Slide in the bezel Step 2 Secure the bezel on the validating head with two screws and two washers page 2 148 Part2 Testing and Repair Rev 05 2003 o CashCode FrontLoad Bill Validator Series Operation amp Service Manual BEZEL INSTALLATION FLB 2111 FLB 2131 FLB 2311 FLB 2333 FLB 2511 FLB 2531 FLB 3111 FLB 3131 FLB 3311 FLB 3331 MFLB 2201 MFLB 2401 MFLB 2601 MFLB 3201 MFLB 3401 Break out the CAP on the plastic cover to ge
8. Rev 05 2003 CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Angle Piece Assembly 0200054 WASHER 5310005 CONTROLLER 0401011 SPRING 5109001 01 GUIDE ASS Y 0200063 ROLLER 5204020 01 2 PCS Screw 4 40x1 4 Phillips Flat 100 Countersunk Head Zinc 8201937 2 pcs ANGLE PIECE ASS Y 0100133 page 2 18 Part 2 Testing and Repair Rev 05 2003 SI CashCod e FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Drive Assembly 0300052 oO zZ 33 27 gt TMOTOR S OBTURATOR ASS Y 0405012 Screw M2x5 Phillips Pan Head Zinc 8201972 CABLE 0500062 Rev 2 Rev 05 2003 Part 2 Testing and Repair PAGE 2 19 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Validating Head MFLV 2110 Nylon Push Rivet Heyco 9030 8102339 2 pcs fi Nylon Push Rivet Heyco 9030 Lock Washer M3 Internal Tooth Zinc 8102339 2 pcs WA 8203002 E COVER ASS Y AI Hex Nut M3 Zinc fy 0100134 y ve 8202940 _ g A Dee Lock Washer M3 T Fa SN Internal Tooth Zinc f N 8203002 I i RESTRAINT ASS Y V 0300051 d d N N N PU Cover ASS Y d H 1 0100135 Hex Nut M3 Zinc SPRING 8202940 3 5409024 d N __ GUIDE ASS Y N 0200055 d K e GUIDE ASS Y
9. __ 5310002 4 pes Screw 4 40x1 4 Phillips _ 100 Flat Countersunk Head Zinc 8201937 4 pcs Fully assembled view page 2 122 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual CABLE ASSEMBLY 0500064 01 for reference only 200000000000000000008G0R JI ADLE From To From To From To Cor Ter Con ler Con Ter Con ler Con Ter Con ler nector minal nector minal nector minal nector minal nector minal nector minal 7 al e SE SS 7 1 x4 X2 X3 2 X2 8 x W x lt FA J gt lt KO ES F gt N O Ka J x ice lt Kn N N 3 N gt N gt lt s x x A A lt gt lt gt lt gt lt lt lt x KX x ze CO gt lt NO BO ef lt lt gt lt lt OK x x OK x X NO gt lt wN x lt UJ 30 gt K N gt fe gt lt NO Ni ni E LA Nh gt lt NO Ww N x lt A Rev 05 2003 Part 2 Testing and Repair PAGE 2 123 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASSETTE DETECTOR 0900016 Tools required Philips screwdriver 1 Step 1 Standoff 1 4 lt 8101A22 Remove two screws and A e cover r
10. 05 2003 Cashc ode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of case assembly 0100222 Hold Down 5210018 2 pcs 5409037 2 pes Slider Light Guide Lens 5205015 3 pcs SS Rev 05 2003 5210017 2 pcs 5205034 2 pcs Part 2 Testing and Repair Spring ty Wo 4 Z WI Hd Light Guide 5205025 Case 5201059 Roller 7 204029 2 pcs PAGE 2 71 Cashc ode Exploded view of case assembly 0100222 01 Hold Down 8 5210018 2 pcs RN s TN WO m Slider 8 E S g SE 5210017 2 pos Seen br a 4 p Light Guide 29 ae 5205034 2 pes gt p 7 eee a Be f sn ee Ke L pS aS j ane Lens i 5205015 3 pcs page 2 72 Part 2 Testing and Repair Ha FrontLoad Bill Validator Series Operation amp Service Manual Spring 5409037 2 pcs Light Guide 5205025 Case e 201059 01 Roller LE 5204029 2 pcs Rev 05 2003 OO I Cash Code FrontLoad Bill Validator Series Operation amp Service Manual LIST OF SPARE PARTS FOR SENSE A CLICK N 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 E ee i 8 E era SE DEEN E 16 WEE E WER 20 ECH EA SH ee 25 EN za E WH E EEE Part Number 0100221 0100
11. 2003 FrontLoad Bill Validator Series Operation amp Service Manual CashCode L Exploded view of Drive Chassis Assembly 0300049 av3H 9 NILYVANVA CSod 2 6L0z8 ouZ peay ued s GZXG ZN MOIS L9000 0 05000 0 ASSY YN ASSY ALV1d SEOEOZS Ser n Sa uvao NAI KS Leoeozs GC ogeeoze 66ZONIC Ou E Z 00SLO Bury Bululejaj 2v00CS 2019 N 6L0Z0v0 d E OvOg HOSN3S LNdNI if fy S9dw 8roz0ozs enen agin 66ZONIG Du Z 00SLG Bury Buiurejoy 6e000e0 byO00 0 CSa EI 6EEZ018 0 06 09 H Ton YSN UOJ N Od Z yeeeozs QUIZ 00 Jeu1 u e cW asp 4907 ASSY LAVHS ASSY LAVHS Z00 028 OUIZ Y OO JeUJE U EN JeyseM 4907 SUIZ EW INN X8H va Lr000 0 Or000 0 6 000 0 8 000 0 Hed saljgwassy Heys jo sped y ose sod 7 GEELLZ8 Hed OLYAN SS10 57 WA sbuly O x 6ZL00L0 ASSY SISSVHO _S 000S0 ASSY 318v9 000S0 ASSY 318v9 Od 2 SEELLZS OZYEN SSL0 57Wa Dutot __8 000 0 ASSY LAVHS LZOLOLS _ 700050 ASSY 318v9 E S 290000 A ASSY JANG sddw S 0d 2 Lorooogo szov0zs _6eezozsg ASSY LJVHS ONINVS Ou G ZW INN en PAGE 2 13 Part 2 Testing and Repair Rev 05 2003 CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Case Assembly 010
12. 8203976 Washer M2 5 Plain Zinc 4 pcs 8203A10 Hex Nut M2 Zinc 4 pcs 8202938 Tapping Screw Cross Recessed Pan Head Type AB ANSI B18 6 4 4 24 X 3 4 2 pcs 8201A07 gt Cable Assembly 0500072 Washer M3 Plain Zinc 8203927 Display Board Assembly 0404013 Screw M3x12 Phillips Pan Head Zinc 8201934 5210022 68 5210022 5210022 72 Rev 05 2003 Part2 Testing and Repair PAGE 2 133 QUCashCode FrontLoad Bill Validator Series Operation amp Service Manual LIST OF SPARE PARTS FOR BEZEL Lore gan ef lolol sche aja eseall kkirktrilrk lr ist small Fri EE EEE EEE EEE Es seat ETL LT RT EEE EEE E Ts seat FELT TL TEE H H ds eii ee le wom FT EEL klicks wom Kl Tri EEL EE LEE LE eds e ity neen El TEE EEL Ki Ce TE EEL Ff Pewee ae REB ea eas GERS ee rE e gee PTT EEE EF EEE EEE EY Ey Tey fs PETE Ey FE et ep HIE EEE eps TTT TT ETT TE e LETTE e Total quant REI EE EE J J pE SEN Les e a1s LLGcCgu Ir LC LL LL LLb e 1s 1001 9134 LLOL 1s Insert E c gt gt gt 2 2 alae K a aja le Zyje 2 5 JEJEJEJE o N S wlolojo 2 S ce YA alojo jajo 12 v a lo e s Di m Z jale 2 2 lt vin 5 gt E le III li A Sle miei els amp Silo lolo S jols Cle fe le le Je O clc O 3_ a V 19 reel ole ee Kal Kaf Ka o
13. FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF MULTI WIDTH VALIDATING HEAD MFLV 2110 Tools required Flat screwdriver Philips screwdriver 1 Extractor 5110050 Hex nut wrench 5 5 mm Tweezers Step 1 to Step 6 Refer to disassembly instructions for single width validating head Step 7 Remove cover and guide by following instructions below Pull out two nylon push rivets and remove cover 0100134 Remove hex nut and disconnect cable from the cover Open the guide by releasing the latch and press on the guide near the axis of the guide Remove the guide Pay attention Restraint assembly and springs are not secured to the guide Screw 4 40x1 4 Flat Phillips 100 Head Zinc Remove angle piece assembly T Nylon Push Rivet Heyco 9030 AA 8102339 COVER ASS Y lt 0100134 l Lock Washer M3 Internal Tooth Zinc SPRING 8203002 5409024 01 7 Hex Nut M3 Zinc 8202940 SPRING 6409024 GUIDE ASS Y 0200055 RESTRAINT ASS Y 0300051 Step 8 Remove angle piece assembly by follow ing instructions below Disconnect three cables from controller board Remove two screws 8201937 ANGLE PIECE ASS Y 0200054 page 2 32 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of multi width validating head MFLV 2
14. M3 Plain Zinc KS Cable Aes 8203027 NS o _Cable Ass y SI Screw M3x12 Phillips Pan Head Zinc 0500035 i ang wa B Holder Assembly 0100196 d V H H Step 2 Remove two screws Remove holder assembly Washer M3 Plain Zinc 2 pes 8203927 Tapping Screw Type AB 4 24 X 3 4 Y Pan Head Phil 2 pcs 8201A07 page 2 140 Part2 Testing and Repair Rev 05 2003 SlCashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Bezel FLB 2511 FLB 2531 MFLB 2601 Step 3 Press on two latches inside the bezel Remove IR port board Disconnect the cable from the board IR Port Board Z 0404014 RA Cable Ass y ILS 0500088 TS Step 4 Press on the latches of the insert as shown by arrows Release latches and remove the insert Rev 05 2003 Part2 Testing and Repair PAGE 2 141 eh CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Bezel FLB 2511 FLB 2531 MFLB 2601 Step 5 Press on the latches of the plug as shown by arrows Release latches and remove the plug 5210023 01 5201045 Step 6 Press on the latches of the eye glass as shown by arrows Release latches and remove the eye glass Eye glass 5210035 page 2 142 Part2 Testing and Repair Rev 05 2003 o CashCode FrontLoad Bill Validator Series Operation amp Service
15. Manual DISASSEMBLY OF BEZEL FLB 3111 FLB 3131 MFLB 3201 Tools required Two flat screwdrivers Phillips screwdriver 1 Step 1 Remove one screw Remove display board and cable Disconnect the cable from the display board Disconnect the display cable from the display board Display Board Ass Os 0404013 oe wes Washer i 5810002 01 in 7i Te Cable Ass y Washer MS Can Zinc Re ee gt 0500072 SS N Cable Ass y Screw M3x12 Phillips Pan Head Zinc T 0500035 8201934 B Step 2 Or Ki Washer M3 Plain Zinc 2 pcs 8203927 Remove two screws l l Tapping Screw Cross Recessed Pan Head Remove holder assembly with display Type AB ANSI B18 6 4 4 24 X 3 4 2 pcs 8201A07 Rev 05 2003 Part2 Testing and Repair PAGE 2 143 o JCashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Bezel FLB 3111 FLB 3131 MFLB 3201 Step 3 Screw M2x8 Phillips Pan Head Zinc 4 pcs 8201A08 Washer M2 Plain Zinc 4 pcs 8203923 R Remove four screws Heyco Standard Nylon Washer Disassemble holder assembly and Part N X050 4 pes Display Ass y displa 8203976 pa Holder Ass y ge SET 0100196 D 8 Ei as Washer M2 5 Plain Zinc 4 pcs 8203A10 Hex Nut M2 Zinc 4 pcs 8202938 Step 4 Press on the latches of the insert as shown by arrows Release the latches and remove the insert
16. Manual Testing Procedure for Drive Chassis Assembly 0300049 with Centering Mechanism Attach module P 1432 4 to the Service Stand base Attach sub module P1432 624 to P1432 4 as a substitute angle piece Install the drive chassis assembly and the connectors to P1432 624 On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Validating head s mechanics Under Unit type select With alignment Click on the Run button located on the toolbar Review test results and failure description St ee Guppi Ee bes Pe ede Colin j D ie Device wlenhivcatron Device of madale to test Not avadable Kiem Fi we Mot Unat type available MU alignment e Failures Nane E Posse causes None f Attach P1432 6 module to the Test preapre validator mechanics for best reler ta tenting procedare invert mechanics imta PLAS 8 module and press Kon button Actual screen shot from a computer using the CashCode Service Stand The listed Failures and Possible causes should help identify the defective components of the validating head Click on the button entitled Show Picture for an x ray view with highlighted details page 2 54 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Testing Procedure for Drive Chassis Ass
17. Zinc 8201A20 f Washer M2 Plain Zinc P 8203923 SWITCH SS 5 FT SPDT OMRON 8025A19 Case 5201056 Hex Nut 2 56 8202573 y Spring XK D 5409045 Lever 5206009 page 2 106 Part 2 Testing and Repair Rev 05 2003 oi ICashCode FrontLoad Bill Validator Series Operation amp Service Manual LIST OF SPARE PARTS FOR HOUSING Total quantity Part Number Description 0100133 02 0700148 0700749 02 0700786 0700204 0500064 07 0900076 0900017 Switch Assembly 5101108 5101178 5106010 5110048 5110049 511004907 5201054 520105407 5201055 5201056 5202081 5203037 5206009 5206010 5210078 5308027 5310002 5409008 Spring BEG E ES Si Ke Rev 05 2003 Part 2 Testing and Repair PAGE 2 107 oi ICash Code FrontLoad Bill Validator Series Operation amp Service Manual LIST OF SPARE PARTS FOR HOUSING CONTINUED Total quantity Part Number Description lt 5409027 5409028 5409044 5409045 5409630 Switch SS 5 FT 8025A 19 OMRON 8101A 22 Standoff 1 4 Screw M3x6 Pan 8201000 Head Phil Zinc Screw M3x10 Pan Head Phil Zinc Screw M3x20 Pan 8201935 Head Phil Zinc Screw 4 40x1 4 100 Flat Countersunk Phil Zinc 8201970 Screw M3x12 Pan Screw 2 56x3 4 8201A03 Pan Head Phil Zinc Screw 2 56x7 16 8201A20 Pan Head Phil Zinc 5202573 8203002 8203923 8203927 5208997 8208998 8208999 3 4 35 oO 6 37 38 8201934 39 4
18. a Guide Part No 2503 Heyco 5102014 01 5102014 01 8102973 Washi 5110033 Insert 210005 Handle 3 5206003 page 2 154 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Cassette FLC 603 Housing Assembly 0100119 N Nylon Push Rivet Heyco No 9030 8102339 Plate 5101097 Cap 5207017 Na Wood Screw 2x1 2 8201280 AN Flat Washer 4 K 8500000 gt g y Cam s N 5106005 N S Bis Case Assembly w S N E 5 a b Bush i T Pa 0100194 m 5204009 Wash 3 asher 5110033 Double D Plugs Part No 2503 Heyco 8102973 N __Insert 5210005 Handle lt 5206003 ES Ql N Rev 05 2003 Part 2 Testing and Repair PAGE 2 155 oeh Cash Code FrontLoad Bill Validator Series Operation Service Manual Exploded View of Housing Assembly 0100119 Packing Mechanism 0300031 ge AA Shaft Assembly 0300037 O Ring OR 110 8211953 RO BEARING 5204017 2 pcs eg Li AA a KN Bag Housing Assemb 0100120 page 2 156 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Case Assembly 0100123 Cap 5207012 4
19. are sod Y SEEL LZ8 Hed OLEAN SSL0 GZWA SBUIY O 05000 0 fi ASSY 31lvid _096 0z8 sod 2 66L9NIQ ou E Z 00SLO 6EEZOLS Bury Buuges 702068 0OKSH TONY USN LOAN sod Z Lor 16010278 UZ Pe H ued S d XZN wee S 00090 00050 062028 tsoaz ASSY Tava ASSY 318v9 Fa SUIZ EW INN X8H ya ozoeoze g oulz 4001 jewaju SS a ZN Jase 4907 So s9d2 a sod gl aergen SEEL IZB Seen OS0X Ped ON SsL0 sawa 7 ASSY LUS J YSEM UO AN paepueig ooiat Bur 0 a sods eee 7 n Gi gt lt a _820v0zS sod z eee ER J x a Me e o Nia ezorocs d gt h ji gt SS 9nisv3ia ogeeoze 68Z9NIG au E Z 0091 0 Bury Bujuiejoy Zee 3ain9d e Noors WEO 00050 ASSY 318v9 a 20 cw NN X H N N a N eene ASSY INYA Ov000E0 _Loorzs YISNIASIA gozoro GuvO YOSNIS 1NdNI d Ke d d L200 028 0 000 0 ASSY LIVHS srozoze a ouz Wee pue ASSY alia eg EN Jase 4907 a sods wr g ozeeoze 7 YA Sing au Z E 0091 0 e Bury Duueen e 6s00020_ ASSY dnl sode 6961 128 F OZUAN SEL GER j vroo0eo Bury O ss Aa ASSY LIVHS SY000 0 S 9po00 0 ASSY L4VHS ASSY LIVHS 500020 ASSY d PAGE 2 21 Part 2 Testing and Repair Rev 05 2003 CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Guide Assembly 0200055 SPRING 5109001 3 PCS ROLLER 520402
20. is continued for a period of 8 hours Step 1 Connect the Service Stand base module and PC as explained in FrontLoad Multi width FrontLoad bill Validator diagnostics with Service Stand Step 2 Place the FrontLoad bill validator in the oven route the interface cables and connect to the bill validator The temperature in the oven should not exceed 30C in order to avoid thermal shock Close the oven and turn the heat mode to 50C Step 3 Power on the Service Stand Click on the icon CashCode Service Centre Support Software Under Device or module to test select Validator thermal test Under Unit type select FrontLoad or Multi width FrontLoad and an appropriate power interface module Step 4 Click the Run button on the toolbar Testing must continue for 8 hours uninterrupted Check on status every 20 or 30 minutes Review test results or failure description Rev 05 2003 Part 2 Testing and Repair PAGE 2 7 9 zZ Ka H F H el i CashCode FrontLoad Bill Validator Series Operation amp Service Manual Currency Validation Acceptance Money Test Money test checks verify validation acceptance capabilities of the bill validator Required for testing A set of 6 street grade bills of each denomination or style according to the configuration of the FrontLoad bill validator being tested Please note there may be more than one type of bill for any given denominati
21. pcs _Holder Assembly ES 0100124 Holder Pa 5101062 Gg Roller Pressure Spring 5204019 5409014 01 gt j 2 pcs 2 pcs Shaft 5408003 N Spring 5409023 CASSETTE Rev 05 2003 Part 2 Testing and Repair PAGE 2 157 ele ashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Case Assembly 0100194 Holder Assembly _ 0100124 N Holder 5101062 Pressuer Spring Roller 5409014 02 5204019 2 pcs 2 pcs Shaft 5408003 Gi T 2 Spring 7 Plate 5409040 E 5110041 1 Spring 5409023 page 2 158 Part 2 Testing and Repair Rev 05 2003 ei ICashCode FrontLoad Bill Validator Series Operation Service Manual LIST OF SPARE PARTS FOR FRONTLOAD CASSETTE Total guantity Part Number Description Nylon Push Rivet 8102339 HEYCO 9030 i Double Dn Plug 8102973 Heyco p n 2503 W te ood Screw 2x1 2 Zinc O Ring OR110 378 8211953 9 16 3 32 A 3 8500000 Flat W asher 4 1 CASSETTE 1 1 1 1 1 z es 3 e 13 my WEE WS mera L_ 18 zi 20 ER 27 28 7 3 4 5 6 7 8 9 0 1 7 8 9 0 1 2 2 AA KEE EE IA BEES Gee chee a BEER Geet Seer Kee 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2
22. release the latch in order to remove light guide 5205014 Light guides 5205013 are secured only by cover 5201026 see Exploded View j of Lower Sense a Click Module eer _LIGHT GUIDE 4 pcs 5205013 Press to stop Check the latches position the right one is shown Th A aN udi V A Assembled view LENS 3 pcs a 5205015 ji SA f gt Step 2 Gently press on the latches in order to release and remove the lenses from the case Assembled view Le S Check the latches position st the right one is shown Rev 05 2003 Part 2 Testing and Repair PAGE 2 77 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Case Assembly 0100221 01 Step 3 Remove O Ring from the wheel gear N Pr LNA eo d NA ee N WHEEL GEAR SC wa et 5203026 SCH O Ring OR 011 8211980 Step 4 Note the cap has been secured in the case with glue and cannot be disassembled When assembling a new part place a small amount of glue on the cap Plastic cement or cyanoacrilate glue is recom mended o CAP 5207013 CASE 5201058 01 WARNING No glue is allowed on the surface B Se page 2 78 Part 2 Testing and Repair Rev 05 2003 Cashc ode DISASSEMBLY OF CASE ASSEMBLY 0100221 02 Tools required Philips screwdriver 1 Flat screwdriver Step 1 Remove light guides Gently release the latch in order
23. remove light guide 5205014 Light guides 5205013 are secured only by cover 5201026 see Exploded View of Lower Sense a Click Module LENS 3 pcs Check the latches position the right one is shown Sse Rev 05 2003 Assembled view Part 2 Testing and Repair LIGHT GUIDE 4 pcs 5205013 LIGHT GUIDE 5205014 Press to stop Check the latches position the right one is shown Step 2 Gently press on the latches to release and remove the lenses from the case PAGE 2 75 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Case Assembly 0100221 Step 3 Remove the O Ring from the wheel gear ft D we LA Be N WHEEL GEAR S AA 5203026 O Ring OR 011 8211980 Step 4 p T 7 CAP 5207013 Note the cap has been secured in Be S PRAY CASE the case with glue and cannot be re f l 520105 disassembled 2 When assembling a new part SR place a small amount of glue on the cap Plastic cement or cyanoacrilate glue is recom mended WARNING No glue is allowed on the surface B 2 s B X cap nage 2 76 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASE ASSEMBLY 0100221 01 Tools required Philips screwdriver 1 Flat screwdriver Step 1 Remove light guides Gently
24. to remove light guide 5205014 Light guides 5205013 are secured only by cover 5201026 see Exploded View of Lower Sense a Click Module LIGHT GUIDE 5205014 Press to stop Correct latch position LENS 3 pcs 5205015 Case _ 520158 01 Assembled view Check the latches position the right one is shown Rev 05 2003 Part 2 Testing and Repair FrontLoad Bill Validator Series Operation amp Service Manual _LIGHT GUIDE 4 pcs d 5205013 Press to stop Assembled view Step 2 Gently press on the latches in order to release and remove the lenses from the case PAGE 2 79 aech CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Case Assembly 0100221 02 Step 3 Remove O Ring from the wheel gear WHEEL GEAR 5203026 8211980 page 2 80 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASE ASSEMBLY 0100222 Tools required Philips screwdriver 1 F P if er HOLD DOWN 2 pcs ae 5210018 SPRING 2 pcs AA 5409037 Step 1 Gently press and release the hold down SLIDER 2 pos latches in order to remove the hold downs SE watch the springs Remove the springs and the sliders Remove the rollers 71 Correct latch position Rev 05 2003 Part 2 Testing and Repair PAGE 2 81 QI CashCode Fr
25. 0 8201937 D gt 42 43 4 2 E E RE 49 50 nage 2 108 Part 2 Testing and Repair Rev 05 2003 SI CashCocde FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF HOUSING AND SUBASSEMBLIES DISASSEMBLY OF HOUSING FLH 0110 Tools required Flat screwdriver Philips screwdriver 1 Lock Washer M3 p Bracket Assembly Internal Tooth Zinc 2 pcs JA 0100138 02 8203002 Step 1 Remove two screws Remove bracket assembly Wa Screw M3x20 Pan Head Zinc 2 pcs 8201935 Rolled Spacer 8208994 Step 2 Remove one screw Remove cover Screw M3x12 Pan Head Zinc 8201970 N Lock Washer M3 Internal Tooth Zinc 8203002 Cover 5101105 Rev 05 2003 Part 2 Testing and Repair PAGE 2 109 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Housing FLH 0110 Step 3 Remove one screw Remove cassette detector Screw M3x6 Pan Head Zinc 8201000 Lock Washer M3 Internal Tooth Zinc 8203002 Cassette Detector 0900016 Step 4 Move the spring as shown and s ier release the shaft Be Remove the shaft and then the d SHAFT gear 5308026 To reassemble move the spring then reinstall the shaft The spring must enter the groove on the shaft as shown in this sectional view Pee _ Move Spring page 2 110 Part 2 Tes
26. 0 01 3 PCS SPRING 5409025 5106007 GUIDE ASS Y 0200056 5308016 page 2 22 Part 2 Testing and Repair Rev 05 2003 CH iCashCode FrontLoad Bill Validator Series Operation amp Service Manual LIST OF SPARE PARTS FOR VALIDATING HEAD 4 OO D Q C Di lt Part Number Description Wal zZ 33 a7 gt ase Assembly hassis Assem bly onnector Assembly ngle Piece Assembly over Assembly over Assembly hassis Assem bly ase Subassembly uide Assembly vide Assembly vide Assembly vide Assembly vide Assembly ngle Piece Assem bly vide Assembly vide Assembly vide Assembly ip Assembly ip Assembly uide Assembly vide Assembly vide Assembly rive Assembly hat Assembly haft Assembly haft Assembly hat Assembly haft Assembly haft Assembly haft Assembly rive Chassis Assem bly late Assembly estraint Assem bly rive Assembly rive Chassis Assem bly ink Assembly ontroller put Sensor Board put Sensor Board 0405012 Tm otor Obturator Assem bly 0405028 Download Board Rev 05 2003 Part 2 Testing and Repair PAGE 2 23 1 bail fb g SESCH Sa CS CH gt LL Lo si ES I Li Loe Le SE sl e s GC L E IL Ooo ee IL LI ee WEE ie LI LI LI LI 1 LI 1 SR LI LI LI 1 LI E RS f Eu ICash Code FrontLoad Bill Validator Series Operation Service Manual LIST OF S
27. 00 3 2 Zinc DIN6799 8203920 SHAFT ASS Y 0300038 5204025 Part 2 Testing and Repair Rev 05 2003 SI CashCod e FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Drive Chassis 0300049 Step 5 Hex Nut M2 5 Zinc i an 8202939 _ DRIVE ASS Y 0300052 Remove the gear from the shaft Remove two screws Remove the drive Oo lt q el 2 gt Lock Washer M2 5 Ee Screw M2 5x25 RR Internal Tooth Zinc Phillips Pan Head Zinc 8203334 8201933 Step 6 Remove the guides by press ing on the bosses in the middle CHASSIE ASSY Pull out two nylon push rivets and remove the bracket GUIDE 5202047 BRACKET 5101071 A Nylon Push Rivet Heyco 9030 8102339 Rev 05 2003 Part 2 Testing and Repair PAGE 2 37 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF DRIVE CHASSIS 0300058 Tools required Flat screwdriver Philips screwdriver 1 Tweezers Step 1 Remove plate and link When assembling pay attention that all 4 pins are properly seated in their holes Step 2 Remove input sensor board and cables Remove the input sensor board by pressing on the latch When assembling place cable 0500044 as shown for drive chassis 0300049 PLATE ASS Y 0300050 Z LINK ASS Y 0300061 CABLE ASS Y page 2 38 Part 2 Testing and Repair Rev 05 2003
28. 0128 5106009 5203031 RETAINING RING D1500 3 2 Zinc 5409026 DIN 6799 8203920 3 pcs CASE SUBASS Y 0100154 SHAFT 5308018 page 2 14 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Guide Assembly 0200050 O zZ za sr g ___FLAT SPRING 5109001 3 PCS ROLLER 5204020 01 lt lt 3 PCS SPRING 5409025 De LATCH _ 5106007 GUIDE ASS Y 0200064 SHAFT 5308016 ke a Ch Rev 05 2003 Part 2 Testing and Repair PAGE 2 15 CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Guide Assembly 0200052 Wood Screw 3x3 8 Phillips Pan Head Zinc 8204001 2 PCS BRACKET CABLE ASS Y 5110044 0500036 DOCKING BOARD ASS Y 0405032 GUIDE ASS Y 0200067 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Guide Assembly 0200053 FLAT SPRING ROLLER 5204001 NS SPRING Pcs 5409025 gt LATCH 5106008 Wood Screw 3x3 8 Phillips Pan Head Zinc 8204001 SHAFT 5308016 CABLE ASS Y 0500034 GUIDE 5202029 A Rev A HEAD Oo z F lt Q 2 gt PAGE 2 17 Part 2 Testing and Repair
29. 110 Step 9 GUIDE ASS Y 0200052 Remove guide 0200052 by follow ing instructions below O Z za sr g Loosen four M3 screws Squeeze walls of the guide from j both sides and remove the guide i from the case 7 Partually unscrew four screws GUIDE ASS Y Step 10 0200057 gt Remove guide 0200057 by following instructions below Squeeze walls of the guide from both sides and remove the guide from the case Rev 05 2003 Part 2 Testing and Repair PAGE 2 33 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of multi width validating head MFLV 2110 Step 11 Nace SHAFT 5308047 Remove connector 0100132 by CONNECTOR ASSY following instructions below e Remove 4 M3x6 screws Remove connector Remove shaft Screw M3x6 Phillips Pan Head 8201000 Lock Washer M3 8203002 Step 12 e Washer M3 Plain Zinc Hex Nut M3 Zinc vA 8203927 8202940 o z AA DRIVE CHASSIS ASS Y Screw M3x3 Phillips SE 0300058 Remove drive chassis assembly by Pan Head Zinc lt Gei 201A01 following instructions below 9 Lock Washer M3 Remove M3x3 screw nternal Tooth Zinc Remove M3 hex nut SST Remove drive chassis assembly Pay attention Plate and link are not secured to the drive chassis CASE ASSY 0100128 page 2 34 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad
30. 2 2 2 2 2 3 3 3 3 1 Rev 05 2003 Part 2 Testing and Repair PAGE 2 159 Jc ashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF FRONTLOAD CASSETTE AND ITS SUBASSEMBLIES DISASSEMBLY OF CASSETTE FLC 003 FLC 103 Tools required Flat screwdriver Philips screwdriver 1 Step 1 Open the cover and pull out the rivet Remove the plate and the cap E Cap Nylon Push Rivet Heyco No 9030 SESCH DE 0081023391 5207017 Plate 5101097 page 2 160 Part 2 Testing and Repair Rev 05 2003 eh CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of FrontLoad Cassette FLC 103 Step 2 Remove the wood screw Remove parts Wood Screw 2x1 2 8201280 Flat Washer 4 8500000 e i Cam Ki 5106005 gt Bush 5204009 7 __ Washer 5110033 Double D Plugs Part No 2503 Heyco E z 8102973 SE d 5210005 8 Handle R 5206003 Note Typically one or two 3 4 tubular locks are installed on a cassette Instructions regard ing disassembly and installation of these locks can be found in Part 1 Operation Manual Rev 05 2003 Part 2 Testing and Repair PAGE 2 161 CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of FrontLoad Cassette FLC 103 Step 3
31. 2 Testing and Repair AB Self Tapping Screw 2x1 2 Phillips Pan Head Steel Zinc 2 pcs 8201280 Holder 5210016 01 S Wheel Gear eee 5203026 2 pcs ji Cap AA 5207013 Ges 5203027 2 pes Light Guide 5205013 4 pcs Case 5201058 p Lens 5205015 3 pos Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of case assembly 0100221 01 AB Self Tapping Screw 2x1 2 Phillips Pan Head Steel Zinc 2 pcs 8201280 Holder Se Holder 5210016 5210016 01 gt Wheel Gear 203026 2 pes O Ring OR 011 2 pcs 8211980 Cap 5207013 Light Guide ee Gear 5205014 5203027 2 pcs Light Guide 5205013 4 pcs ee Case 5201058 01 Lens _ 5205015 3 pcs Rev 05 2003 Part 2 Testing and Repair PAGE 2 69 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of case assembly 0100221 02 AB Self Tapping Screw 2x1 2 Phillips fa Pan Head Steel Zinc 2 pcs 8201280 Holder umo Holder 3210016 5210016 01 Wheel Gear 7 5203026 2 pes O Ring OR 011 2 pcs E 8211980 Light Guide ae its Gear 5205014 wS P 7 5203027 2 pcs Light Guide 5205013 4 pcs a Case 5201058 01 Lens 7 5205015 3 pes page 2 70 Part 2 Testing and Repair Rev
32. 221 01 0100221 02 0100222 0100222 01 0402028 02 0402028 06 0402029 02 0402031 02 0403017 02 0403017 06 0403018 02 0403019 02 5201026 5201028 5201058 5201058 01 5201059 5201059 01 5203026 5203027 5204029 5205013 5205014 5205015 5205025 5205034 5207013 5210016 5210016 01 5210017 5210018 5409037 8201280 8211980 Rev 05 2003 Total quantity Case assent Case Assembly UpperSoara f KowerBoare f eoe WA eov f C E EECHER W heel Gear AB Self Tapping Screw 2x1 2 Pan Head Phil Zinc O Ring OR 011 5 16 7 16 1 16 1 1 1 1 1 1 1 1 ee eehh H AH AA H e ee eehh H A bt ee eehh IA Le BAGH Hid HHA HUHH Part 2 Testing and Repair PAGE 2 73 Ie ashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF SENSE A CLICK MODULES AND SUBASSEMBLIES DISASSEMBLY OF SENSE A CLICK MODULES FLS 1704L FLS 1704U FLS 1705L FLS 1705U FLS 1801L FLS 1801U FLS 1901L FLS 1901U Tools required Philips screwdriver 1 Refer to corresponding exploded views from preceding pages Be careful not to overtighten the self tapping screws page 2 74 Part 2 Testing and Repair Rev 05 2003 Cashc ode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASE ASSEMBLY 0100221 Tools required Philips screwdriver 1 Flat screwdriver Step 1 Remove light guides Gently release the latch in order to
33. 3 e Tapping Screw Cross Recessed Pan Head Type AB ANSI B18 6 4 4 24 X 3 4 2 pcs 8201A07 Washer M3 Plain Zinc 8203927 Cable Ass y 0500072 5210022 68 5210022 72 5210022 page 2 130 Part2 Testing and Repair Rev 05 2003 SlCashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of CashCode Bezel with Running Lights and IR Communication Port FLB 2511 FLB 2531 MFLB 2601 Panel Eye glass 5201045 5210035 Holder Assembl Pa 0100196 Pe Washer M3 Plain Zinc 2 pcs a 8203927 wo Insert see chart below IR Port Board 0404014 Display Board Ass y 0404013 Cable Assembly 0500088 Washer M3 Plain Zinc 8203927 o e Screw M3x12 Phillips Pan Head Zinc 8201934 Tapping Screw Cross Recessed Pan Head Type AB ANSI B18 6 4 4 24 X 3 4 2 pes 8201A07 Cable Assembly 0500072 5810002 01 Cable Ass y SSS 0500035 5210022 68 5210022 72 5210022 Rev 05 2003 Part2 Testing and Repair PAGE 2 131 FrontLoad Bill Validator Series Operation amp Service Manual o JCashCod Exploded View of CashCode Bezel with Running Lights and Digital Display FLB 3111 FLB 3131 MFLB 3201 Screw M2x8 Phillips Pan Head Zinc 4 pcs Panel Eye glass Window 8201A08 5201045 5210021 Washer M2 Plain Zinc 4 p
34. 3x6 Pan Head Zinc 8201000 Lock Washer M3 Internal Tooth Zinc Cassette Detector 0900016 Step 4 Remove two screws Remove the switch assembly Screw M3x6 Pan Head Zinc 8201000 Lock Washer M3 Internal Tooth Zinc 8203002 page 2 120 Part 2 Testing and Repair Rev 05 2003 CashCode GEAR fo Q 5203031 Rev 05 2003 FrontLoad Bill Validator Series Operation amp Service Manual SHAFT 5308026 Move Spring Part 2 Testing and Repair Disassembly of Housing FLH 3510 Step 5 Move the spring as shown and release the shaft Remove the shaft and the gear To reassemble move the spring then reinstall the shaft The spring must enter the groove on the shaft as shown in sectional view Steps 6 7 8 9 Refer to steps 5 to 8 as de scribed in Disassembly of Housing FLH 0110 PAGE 2 121 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF BRACKET ASSEMBLY 0100138 01 Tools required Philips screwdriver 1 Please refer to the exploded view When assemblying take care to ensure that the 25 pin and the 37 pin connectors move freely in their slots For cable connections please refer to the next page Washer M3 Plain Zinc 8203927 4 pcs Screw M3x10 Phillips Pan Head Zinc 8201934 2 pcs _ CABLE ASS Y 0500064 01 BRACKET ASS Y Ba 0100149 02 BUSHING
35. 5 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of lower Sense a Click module FLS 1705L AB Self Tapping Screw 2x1 2 Phillips Pan Head Steel Zinc 4 pcs YA 8201280 Cover 5201026 Lower Board a 0403017 06 Case Assembly Ba 0100221 Rev 05 2003 Part 2 Testing and Repair PAGE 2 65 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of lower Sense a Click module FLS 1801L AB Self Tapping Screw 2x1 2 Phillips Pan Head Steel Zinc 4 pcs 8201280 Seen Cover 5201026 Lower Board 0403018 02 Case Assembly 0100221 01 page 2 66 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of lower Sense a Click module FLS 1901L AB Self Tapping Screw 2x1 2 Phillips Pan Head Steel Zinc 4 pcs 7 8201280 Cover 5201026 TI Lower Board i SH 0403019 02 Case Assembly Ba 0100221 02 Rev 05 2003 Part 2 Testing and Repair PAGE 2 67 Cashc ode Exploded view of case assembly 0100221 Holder 5210016 Se O Ring OR 011 2 pcs ii 8211980 Light Guide 5205014 E e Jd page 2 68 FrontLoad Bill Validator Series Operation amp Service Manual Part
36. 5205034 _ LIGHT GUIDE 5205025 CASE 5202059 page 2 84 Part 2 Testing and Repair Rev 05 2003 oehle ashCode FrontLoad Bill Validator Series Operation amp Service Manual TESTING PROCEDURES FOR SENSE A CLICK MODULES Upper Sense a Click Module Test FLS 1704U FLS 1705U FLS 1801U FLS 1901U Attach module P 1432 4 to the Service Stand base Install validating head P1432 622 to module P1432 4 Remove upper Sense A Click module P1432 628 from validating head P1432 622 Install the upper Sense A Click module being tested Ensure lower Sense A Click module P 1432 627 is in the validating head Rev 05 2003 Part 2 Testing and Repair PAGE 2 85 CLICK 3 lt q wi o Z m o QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Upper Sense A Click Module Under Unit type select appropriate model number Click on the Run button located on the toolbar Review test results and failure description Cidh ode Saivi Detail Supp german Coggigh MOF Ci ode Colic sl Device aia JIKE MBONA Test Result evict or mie Des Not avaiable 8 eat be Upper module FES e Not Umit type available KU Treat Fake Nowe E Possible causes None E Attach P1432 6 module to the Test Station and insert P
37. Bezel for Double Diamond Gaming Machine FLB 1011 FLB 1021 Standard Cashcode Bezel FLB 2311 FLB 2331 MFLB 2401 CashCode Bezel with Running Lights FLB 2111 FLB 2131 MFLB 2201 CashCode Bezel with Running Lights and IR Communication Port FLB 2511 FLB 2531 MFLB 2601 CashCode Bezel with Running Lights and Digital Display FLB 3111 FLB 3131 MFLB 3201 CashCode Bezel with Running Lights Digital Display and IR Communication Port FLB 3311 FLB 3331 MFLB 3401 Rev 05 2003 Part2 Testing and Repair PAGE 2 127 BEZELS eh CashCode FrontLoad Bill Validator Series Operation amp Service Manual Perspective View of CashCode Bezel for Double Diamond Gaming machine FLB 1011 FLB 1021 Inlet see chart below page 2 128 Part2 Testing and Repair Rev 05 2003 o CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Standard CashCode Bezel FLB 2311 FLB 2331 MFLB 2401 Panel 5201045 Light Pipe 5210037 see chart below 5210022 68 01 5210022 72 01 5210022 01 Rev 05 2003 Part2 Testing and Repair PAGE 2 129 eh CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of CashCode Bezel with Running Lights FLB 2111 FLB 2131 MFLB 2201 Panel 5201045 Holder Ass 0100196 Washer M3 Plain Zinc 2 pcs 8203927 nsert see chart below E 040401
38. Bill Validator Series Operation amp Service Manual DISASSEMBLY OF DRIVE CHASSIS 0300049 Tools required Flat screwdriver Philips screwdriver 1 Tweezers Oo z F lt Q 2 gt PLATE ASS Y 0300050 Step 1 Remove plate and link When assembling pay close j S E attention that all 4 pins are properly j SS 0300061 seated in their holes CABLE ASS Y d 0500033 CABLE ASS Y 0500035 Press here Step 2 INPUT SENSOR BOARD 0402019 Remove input sensor board and cables When removing input sensor board press on the latch When assembling place cable 0500044 as shown Lock Washer M3 Internal Tooth Zinc J 8203002 a Hex Nut M3 Zinc 8202940 CABLE ASS Y 0500044 Rev 05 2003 Part 2 Testing and Repair PAGE 2 35 QI Cash Code Step 3 Remove retaining ring and gear When assembling both mating gears must be oriented in the same direction Step 4 Remove retaining rings by press ing on the latches of the bearings Remove them with the shafts from the chassis When assembling add Super Lube with Syncolon PTFE lubricant to all bearings and gears except O Rings page 2 36 FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Drive Chassis 0300049 5203037 Retaining Ring D1500 2 3 Zinc DIN6799 8203960 SHAFT ASS Y SHAFTASS Y SHAFT ASS Y 0300039 0300040 0300041 Retaining Ring D15
39. Bill Validator Series Operation amp Service Manual Testing Procedure for Validating Head MFLV 2110 Multi width with Centering Mechanism Attach module P 1432 4 to the Service Stand base Attach the validating head to module P 1432 4 On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Validating head Under Unit type select With alignment Click on the Run button located on the toolbar Review test results and failure description O zZ ck sr S RR WERT RTE Loppi JUUS LashLode Lo Imt E pi gt T e EE About Firn DpH Help Eet ES r s Device wergrfeatson Device or module to test Not available _j Test Result Falidating Head e Nat Umit type available Hih afigament MFLV ZITO e Fadures None E Possible causes None E Atach PLA3A7 6 modale te the Test Station and insert Validating Head into it Set 4th switch on the Download board ON ond then press Run button E E Actual screen shot from a computer using the CashCode Service Stand The listed Failures and Possible causes should help identify the defective components of the validating head Click on the button entitled Show Picture for an x ray view with highlighted details Rev 05 2003 Part 2 Testing and Repair PAGE 2 53 eh CashCode FrontLoad Bill Validator Series Operation amp Service
40. C ICashCode FrontLoad Bill Validator Series Operation amp Service Manual 1 FRONTLOAD BILL VALIDATOR FL TESTING Operation and Service Manual PART 2 TESTING AND REPAIR Rev 05 2003 Part 2 Testing and Repair PAGE 2 1 oe ICashCode FrontLoad Bill Validator Series Operation amp Service Manual TABLE OF CONTENTS FRONTLOAD TES TING ere 3 VALIDATING HEAD icuisesssnssaisantcecesncetentnsstanusaseusenereturetenaddesuduasseuusesrecwaesraddaensdussrsedvaneesiucenien 11 DEN SEF CLICK E 59 POWER INTERFACE MODULE siiciesticiscrtsesscsieronsinsisedsdersesessiseereisaneus corterecriniusdaroneiuaseninestinn 89 FON 1 E PE E EA E EE aces 99 BEZEL PA EAEE A AE A A A A 127 Ee EE 151 page 2 2 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual FRONTLOAD TESTING CashCode has developed a Service Stand to diagnose and extensively test the FrontLoad as a whole or any subassembly to ensure it meets with CashCode s specifications It is highly recom mended that all tests are carried out using the CashCode Service Stand CASHCODE SERVICE STAND For a more detailed description of the CashCode Service Stand you may refer to the manual supplied with the Service Stand The CashCode Service Stand operates with a Personal Computer PC using Windows 98 or XP but with an additional PC card The CashCode Service Stand consists of the base module and a set of individual
41. Cashc ode Step 3 Pull out four nylon push rivets by removing the bearings and lips When assembling ensure the lips are properly positioned on the roller shaft Step 4 Remove retaining ring by pressing the latches on the bearings Remove them with the shafts from the chassis When assembling add Super Lube with Syncolon PTFE lubri cant to all bearings and gears except O Rings Rev 05 2003 FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Drive Chassis 0300058 LIP ASS Y 0200059 UP ASSY 0200058 O Z za sr g BEARING 8102339 WA __SHAFT ASS Y 0300044 Retaining Ring D1500 3 2 Zinc DIN6799 8203920 BEARING 5204025 Part 2 Testing and Repair PAGE 2 39 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Drive Chassis 0300058 Step 5 Remove the retaining ring and gear When assembling both mating gears must be oriented in the same direction Retaining Ring D1500 2 3 Zinc DIN6799 ee 5203037 8203960 SHAFT ASS Y Retaining Ring SHAFT ASS Y 0300045 N D1500 3 2 Zinc DIN67 Y 8203920 SHAFT ASS Y 0300046 0300040 li Ce C Step 6 S Remove retaining ring by pressing SHAFT ASSY N on the latches on the bearings Ee Remove them with the shafts from the chassis When assembling add Super Lub
42. D 9200053 Wi SPRING 7 5409024 01 _GUIDE ASS Y 0200052 fle ETES F aa 8202940 Ss K GUIDE ASS Y Screw M3x3 Phillips 0200057 Pan Head Zinc 8201A01 Ki Lock Washer M3 SE Nov Internal Tooth Zinc iji iO A N 8203002 g ee DRIVE CHASSIS ASS Y WA jad CE SW L 0300058 SC ff ft NN Washer M3 Plain Zinc COVER 4 er 75201043 a W N A AA Ze a d SCH f g ji j p N a SZ 5201040 i S d S i WA A COVER S 5201022 NZ CONNECTOR ASS Y 0100132 DOWNLOAD BOARD ma Screw M3x6 Phillips Pan Head 0405028 s 8201922 4 pcs Lock Washer M3 8203002 4 pcs CASE ASS Y 0100128 Screw 4 40x1 4 Phillips Ss Flat 100 Head Zinc S 8201937 2 pcs FLASH CARD MEMORY N 0405049 NN Nylon screw M3x6 Slot KO Pan Head 8201A32 ANGLE PIECE ASS Y 0200054 page 2 20 Part 2 Testing and Repair Rev 05 2003 9 JCashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Drive Chassis Assembly 0300058 SNILVGITVA s9972 s9d2 Caen zzoeozs Longen 2E0E0zS seoeozs EERLIER peeeozs YO ASSYJNN vue GEN 207 Deen Ued sm iz WOOL ue S GZXG ZN Mais ech eyseM 4907 SiO016 anon 4 e vA J ASSY SISSVHO 9r000 0 Sr000 0 Hed saijgwassy yeys Jo syed y ag sod 6964 LZ8 Hed 0ZYAN SELO SZING SBUY O ss 0r000 0 8E000 0 Hed sel quiessy yeys Jo sped ay
43. DIN 7980 8203984 Screw M3x4 Phillips Pan Head Zinc 8201538 DRIVE ASS Y INTERFACE BOARD see chart below Retaining Ring N D1500 3 2 Zinc DIN6799 8203920 4 pes SHAFT Moe Retaining Ring N D1500 2 3 Zinc DIN6799 8203960 SHUTTER 5106013 5409035 CHASSIS ASS Y 0200072 Screw 4 40x1 4 Phillips 100 Flat Countersunk Head Zinc 5308044 a 8201937 2 pes FLP 171 0405027 i ooo S d S AI page 2 90 Part2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Drive Assembly 0300056 Cable Assembly 0500037 by p Filter Board Assembly lt a a A 0405035 6 Gg D Leo Dk Z Drive Assembly 0300084 Rev 05 2003 Part2 Testing and Repair PAGE 2 91 ei iCashCode FrontLoad Bill Validator Series Operation amp Service Manual LIST OF SPARE PARTS FOR POWER INTERFACE MODULE Total quantity Part Num ber Description 0300056 0300067 0300054 0405027 FL BDP Interface Board F ilter Board Assembly RS232 Interface Board RS232 Interface Board 0405045 CC RS232 Interface Board 5106013 5308043 EELER Screw M3x4 Pan Seo hae Head Phil Zinc Screw 4 40x1 4 100 Flat Countersunk Phil Zinc Lock W asherM 3 Internal Teeth Zinc Retaining Ring D1500 3 2 Zinc DIN6799 Washer M 3 Plain Zinc Retaining R
44. FLH 3110 Rolled Spacer 8208994 0100138 02 Lock Washer M3 Internal Tooth Zinc 8203002 2 pes Screw M3x20 Phillips Pan Head Zinc 8201935 2 pes 5203031 Screw M3x12 Phillips Pan Head Zinc 8201970 3 pes Lock Washer M3 Internal Tooth Zinc 8203002 5101119 wv M3x6 Phillips Pan Head Zinc 8201000 lt Washer MB Internal Tooth Zinc 8203002 Cassete Detector 0900016 page 2 102 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of HOUSING FLH 3510 Rolled Spacer Bracket Assembly _ 8208994 0100138 02 Lock Washer M3 Internal Tooth Zinc Screw M3x20 Phillips Pan Hean zinc 8203002 2 x 3 pcs 2 pes Lock Washer M3 Internal Tooth Zinc Screw M3x20 Phillips Pan Head Zinc 8203002 8201935 2 pcs Cover Assembly 0100204 GEAR SHAFT 5203031 5308026 Rolled Spacer a 8208998 PA CONNECTOR eI A y 5202031 of Flat Washer 8203999 FLAT SPRING Bis 5109015 SPRING 2 pes R 5409028 LATCH aw 5106010 lt lt Lever Assembly 0100148 Wa 5308027 N SPRING LEVER 5409027 5110048 i AA TIP A SPRING 5210015 SPRING 5409630 5409008 Screw M3x6 Phillips Pan Head Zinc 8201000 Lock Washer M3 I
45. INGLE WIDTH VALIDATING HEAD FLV 0310 and FLV 0510 AND MULTI WIDTH VALIDATING HEAD WITH CENTERING MECHANISM MFLV 2110 Rev 05 2003 Part 2 Testing and Repair PAGE 2 11 O zZ 43 sr S o CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of Validating Head FLV 0310 and FLV 0510 Nylon Push Rivet Heyco 9030 8102339 2 pcs Nylon Push Rivet Heyco 9030 Lock Washer M3 Internal Tooth Zinc ya 8102339 2 pcs f 8203002 d COVER ASS Y Hex Nut M3 Zinc 0100134 Lock Washer M3 Internal Tooth Zinc 8203002 ef 8202940 e Bai ef RESTRAINT ASS Y 0300051 i H i i 1 SE Hex Nut M3 Zinc 8202940 __ GUIDE ASS Y 0200050 GUIDE ASS Y S oe 0200053 TER H SPRING 5409024 01 _GUIDE ASS Y 5308047 ___ GUIDE ASS Y FLV 0310 0200051 FLV 0310 0200051 70 Hex Nut M3 Zinc f 8202940 Screw M3x3 Phillips Pan Head Zinc 8201A01 1 Lock Washer M3 COVER 5201022 AS gt CONNECTOR ASS Y 0100132 DOWNLOAD BOARD 0405028 Screw M3x6 Phillips Pan Head 8201922 4 pcs Lock Washer M3 8203002 4 pcs CASE ASS Y 0100128 Screw 4 40x1 4 Phillips Flat 100 Head Zinc ANGLE PIECE ASS Y TA 8201937 2 pcs 0200054 _FLASH CARD MEMORY KH 0405049 K Nylon screw M3x6 Slot Pan Head 85 036 n 8201A32 page 2 12 Part 2 Testing and Repair Rev 05
46. M3 Zinc 8202940 N COVER ASS Y 0100135 GUIDE ASS Y 0200053 Press here to release page 2 28 Part 2 Testing and Repair Rev 05 2003 SI CashCod e FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of single width validating head FLV 0310 and FLV 0510 Step 7 Nylon Push Rivet Si Heyco 9030 Remove cover and guide by following RaT 8102339 instructions below COVER ASS Y 0100134 Wal zZ lt 3 27 gt __ SPRING Pull out two nylon push rivets and 5409024 01 remove cover 0100134 Remove hex nut and disconnect cable from the cover Open the guide by releasing the latch and press on the guide near guide axis Hex Nut M3 Zinc 8202940 SPRING Remove the guide GUIDE ASS Y gt 5409024 0200050 Press here to release Pay attention Restraint Assembly and springs are not secured to the guide RESTRAINT ASS Y 0300051 Step 8 Remove angle piece assembly by following instructions below Disconnect three cables from controller board Remove two screws Remove Angle Piece Assembly Ki Screw 4 40x1 4 Flat Phillips 100 Head Zinc ANGLE PIECE ASS Y 8201937 0200054 Rev 05 2003 Part 2 Testing and Repair PAGE 2 29 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of single width validating head FLV 0310 and FLV 0510 Step 9 Remove Guide 0200052 b
47. Nylon Push Rivet Heyco 9032 2 pcs ue 81 02003_ 7 Lock Washer M3 Internal Tooth Zinc 2 pcs 8203002 Screw M3x6 Phillips Pan Head Zinc 4 pcs 8201000 NG Heyco Nylon Round Spacer RSP 145 2 Part No X916 2 pcs 8208A15 page 2 26 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of single width validating head FLV 0310 and FLV 0510 Step 3 Oo z F lt Q 2 gt __ EXTRACTOR OPT HW FT01 Remove Sense a Click sensor modules Step 4 Remove plastic cover by opening latch with screwdriver COVER 5201043 Rev 05 2003 Part 2 Testing and Repair PAGE 2 27 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of single width validating head FLV 0310 and FLV 0510 Step 5 COVER 5201040 Remove covers and download board COVER 5201022 Pan Head 85 036 n 8201A32 DOWNLOAD BOARD 0405028 Step 6 Remove cover and guide by following instructions below amp Nylon Push Rivet is ___Heyco 9030 7 8102339 Pull out two nylon push rivets and remove cover 0100135 Remove hex nut and disconnect cable from the cover Disconnect ribbon cable Open the Guide by releasing the latch Press on the guide near the guide axis Remove the Guide Lock Washer M3 Internal Tooth Zinc 8203002 Hex Nut
48. PARE PARTS FOR VALIDATING HEAD continue Total guantity Part Number Description 0405032 0405047 0405049 0500033 0500034 0500035 0500036 0500044 0500062 5101071 5106007 5106008 5106009 5109001 5109001 01 5110044 5110064 5201022 5201040 5201043 5202029 5202047 5202048 5203022 5203031 5203035 5203037 5204001 5204020 01 5204023 5204025 5210011 5308016 5308017 5308018 5308047 5310005 5409024 5409024 01 5409025 5409026 Docking Board Assembi Docking Board Assembi Flash Card Memory Cable Assembly Cable Assembly Cable Assembly Cable Assembly Cable Assembly Cable Assembly racket atch atch atch lat Spring lat Spring racket asher over over over uide uide uide ear ear ear ear oller oller earing earing ispenser haft haft haft haft tandoff pring pring pring pring g eo SC SS SS SH oo oo ol ol wo wo oo om GI A A enee olololclsimm mc re Ire el H PEL PHA eed page 2 24 Part 2 Testing and Repair Rev 05 2003 ei ICashCode FrontLoad Bill Validator Series Operation Service Manual LIST OF SPARE PARTS FOR VALIDATING HEAD continue Total guantity Part Number Description Nylon Push Rivet SE HEYCO 9030 8201922 Screw M3x6 Philips Pan 4 019 head Zinc Screw M2 5x25 Philips Sek Ee Pan Head Zinc 2 Screw 4 40x1 4 8201937 Philips Flat 100 Head Zinc Screw M2x5 Philips Pan Head Zinc Screw M 3x3 Philips
49. Pan See s Head Zinc Nylon screw M 3x6 Slot 8202939 8202940 8203002 Lock Washer M 3 internal teeth Zinc 8203020 Lock Washer M2 Internal teeth Zinc 32 4 Lock W asher M2 5 2 0333 Internal teeth Zinc 32 20 Retaining Ring D1500 4 033 3 2 Zinc DIN6799 8203927 W asher M3 Plain Zinc 1 Retaining Ring D1500 EZ Ge 2 3 Zinc DIN6799 1 HEYCO Standard Nylon W asher p n X050 W ood Screw 3x3 8 8204001 P hilips Pan Head Zinc 3 8211335 O Ring BM 25 155 NBRZ70 7 8211969 O Ring BM25 135 NBR7O OP T HW FTO1 VALIDATING HEAD wo aN 4 2 8201972 CO 1 2 4 a E a a FLV 0510 1 2 4 10 2 E 96 8203976 aja ojo o A CH N CH CH Rev 05 2003 Part 2 Testing and Repair PAGE 2 25 QI ClashCocde FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF VALIDATING HEAD AND SUBASSEMBLIES DISASSEMBLY OF SINGLE WIDTH VALIDATING HEAD FLV 0310 AND FLV 0510 Tools required Flat screwdriver Philips screwdriver 1 Extractor 5110050 Hex nut wrench 5 5 mm Tweezers Step 1 ASS Remove memory card or dummy card L Step 2 Remove bezel by following instructions below Pull out two nylon push rivets Open the Guide in the validating head Lift up the bezel and remove it from the validating head Disconnect the cable from the bezel Remove four M3x6 screws Remove holder from the validating head
50. cription Cazht ode Serve Lenba Supa pegam LCoppeght 2002 Cith Code Colne D Km H T EEN ux Device or module to test Device identiiteation SEH Ai Not available ORR oad Lae Poul e ka Umit type EES ITOE Ki Possible cares Nome Attach P1432 5 modale to the Test Station and insert P1432013 Head inte it Insert lower fense A Click modale and upper etalon module PI432 028 inte the head and then press Kum button Actual screen shot from a computer using the CashCode Service Stand The listed Failures and Possible causes should help identify any defective components in the validating head Click on button entitled Show Picture for an x ray view with highlighted details page 2 88 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual POWER INTERFACE MODULE 12V CC FLBDP Opto lsolated FLP 1710 12V CC BDPS CCNET Single Slave Mode FLP 2710 12V CC IPL Isolated Pulse Low Current FLP 2810 24V CC GPS22 CCNET Single Slave Mode FLP 5710 S SE zg Ou SE Z Rev 05 2003 Part2 Testing and Repair PAGE 2 89 Jc ashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Power Interface Module FLP 1710 FLP 2710 FLP 2810 FLP 5710 COVER 5201039 Interface Unit e f Metric Flat Washer M4 DIN 433 8203985 Washer M3 Plain Zinc 8203927 Metric Lock Washer M3
51. cs 8203923 Display Assembly 0600014 Holder Ass y 0100196 Washer M3 Plain Zinc 2 pcs 8203927 Insert see chart below A Heyco Standard Nylon Washer Part N X050 4 pcs 8203976 Washer M2 5 Plain Zinc 4 pcs 8203A10 Hex Nut M2 Zinc 4 pcs 8202938 Tapping Screw Cross Recessed Pan Head Type AB ANSI B18 6 4 4 24 X 3 4 2 pcs 8201A07 Washer 5810002 01 2 Cable Ass y Cable Assembly 0500035 0500072 Washer M3 Plain Zinc 8203927 Screw M3x12 Phillips Pan Head Zinc HSN Board Assembly 8201934 __s210022 68 _ eene _s210022 Rev 05 2003 Part2 Testing and Repair page 2 132 SlCashCode FrontLoad Bill Validator Series Operation Service Manual Exploded View of CashCode Bezel with Running Lights Digital Display and IR Communication Port FLB 3311 FLB 3331 MFLB 3401 Panel Eye glass Window 5210035 5210021 Screw M2x8 Phillips Pan Head Zinc 4 pcs 8201A08 5201045 Washer M2 Plain Zinc 4 pcs 8203923 Display Assembl 0600014 Holder Assemb Ba 0100196 Ps Washer M3 Plain Zinc 2 pcs SC 8203927 SEH gt g ye Ba e Insert see chart below IR Port Board 0404014 Cable Assembly 0500088 Heyco Standard Nylon Washer Part N X050 4 pcs
52. e Metric Flat Washer M4 DIN 433 8203985 Washer M3 Plain Zinc 8203927 Metric Lock Washer M3 DIN 7980 8203984 nage 2 94 8201538 DRIVER ASS Y 0300056 Retaining Ring No D1500 3 2 Zinc DIN6799 8203920 2 pcs Part2 Testing and Repair Rev 05 2003 SI CashCod e FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Power Interface Module Retaining Ring No D1500 3 2 Zinc DIN6799 2 pcs Step 3 8203920 SPRING 2 pcs Release the springs remove the 5409036 retaining rings and pull out the shaft POWER DI 2 H D W Z Retaining Ring No D1500 2 3 Zinc DIN6799__ 8203960 y A a Step 4 e SPRING Remove the retaining ring and take 5409034 off the shutter YA SHUTTER 5106013 SPRING S 5409035 Step 5 Remove Spring CHASSIS AS 0200072 Rev 05 2003 Part2 Testing and Repair PAGE 2 95 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF DRIVE ASSEMBLY 0300056 Tools required Philips screwdriver 1 Soldering iron Step 1 Disconnect the cable CABLE ASS Y 0500037 Step 2 Solder out the filter board assembly Bend terminals when assembling _ FILTER BOARD ASS Y KL ert Ba 0405035 WE A H SoA ae Ss RED MARK 2 Bend to 45 min DRIVE ASS Y 0300084 SOLDER 3 pls Z pag
53. e 2 96 Part2 Testing and Repair Rev 05 2003 oehle ashCode FrontLoad Bill Validator Series Operation amp Service Manual TESTING PROCEDURES FOR THE POWER INTERFACE MODULE Attach module P1432 2 to the Service Stand base Insert the power interface module into P1432 2 as shown below D wi el INTERFACE Install power interface module in place as shown below Do not connect 2 and 3 wire cables Rev 05 2003 Part2 Testing and Repair PAGE 2 97 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Power interface module Under Unit type select the appropriate module based on voltage and interface Click on the Run button located on the toolbar Review test results and failure description gt Lagbl aete Lene Lane beep rengen Lntsehg AUO Caah ode Lo lmz EN WI ha j Le Device identi t i Device or module to test Not available a Wi Power modur FEF r hi Unst hpa EX ailalsle IIF RDP module FL PITT e Attach module P14 2 2 te the Mam madale and attach Power loterface module FLPS te it as thiows on the pictore Then press Ron baitan Actual screen shot from a computer using the CashCode Service Stand The listed Failures and Possible causes should help to ident
54. e Co Inc E Ze E gt Ti About Run Options Print Device identification Test Result Not available Not available Device or module to test Display board assembly 0404013 v Possible causes None Attach module P1432 5 to the main stand s module connect it to board which You want to test and click on Run button Actual screen shot from a computer using the CashCode Service Stand The listed Failures and Possible causes should help to identify the defective components of the validating head Click on button entitled Show Picture for an x ray view with highlighted details page 2 150 Part2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual FRONTLOAD CASSETTE FLC 003 600 bills bill length FLC 503 1000 bills bill 125 150 mm length 125 150 mm FLC 103 600 bills bill length FLC 603 1000 bills bill 140 172 mm length 140 172 mm OL Ze Z Ce CASSETTE Rev 05 2003 Part 2 Testing and Repair PAGE 2 151 Cashc ode Exploded View of Cassette FLC 003 Housing Assembly 0100119 N FrontLoad Bill Validator Series Operation amp Service Manual Plate 5101097 Nylon Push Rivet Heyco No 9030 a Case Assembly
55. e Sepp pee Lope AUA larti ode Lr m Le i Deeg or module to test Sentar Board Goor e Dat pa ot available Attach module P1432 3 bo the main stands module cammert ii bo board which You want to best and click om Koo botton Actual Screen Shot from computer using CashCode Service Stand The listed Failures and Possible causes should help identify any defective components in the validating head Click on button entitled Show Picture for an x ray view with highlighted details page 2 58 Part 2 Testing and Repair Rev 05 2003 FrontLoad Bill Validator Series Operation Service Manual CashCode d RB 3 SENSE A CLICK SENSOR SET UPPER MODULES LOWER MODULES gt boli bo V SSNAS FLS 1704U FLS 1705U FLS 1704L FLS 1705L FLS 1704 1705 FLS FLS 1801U FLS 1801L FLS 1801 1901 FLS For Sense a Click modules designations refer to pages 1 15 of the Operations Manual PAGE 2 59 Part 2 Testing and Repair Rev 05 2003 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of upper Sense a Click module FLS 1704U si AB Self Tapping Screw 2x1 2 t Phillips Pan Head Steel Zinc 2 pcs _ ae 8201280 __ Cover 5201028 Upper Board 0402028 02 Case Assembly 2 0100222 page 2 60 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation a
56. e with Syncolon PTFE lubri cant to all bearings and gears except O Rings BEARING 5204025 nage 2 40 Part 2 Testing and Repair Rev 05 2003 SI CashCod e FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Drive Chassis 0300058 Step 7 Retaining Ring D1500 2 3 Zinc DIN6799 8203960 VALIDATING HEAD Remove the gear from the shaft of the drive Remove retaining ring Remove the other gear 5203022 KR Step 8 DRIVE ASS Y 0300030 Remove two screws Remove the drive and the dispenser DISPENSER 5210011 Screw M2x6 Phillips Pan Head Zinc 8201091 amp Lock Washer M2 J Saa Heyco Standard Nylon Internal Tooth Zinc Washer Part X050 8203020 8203976 Rev 05 2003 Part 2 Testing and Repair PAGE 2 41 QI CashCode Step 9 Remove two screws Remove the drive Step 10 Remove guides by pressing on the bosses in the middle Pull out two nylon push rivets and remove bracket page 2 42 FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Drive Chassis 0300058 DRIVE ASS Y i 0300052 Ss Her Nut M2 5 Zinc 8202939 Screw M2 5x25 Lock WasherM25 _Phillips Pan Head Zinc Internal Tooth Zinc 8201933 8203334 GUIDE 5202048 CHASSIS ASS Y 0100143 GUIDE 5202047 Nylon Push Rivet Heyco 9030 BRACKET 8102339 5101071 H Part 2 Testing a
57. embly 0300058 Single Width Attach module P1432 4 to the Service Stand base Attach sub module P1432 624 to P1432 4 as a substitute angle piece Install the drive chassis assembly and the connectors to P1432 624 On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Validating head s mechanics Under Unit type select Without alignment Click on the Run button located on the toolbar Review test results and failure description O zZ ck sr S E Cah ie Service Cenher Suppt Ceivg zm Caopptight M0 CashCade Colmi LIES S Gei Lee whch ate Device or madale to test Not avadable Erd Se Fi we Wb Unit type available RI alpamrai T Failures None AN Posse causes None A Attach P1432 6 module to the Test Station preapre validater s mechanics for best refer te eating procedore invert mechanics inte P1432 G module and press Kon button si Actual screen shot from a computer using the CashCode Service Stand The listed Failures and Possible causes should help identify any defective components of the validating head Click on button entitled Show Picture for an x ray view with highlighted details Rev 05 2003 Part 2 Testing and Repair PAGE 2 55 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Testing procedure for Controll
58. emove covers Si When assembling check for free and smooth movement of the lever Ge ng 5201054 Bag Hex Nut 2 56 2 pcs COVER 8202573 5201054 01 Washer M2 Plain Zinc 2 pes 8203923 yA Screw 2 56x3 4 Philips Pan Head Zinc 2 pcs yA 8201A03 DE ES ET SPOT OMRON CASE 5201055 Step 2 Remove the switch the lever and the LEVER spring 5206010 ee SPRING 5409044 page 2 124 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASSETTE DETECTOR 0900016 Tools required ii Screw 2 56x7 16 Phillips Pan Head Zinc Philips screwdriver 1 RB 8201A20 Ha r Washer M2 Plain Zinc Step 1 YA SWITCH SS 5 FT SPDT OMRON EA 8025A19 Remove one screw and remove the switch When assembling check for free and smooth movement of the lever Assembled view N Hex Nut 2 56 8202573 Step 2 Rotate the lever and remove it from the case Remove the spring Sei KO CASE Sa NE 5201056 Assembled view NS N SPRING WA 5409045 d SZ LEVER 5206009 Rev 05 2003 Part 2 Testing and Repair PAGE 2 125 CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual page 2 126 Part 2 Testing and Repair Rev 05 2003 eh CashCode FrontLoad Bill Validator Series Operation amp Service Manual CashCode
59. er 0401011 Attach module P1432 1 to the Service Stand base Install the controller to module P1432 1 and cConnect the flex cables as shown On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Main Controller Board 0401011 Click on the Run button located on the toolbar Review test results and failure description CashCode Sermice Center Suppat pogam Coppight AE CashCode Co kee Ea A ZS S 2 H i Device identic athi er made to test Mat available eg available zi Ablach madale PI432 ta the main standis module conmect if to board which You wani te best and click om Ron butten Actual Screen Shot from computer using CashCode Service Stand The listed Failures and Possible causes should help identify the defective components of the validating head Click on button entitled Show Picture for an x ray view with highlighted details page 2 56 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Testing Procedure for Download Board 0405028 Attach module P1432 1 to the Service Stand base Install sub module P1432 1 3 to P1432 1 Install the download board to module P1432 1 3 On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or
60. ers from the case _ Spring _ 5409040 Spring 5409023 Jf Plate we P _Roller _ 5204019 wo ao 2 pcs 5408003 nage 2 168 Part 2 Testing and Repair Rev 05 2003 SI CashCocde FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF HOUSING ASSEMBLY 0100119 Tools required Tweezers Flat screwdriver Step 1 Release locking spring in the packing mechanism Slide the packing mechanism along the housing and remove it Packing Mechanism 0300031 Housing Assembly 0100120 Rev 05 2003 Part 2 Testing and Repair PAGE 2 169 CASSETTE aech CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF HOLDER ASSEMBLY 0100124 Tools required No Tools required Step 1 Remove Cups Holder 5101062 5207012 page 2 170 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF HOUSING ASSEMBLY 0100120 Tools required No tools required Step 1 Slightly press on the walls of the housing Remove the shaft with the bearing Bearing Shaft Assembly 0300037 CASSETTE Rev 05 2003 Part 2 Testing and Repair PAGE 2 171
61. ev 05 2003 Part 2 Testing and Repair PAGE 2 5 9 zZ Ka H F UN OC ICash Code FrontLoad Bill Validator Series Operation amp Service Manual E Failed modules X ray view of FrontLoad device Next extract the defective module and proceed to module board testing Please refer to detailed testing procedures at the end of each section of this manual FINAL TESTS OF FRONTLOAD BILL VALIDATOR A final test should be performed after completing any repairs to the bill validator It is strongly recommended to perform all the testing procedures described below The final test consists of the following procedures e Functional Test FrontLoadL Multi width FrontLoad diagnostics page 4 High Temperature Test e Currency Validation Acceptance Money Test Any FrontLoad bill validator that passes these tests is understood to have met CashCode s specifications It is strictly recommended that units serviced under CashCode s warranty period have pass these tests page 2 6 Part 2 Testing and Repair Rev 05 2003 ei ICashCode FrontLoad Bill Validator Series Operation amp Service Manual High Temperature Test The high temperature test is performed after the functional test Here the functional test is repeated at specific intervals with the test FrontLoad Multi width FrontLoad placed in a high temperature chamber For this test it is necessary to have an oven with temperature controls ranging from 50C to 2C The test
62. he controller and the guide Step 2 Remove the springs and the rollers When assembling please refer to the drawing on this page _ STANDOFF 5310005 WASHER 5110064 O zZ ek IT g CONTROLLER ASS Y 0401011 GUIDE SCREW 4 40 x 1 4 8201937 Tighten these screws first N Use the Locktite Threadlocker 24 under the head of the screw ANGLE PIECE ASS Y 0100133 ROLLER 5204020 01 P GUIDE ASS Y 0200063 Apply a small amount of Super Lube with Wa Syncolon PTFE lubricant on the shafts of 5109001 01 the rollers Rev 05 2003 Part 2 Testing and Repair PAGE 2 47 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF DRIVE 0300052 Tools required Philips screwdriver 1 Step 1 Disconnect the cable CABLE ASS Y 0500062 Step 2 Screw M2x5 Phillips Pan Head Zinc Remove the Tmotor obturator 8201972 7 board TMOTOR S OBTURATOR ASS Y 0405012 page 2 48 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF GUIDE 0200055 Tools required i O Flat screwdriver zZ Tweezers z 2 F lt g SPRING a Step 1 aie SE We F See Remove the shaft the latch and the spring SHAFT 5308016 __FLAT SPRING 7 5109001 j Step 2 Remove the s
63. ify any defective components of the validating head Click on the button entitled Show Picture for an x ray view with highlighted details page 2 98 Part2 Testing and Repair Rev 05 2003 ER FrontLoad Bill Validator Series Operation amp Service Manual CashCode d m HOUSING Plain Bracket 600 cassette standard standard 600 cassette Lock Bracket connector FLH FLH 0110 connector 0810 1000 cassette standard FLH 3110 Plain Bracket standard Lock Bracket 1000 cassette connector FLH 3510 connector Part 2 Testing and Repair PAGE 2 99 Rev 05 2003 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of HOUSING FLH 0110 0 Rolled Spacer 8208994 Bracket assembl 0100138 02 N NN Lock Washer M3 Internal Tooth Zinc 8203002 2 pcs Screw M3x20 Phillips Pan Head Zinc 8201935 2 pes GEAR lt _SHAFT 5203031 5308026 A Y cw CONNECTOR 5202031 S s S FLAT SPRING we 5109015 mo 2 pes oe x P p Sa S a HF os gt Bag Ye e WA Screw M3x12 Phillips Pan Head Zinc 8201970 g Lock Washer MB Internal Tooth Zinc 8203002 Cover 5101105 N Z SPRING ES EE we 5409630 Screw M3x6 Phillips Pan Head Zinc SPRING 5409027 TIP 5210015 gt 8201000
64. ing D1500 2 3 Zinc DIN6799 Metric Flat W asher M 4 DIN 433 0405035 N 0405041 0405041 01 10 11 12 13 14 15 16 17 18 8201937 8203002 8203920 8203927 N 8203960 24 8203985 EEE e eee 1 E Eeee eee e e KAA e e eee HHE bee e e e eh i LEE be e ES SR EA Cas SS SS SS SES page 2 92 Part2 Testing and Repair Rev 05 2003 SI CashCocde FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF POWER INTERFACE MODULE AND SUBASSEMBLIES DISASSEMBLY OF POWER INTERFACE MODULE FLP 1710 FLP 2710 FLP 2810 FLP 5710 Tools required Flat screwdriver Philips screwdriver 1 Applicator tools for retaining rings DIN 6799 877 324 and 877 325 Step 1 Press on the latches of the cover from both sides and remove it Disconnect the cable from the board Remove two screws and remove inteface board D ug D Ow Dk z INTERFACE BOARD See chart below exploded view 2 INTERFACE UNIT ASS Y 0300067 Screw 4 40x1 4 Flat Phillips 100 Head Zinc 8201937 2 pcs Rev 05 2003 Part2 Testing and Repair PAGE 2 93 CashCode Step 2 Remove one M3x4 screw Remove retaining rings Pull out the shaft Detach the drive When assembling Lay the cable on UNIT Screw M3x4 Phillips Pan Head Zinc FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of POWER INTERFACE Modul
65. ir Rev 05 2003 eh CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF BEZEL FLB 2311 FLB 2331 MFLB 2401 Tools required Two flat screwdrivers Step 1 Press on latches of the insert as shown by arrows Release latches and remove the insert Step 2 Press on latches of the plug as shown by arrows Release latches and remove the plug page 2 136 Part2 Testing and Repair Rev 05 2003 o JCasbtode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Bezel FLB 2311 FLB 2331 MFLB 2401 Panel 5201045 _ Step 3 Press on the latches of the eye glass as shown by arrows Release the latches and remove the eye glass SS Eye glass 5210035 01 Step 4 Note the light pipe has been secured in the plug with glue and it cannot be disassembled When assembling a new light pipe place a j small amount of glue on its tab Plug lt Plastic cement or cyano acrilate glue is 9210023 recommended Light Pipe 5210037 Rev 05 2003 Part2 Testing and Repair PAGE 2 137 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF BEZEL FLB 2111 FLB 2131 MFLB 2201 Tools required Two flat screwdrivers Phillips screwdriver 1 Step 1 Remove one screw Remove display board and cable Disconnect the cable from the dis
66. l432 622 Head inte it Insert upper Sense A Click modale and lower etalon modale P1432 627 into the head and then press Run bution E Actual screen shot from a computer using the CashCode Service Stand The listed Failures and Possible causes should help identify any defective components of the validating head Click on the button entitled Show Picture for an x ray view with highlighted details page 2 86 Part 2 Testing and Repair Rev 05 2003 oehle ashCode FrontLoad Bill Validator Series Operation amp Service Manual Lower Sense a Click Module Test FLS 1704L FLS 1705L FLS 1801L FLS 1901L Attach module P 1432 4 to the Service Stand base Install validating head P 1432 622 to module P 1432 4 Remove lower Sense A Click module P 1432 627 from validating head P1432 622 Install the lower Sense A Click module to be tested Ensure upper Sense A Click module P 1432 628 is in the validating head 3 lt q wi o Z ii o CLICK Rev 05 2003 Part 2 Testing and Repair PAGE 2 87 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Lower Sense A Click module Under Unit type select appropriate model number Click on the Run button located on the toolbar Review test results and failure des
67. lala Il l lalo oo a a ja a ja 2 c Ele jojojo jo o jo je 8 L gt L o 2 a jy S o 2 le jo S 2 2 e ele 2 2 gt gt 2 ze UU jo o A lt jo jojo T ja Z a la ju ju ODIsls tot ken 2 COIN v 0 N ka E N dk E L KR 9 5 m It lO au uli ua IG IN AN N amo fofoIniIn o o gt lt LH IM Njolla na ka N N Gd IG ieilenienlel o o loldololaolol JalalalololJolo CG oleo S S r t ls lo lolosfol JHIANINJoOlosaolo ro ellos So a oO oO JOJO JOJO lOO JOJO Leck Kal kal Ka e e ez ec le le lei CH CH o ITM MIM JO JHIAIANIAIAN TA IATA N Cl IN IIe TA lol N o 101d S S So jn H H jo Jw jo Jw ei LO to to Jo Ji o o N Joel Io Ol NJM M O n JolmMlol lt Nlo wo page 2 134 Part2 Testing and Repair Rev 05 2003 FrontLoad Bill Validator Series Operation amp Service Manual CashCode LIST OF SPARE PARTS FOR BEZEL continued SETEL vLOVZOSHE L i 1992dS III ek OU TTT Lass zk viv vivijr v u d Jayse UON 9 6 0Z8 bt DISDUEIG OOASH OU 000000000000 mama e UIZ eee SS umesena ee fe QUIZ Leet IELUS PPP PPP PPP DD DD DODERER viv lr r r r o oumsen seszoze e _ SUIZ NY PESH UG NY Pe H ued PIECH OM ZOVLOC8 8Z elt wee Buidde JUIZ Wd PREAH ued OLXEN Mee V 6L008 D uonduosag JagWnN Hed L0re 813W LOce a OW L09c a OW LOove d OW Ayquenb jejo L PAGE 2 135 Part2 Testing and Repa
68. ll If it is rejected for the second time it indicates failure Step 5 Repeat step 4 in the third orientation as suggested by the picture below Insertion Direction gt This side UP ll POLED LEED If any bill is rejected it must be inserted a second time before inserting the next bill If it is rejected for the second time it indicates failure Step 6 Repeat step 4 in the fourth orientation as suggested by the picture below Insertion Direction gt This side UP If any bill is rejected it must be inserted a second time before inserting the next bill If it is rejected for the second time it indicates failure Rev 05 2003 Part 2 Testing and Repair PAGE 2 9 9 zZ N H F UN OO ICashCode FrontLoad Bill Validator Series Operation amp Service Manual Notes A Canadian five dollar bill is shown in the preceding pages in order to illustrate the money test Street grade bills are those which have been in use for some time but without significant wear and tear There must not be any perforations or cut corners It is likely to have more than one style old and new for a denomination The bill validator may have been set to accept or to not accept a certain bill style Please refer to specific users guide software description page 2 10 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual VALIDATING HEAD S
69. module to test select Download board 0405028 Click on the Run button located on the toolbar Review test results and failure description O zZ ck sr S CashCeds Smvice Cente Suppo pogam Coppighi 7007 CarthCade Co ne A Em A Fre x Device or module to test eer Kigali BiN Test Result Not avudable Wot faeralcad Board O40 7028 w Go available BI Attach madale P1432 bo the main stand module commect it bo board which You want to test Use adapter beard to besi Download board board Then click on Rao bulion Actual Screen Shot from computer using the CashCode Service Stand The listed Failures and Possible causes should help identify any defective components in the validating head Click on the button entitled Show Picture for an x ray view with highlighted details Rev 05 2003 Part 2 Testing and Repair PAGE 2 57 QI CashCiode FrontLoad Bill Validator Series Operation amp Service Manual Testing Procedure for Input Sensor Board 0402018 and 0402019 Attach module P1432 3 to the Service Stand base Install the input sensor board to module P 1432 3 On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select With or Without Alignment Click on the Run button located on the toolbar Review test results and failure description aa AA Soece Le
70. mp Service Manual Exploded view of upper Sense a Click module FLS 1705U pi AB Self Tapping Screw 2x1 2 Phillips Pan Head Steel Zinc 2 pcs SZ 8201280 Cover 5201028 _ Upper Board 0402028 06 _ Case Assembly oe 0100222 Rev 05 2003 Part 2 Testing and Repair PAGE 2 61 FrontLoad Bill Validator Series Operation amp Service Manual CO JCashCode Exploded view of upper Sense a Click module FLS 1801U AB Self Tapping Screw 2x1 2 ____ Phillips Pan Head Steel Zinc 2 pcs 8201280 Cover 5201028 Da Lei SF O MN alo ON Qo Qy 50 Case Assembly 0100222 01 Part 2 Testing and Repair Rev 05 2003 page 2 62 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of upper Sense a Click module FLS 1901U AB Self Tapping Screw 2x1 2 _____ Phillips Pan Head Steel Zinc 2 pcs e 8201280 Cover 5201028 Upper Board 0402031 02 _ Case Assembly lt 0100222 01 Rev 05 2003 Part 2 Testing and Repair PAGE 2 63 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded view of lower Sense a Click module FLS 1704L AB Self Tapping Screw 2x1 2 __Phillips Pan Head Steel Zinc 4 pcs 8201280 D Cover 5201026 Lower Board 7 0403017 02 Case Assembly 0100221 page 2 64 Part 2 Testing and Repair Rev 0
71. must be tested before being installed to the parent assembly Rev 05 2003 Part 2 Testing and Repair PAGE 2 51 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Testing Procedure for Validating Head FLV 0310 and FLV 0510 Single Width Attach module P1432 4 to the Service Stand base Attach the validating head to module P 1432 4 On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Validating head Under Unit type select Without alignment Click on the Run button located on the toolbar Review test results and failure description Er CashCode Servite Cente Supe popam Copenh 2002 Casak ode Colne i EE mnie Eng Dever ar module to test oer SIA Test Result Not available ny Fotidoting Head e Not Unit type aviilalle Pint alignment MFE 2170 F Al Possible causes None al Altech FLANI G modale te the Test Sistion amd insert Validating Head imta it Set 4th ariteh on the Download board OR and then press Ren botton A Actual screen shot from a computer using the CashCode Service Stand The listed Failures and Possible causes should help identify any defective components in the validating head Click on the button entitled Show Picture for an x ray view with highlighted details page 2 52 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad
72. n and release the shaft Remove the shaft and the gear To reassemble move the spring then reinstall the shaft The spring must enter the groove on the shaft as shown in sectional view _ Move Spring Refer to steps 5 to 8 as described in Disassembly of Housing FLH 0110 nage 2 116 Part 2 Testing and Repair Rev 05 2003 FrontLoad Bill Validator Series Operation amp Service Manual SI CashCode DISASSEMBLY OF HOUSING FLH 3110 Tools reguired Flat screwdriver Philips screwdriver 1 Step 1 Remove two screws Remove bracket assembly Screw M3x12 Pan Head Zinc 3pcs 8201970 Se Lock Washer M3 8203002 H Ps T Internal Tooth Zinc 3pcs Cover 5101119 Pe Rev 05 2003 Bracket Assembly 0100138 02 Lock Washer M3 Internal Tooth Zinc 2 pcs 8203002 Screw M3x20 Pan Head Zinc 2 pcs 7 8201935 N 8 a _ Rolled Spacer ES 8208994 Step 2 Remove three screws Remove the cover PAGE 2 117 Part 2 Testing and Repair QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Housing FLH 3110 Step 3 Remove one screw Remove cassette detector Screw M3x6 Pan Head Zinc 8201000 K KO Lock Washer M3 paee Internal Tooth Zinc 8203002 Cassette Detector 0900016 Step 4 Move the spring as shown and release the shaft Remove the shaft and
73. n Head Zinc 8201970 Lock Washer M3 Sprin Internal Tooth Zinc Sin a 8203002 SE s Cover Assembly 5100186 fatehi e gt J 5106010 A 2 gt fo Shaft 308027 Lever Step 2 BUTTite Rolled Spacer pe SPAENAUR No 607 070 8208998 Remove one screw and re move the cover assembly Slightly squeeze the lever assembly from both sides and remove it from the housing watch the Spring Pull out the shaft and disas semble the lever latch and spring Steel Flat Washer SPAENAUR No 656 057 8208999 Lever Assembly a 0100148 Spring 5409008 page 2 114 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Housing FLH 0810 Step 3 Remove one screw Remove cassette detector Screw M3x6 Pan Head Zinc 8201000 A d Lock Washer M3 pa Internal Tooth Zinc 8203002 Cassette Detector 0900016 Step 4 Remove two screws Remove the switch assembly Screw M3x6 Pan Head Zinc 8201000 Lock Washer M3 Internal Tooth Zinc 8203002 Switch Assembly 0900017 Rev 05 2003 Part 2 Testing and Repair PAGE 2 115 CashCode Steps 6 7 8 9 FrontLoad Bill Validator Series Operation amp Service Manual GEAR 5203031 SHAFT 5308026 Disassembly of Housing FLH 0810 Step 5 Move the spring as show
74. nd Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF CASE 0100128 Tools required Flat screwdriver 9 Tweezers S 9 a ke I g Step 1 GEAR 5203031 Remove the retaining ring and the gear RETAINING RING _ D1500 3 2 Zinc DIN 6799 8203920 a ol S Geh SPRING 8 b _ 5409026 q LATCH 5106009 RETAINING RING D1500 3 2 Zinc DIN 6799 2 pcs 8203920 Step 2 Remove the retaining rings the latch the spring and the shaft gd CASE ASSEMBLY 0100154 Sa L yA SHAFT 5308018 Rev 05 2003 Part 2 Testing and Repair PAGE 2 43 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF GUIDE 0200050 Tools required Flat screwdriver Tweezers Step 1 SPRING SPRING LATCH after re assebbly 5409025 HD 5106007 g Remove the shaft latch and the spring SHAFT 5308016 Step 2 FLAT SPRING 5109001 Remove the springs and the rollers To remove springs press in the direction of arrow 1 and lift up on the edge as shown by arrow 2 ROLLER 5204020 01 GUIDE ASS Y 0200064 page 2 44 Part 2 Testing and Repair Rev 05 2003 SI ClashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF GUIDE 0200052 Tools required Philips screwdriver 1 Tweeze
75. nternal Tooth Zinc 8203002 YU e Ki Cassette Detector 0900016 Ki Screw M3x6 Phillips Pan Head Zinc 8201000 2 pcs ae oe Switch Assembly N Lock Washer M3 Internal Tooth Zinc Zi a 0900017 8203002 lw 2 pes Rev 05 2003 Part 2 Testing and Repair PAGE 2 103 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of BRACKET Assembly 0100138 02 page 2 104 Washer M3 Plain Zinc 8203927 4 pcs Screw M3x10 Phillips Pan Head Zinc 8201934 2 pcs CABLE ASS Y ae 0500064 01 BRACKET ASS Y ye 0100149 02 BUSHING 5310002 4 pes Screw 4 40x1 4 Phillips ____ 100 Flat Countersunk Head Zinc 8201937 4 pcs Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Cassette Detector 0900016 8025A19 1 Switch SS 5 FT SPDT OMRON Standoff 1 4 B101A22 Cover 5201054 5201054 01 Hex Nut 2 56 2 pcs 8202573 Ka Lever _ 5206010 Case we Spring 5201055 5409044 Washer M2 Plain Zinc 2 pes 8203923 Screw 2 56x3 4 Philips Pan Head Zinc 2 pcs 8201A03 Rev 05 2003 Part 2 Testing and Repair PAGE 2 105 eh CashCode FrontLoad Bill Validator Series Operation amp Service Manual Exploded View of Switch Assembly 0900017 Screw 2 56x7 16 Phillips Pan Head
76. on Step 1 Connect the FrontLoad bill validator to the Service Stand base module as explained in the FrontLoad Multi width FrontLoad bill validator diagnostics with Service Stand section Switch 2 1 must be set to 4 way and switch 2 4 must be set to validation mode Please refer to the bill Step 2 Start by clicking on the icon CashCode Service Centre Support Software Under Device or module to test select Money test Under Unit type select an appropriate interface module Click on the Run button on the toolbar Turn on the reguired communication protocol in order to launch the test application Enable the bill validator by polling Please refer to the help option for further details Step 3 Insert the bills one by one in the first orientation as suggested by the picture below Insertion Direction gt This side UP If any bill is rejected it must be inserted a second time before inserting the next bill If it is rejected for the second time it indicates failure page 2 8 Part 2 Testing and Repair Rev 05 2003 oehle ashCode FrontLoad Bill Validator Series Operation amp Service Manual Step 4 Collect the bills from the cassette Insert them in the second orientation as suggested by the picture below Insertion Direction gt This side UP If any bill is rejected it must be inserted a second time before inserting the next bi
77. ontLoad Bill Validator Series Operation amp Service Manual Disassembly of Case Assembly 0100222 Step 2 Gently press on the latches in order to release and remove the lenses from the case LENS 3 pcs ji 5205015 Correct latch position Step 3 Remove the light guides from the case LIGHT GUIDE 2 pcs LIGHT GUIDE 5205025 CASE 5202059 page 2 82 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation Service Manual DISASSEMBLY OF CASE ASSEMBLY 0100222 01 A HOLD DOWN 2 pcs Tools required DOWN SPRING 2 pcs Philips screwdriver 1 5409037 Flat screwdriver SLIDER 2 pes 5210017 Step 1 Gently press and release the hold down latches in order to remove the hold downs watch the springs Remove the springs and the sliders Remove the rollers ROLLER 2 pcs _ 5204029 a ec L 1 fat Correct latch position Rev 05 2003 Part 2 Testing and Repair PAGE 2 83 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Case Assembly 0100222 01 Step 2 Gently press on the latches in order to release and remove the lenses from the case __LENS 3 pcs 5205015 Correct latch position A e Step 3 Remove light guides from the case LIGHT GUIDE 2 pcs
78. play board Display Board Ass y p 0404013 SE K a 885 No E WE _ Washer 5810002 01 4 a Y Cable Ass y Washer M3 Plain Zinc 2S 8203927 EA 0590072 Ne Cable Ass y Screw M3x12 Phillips Pan Head Zinc 0500035 8201934 A Step 2 Holder Assembly Remove two screws 0100196 Remove holder assembly 4 e Ke S 3 Washer M3 Plain Zinc 2 pcs N 8203927 Tapping Screw Type AB 4 24 X 3 4 Pan Head Phil 2 pcs 8201A07 page 2 138 Part2 Testing and Repair Rev 05 2003 o JCasbtode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Bezel FLB 2111 FLB 2131 MFLB 2201 Step 3 Press on latches of the insert as shown by arrows Release latches and remove the insert Step 4 Press on latches of the plug as shown by arrows Release the latches and remove the plug Panel 5201045 Step 5 Press on the latches of the eye glass as shown by arrows Release the latches and remove the eye glass Eye glass 5210035 01 Rev 05 2003 Part2 Testing and Repair PAGE 2 139 o JCashCod FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF BEZEL FLB 2511 FLB 2531 MFLB 2601 Tools required Two flat screwdrivers Phillips screwdriver 1 Step 1 Remove one screw Remove display board and cable Disconnect the cable from the display board eS Washer
79. prings and the rollers To remove the springs press in the direction of arrow 1 and lift up on the edge as shown by arrow 2 ROLLER GUIDE ASS Y 0200056 Rev 05 2003 Part 2 Testing and Repair PAGE 2 49 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual REASSEMBLY OF VALIDATING HEAD AND SUBASSEMBLIES To reassemble the validating head please follow the disassembly instructions in the reverse order Take care to Check all parts before reassembly for visible physical defects cracks deformities loose or dis connected cable wires missed elements etc Remove dirt from all parts with a soft cloth when needed some alcohol may be used as a solvent Apply a small amount of Super Lube with Syncolon PTFE lubricant to all bearings and gears Check the free movement of all movable parts Check that no loose parts or tools are left behind in the assembly page 2 50 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual TESTING PROCEDURES FOR VALIDATING HEAD AND SUBASSEMBLIES After the reassembly process is complete the following subassemblies should be tested Drive chassis assembly 0300049 and 0300058 Download board 0405028 Controller 0401011 Input sensor board 0402018 and 0402019 Validating head FLV 0310 FLV 0510 and MFLV 2110 Wal zZ lt 3 27 gt Each subassembly
80. rs VALIDATING HEAD Wood Screw 3x3 8 Phillips Pan Head Zinc Step 1 78204001 d ag ja ri y Remove two wood screws the bracket and the cable Remove docking board Remove shafts ee at BRACKET E 7 5110044 When assembling fold cable as shown below DOCKING BOARD ASS Y 0405032 SHAFT 5308017 Rev 05 2003 Part 2 Testing and Repair PAGE 2 45 QI ClashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF GUIDE 0200053 Tools required Flat screwdriver Philips screwdriver 1 N Wood Screw 3x3 8 A Phillips Pan Head Zinc kai SPRING on Tweezers See 8204001 Y g OX ee lt ex LATCH _ lt S 5106008 x g ji Ce DOCKING BOARD ASS Y be 0405011 Step 1 SHAFT 530816 i CABLE ASS Y 0500034 Remove the wood screw the docking board and the cable Remove the shaft the latch and A the spring e When assembling fold the cable as shown Step 2 SPRING Remove the springs and the rollers GUIDE 5202029 page 2 46 Part 2 Testing and Repair Rev 05 2003 Cashc ode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF ANGLE PIECE 0200054 Tools required Flat screwdriver Philips screwdriver 1 Hex nut wrench 5 5 mm Tweezers Step 1 Remove the standoff and the washer Remove two screws Remove t
81. t the access to connector Holder Seg 5101110 a N Nylon Push Rivet Heyco 9032 2 pcs lt LA 8102003 Lock Washer MB Internal Tooth Zinc 2 pcs 8203002 Screw M3x6 Phillips Pan Head Zinc 4 pcs 8201000 Microplastic Round Spacer 13RS024014 2 pcs 8208A15 Step 1 Break out the cap on the plastic cover only for installation of bezels with electronics Step 2 Place the holder on the validating head and secure it with screws washers and spacers as shown Secure the cable terminal to one of the screws where applicable Step 3 Connect the cable from the bezel to the validating head where applicable Step 4 Slide in the two tabs from the bezel into the corresponding two slots in the validating head Secure the bezel with two nylon push rivets Rev 05 2003 Part2 Testing and Repair PAGE 2 149 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual TESTING PROCEDURE FOR THE DISPLAY BOARD ASSEMBLY 0404013 01 02 03 Attach module P1432 5 to the Service Stand base Install the display board onto P1432 5 On the PC start by clicking on the icon entitled CashCode Service Centre Support Software Under Device or module to test select Display board assembly Click on the Run button located on the toolbar Review test results and failure description E CashCode Service Center Support program Copyright 2002 CashCod
82. testing modules Each testing module is designed to test one or more devices ie the FrontLoad bill validator and subassemblies or modules ie the validating head Sense a Click sensor paks etc Base module P1432 0 Individual Testing modules National Instruments Multi Input Output Data Acquisition Card PCI 3 Rev 05 2003 Part 2 Testing and Repair PAGE 2 3 O zZ N W F UN el i CashCode FrontLoad Bill Validator Series Operation amp Service Manual FRONTLOADL MULTI WIDTH FRONTLOAD BILL VALIDATOR DIAGNOSTICS USING THE CASHCODE SERVICE STAND Step 1 Connect the FrontLoad bill validator to the Service Stand base module as shown below Switch 2 4 must be set to service mode refer to bill validator users guide For FrontLoad bill validators having one interface connector one cable should be left unconnected PC SYSTEM BLOCK ee See 7 WA CABLE P1432 408A AN Pa ki S e a COM1 2 SERIAL PORT ER P1432 409 i CO a E i TEE v e p DA J ct L J ya 2 ik A D S S a o II W NI PCI DAQ PC CARD JI REAR VIEW CONNECTORS SIDE SERVICE CENTRE lic cl D BASE MODULE lt ee gt POWER SWITCH P1432 0 SS gt
83. the gear mer To reassemble move the Ee Spring then reinstall the shaft The spring must enter the groove on the shaft as shown in sectional view Move Spring GEAR 5203031 Steps 5 6 7 8 Refer to steps 5 to 8 as de scribed in Disassembly of Housing FLH 0110 page 2 118 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF HOUSING FLH 3510 Tools required Flat screwdriver Philips screwdriver 1 ji Bracket Assembly Lock Washer M3 Z 0100138 02 Internal Tooth Zinc 2 pes 8203002 l Step 1 Screw M3x20 Remove two screws Se de Remove bracket assembly e Rolled Spacer 8208994 Screw M3x12 Pan Head Zinc 8201970 Lock Washer M3 Internal Tooth Zinc Spring 5409028 e Cover Assembly 0100204 Latch 5106010 a ET 5110048 Step 2 an 4 Remove one screw and re move the cover assembly Slightly squeeze the lever assembly from both sides and remove it from the housing watch the Spring Pull out the shaft and disas semble the lever the latch and the spring Lever Assembly 0100148 Spring 5409008 Rev 05 2003 Part 2 Testing and Repair PAGE 2 119 Co ICashCode FrontLoad Bill Validator Series Operation Service Manual Disassembly of Housing FLH 3510 Step 3 Remove one screw Remove cassette detector Screw M
84. ting and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Housing FLH 0110 Step 5 Spring Remove the spring from the housing 5409027 Step 6 Remove the spring from the housing Spring 5409630 View in assembled position Rev 05 2003 Part 2 Testing and Repair PAGE 2 111 CH CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Housing FLH 0110 Step 7 Push on two latches and pull up the center portion of the connector Slide the connector towards the back wall Remove the connector CONNECTOR 5202031 page 2 112 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of Housing FLH 0110 Step 8 FLAT SPRING 2 pcs d 5109015 Remove the flat springs and the tip TIP 5210015 Rev 05 2003 Part 2 Testing and Repair PAGE 2 113 QI CashCode FrontLoad Bill Validator Series Operation amp Service Manual DISASSEMBLY OF HOUSING FLH 0810 Tools required Flat screwdriver Philips screwdriver 1 Bracket Assembly H Lock Washer M3 j 0100138 02 Internal Tooth Zinc 2 pcs 8203002 Ste p 1 Screw M3x20 Pan Head Zinc 2 pcs pa ELCA A N ya 8201935 Ne Remove two screws Remove bracket assembly Rolled Spacer 8208994 Screw M3x12 Pa
85. y following instructions below Partially remove four M3 screws Squeeze walls of the guide from both sides and remove the guide from the case Step 10 Remove guide 0200051 by following instructions below Squeeze walls of the guide from both sides and remove the guide from the Case GUIDE ASS Y 0200052 lt Partually unscrew four screws GUIDE ASS Y 0200051 E page 2 30 Part 2 Testing and Repair Rev 05 2003 SI CashCode FrontLoad Bill Validator Series Operation amp Service Manual Disassembly of single width validating head FLV 0310 and FLV 0510 Step 11 S Remove connector 0100132 by E an S following instructions below a CONNECTOR ASS Y lt Remove 4 M3x6 screws 09100132 Remove connector 7 Remove shaft __ Screw M3x6 Phillips Pan Head 8201000 Lock Washer M3 8203002 Washer M3 Plain Zinc Hex Nut M3 Zino 8203927 8202940 Screw M3x3 Phillips pr Pan Head Zinc 8201A01 Lock Washer M3 Internal Tooth Zinc 8203002 J DRIVE CHASSIS ASS Y 0300049 Step 12 Remove Drive Chassis Assembly by following instructions below Remove M3x3 screw Remove M3 hex nut i x CASE ASS Y Remove drive chassis assembly 0100128 0100128 d A Lubri tS Lub ith S l PTFE Pay attention Plate and link are EE not secured to the drive chassis Rev 05 2003 Part 2 Testing and Repair PAGE 2 31 QI CashCode

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