D-100 Service Manual for All Version
Contents
1. to reduce the Feed Gap 28 CHAPTER6 TROUBLESHOOTING Error Massage Solution When an error occurs the corresponding error message will appear on the LCD display To remove the error and continue counting please take necessary measures according to the following procedures Error Message CHECK HOPPER SENSOR CHECK STACKER DIMENSION ERROR ERROR CHAIN NOTES ERROR DOUBLE NOTES SUSPECT NOTE UV SUSPECT NOTE MR Cause of Error Hopper Sensor is covered Notes on Stacker when power is on 1 Half sized note is fed 2 Asmall note passes from the left or right side More than two notes are fed in chain Two notes are fed ata time ora dirty note is fed Suspected counterfeit note is detected by UV detection Suspected counterfeit note is detected by MR detection 29 Possible Solution Remove notes or objects from Hopper Sensor Remove banknotes from the Stacker 1 Remove the half sized note 2 Align banknotes nicely and place them on the middle of the Hopper If this error appears very often the thickness adjustment Gap might be too wide Adjust the size of the gap Refer to section 4 3 Adjust thickness adjustment knob Adjust Contrast of banknotes See section 9 2 Set Contrast of Notes of the User Manual 1 Remove the last note from the Stacker 2 Press START ENTER key 3 If false alarm occurs recount the last note removed from the Stacker 1 Remove th2. 0 enter H 3 data Count genuine banknotes If not adjust LVRI RVR1 and MVRI the middle two digits show the sum data of potentiometers the Right Magnetic Sensor and the Left Magnetic Sensor The last two digits show the data of the Middle Magnetic Sensor we gm E m E Left Magnetic Sensor ae connector Right Magnetic Sensor connector Adjust MVRI1 potentiometer to increase counter clockwise or reduce clockwise the Middle Magnetic Sensor s sensitivity The last two digits of H 3 data of genuine 5 color version should be above 10 Disconnect the Left Magnetic Sensor connector and count genuine 1 The middle two digits of H 3 data should be above 10 If not adjust LVR1 to increase counter clockwise or reduce clockwise the Right Magnetic Sensor s sensitivity Then disconnect the Right Magnetic Sensor connector and adjust RVRI the similar way if the middle two digits of H 3 data of genuine 1 are not above 10 Finally count a batch of different denomination notes to make sure the adjustment is OK for all notes 24 5 CIS Contrast Adjustment Things to check if the image board is working 1 When switching on the machine L LED should be from on to off This means the image software is successfully downloaded to the image processor 2 C LED should be on when encoder disk moves This means the image processor is working C LED If NO ID occurs very often please adjust the CIS Cont
3. 004 1 p 2 22 ee ey es 7 gt i oe gt ope m he Display Panel Keys Part s name o LCD amp LCD Board 1 f 19 LCD Board Wire 1 p7 20 LefKeyboardPCB 1 21 Right Keyboard PCB 1 f pf 54 Hopper Sensor 1 o4 10 DisplayPanei 1 ou Keys Main PCB Blank Hopper Sensor Blank 6 The Disassembly of Stacker Screw off the two screws fixing Stacker the Stacker MA e 7 The Disassembly of Signal PCB Press two tabs on the left and Screw off the four screws fixing Signal PCB Cover right as shown by the arrow the Signal PCB Cover sign and the Cover will pop up a little Screw off the two screws fixing Disconnect all the connectors Signal PCB the Signal PCB on the Signal PCB pf Signal PCB Cover 1 og 22 Signal PCB Wire 1 z3 Signal PCB 1 sm UES Left MR Sensor Right MR Sensor 8 The Disassembly of Back Transfer Mechanism Assembly Screw off the two screws fixing the Back Transfer Mechanism on the right and left sides a ill Receiver Counting Sensors Part UV Sensor Assembly MR Sensor No 55 Left Right MR Sensor Back Transfer Mechanism Upper Press Roller SA 58C QTY 4 5 UV Sensor Assembly O 58A MRSensor l 58C Left Right MR Sensor 2 Screw off the two small screws Screw off the two screws fixing Disconnect the connector on the fixing the CIS on the left side the CIS on the
4. c ring with a the Front Upper Transfer Part No 51A screwdriver Mechanism on the right and left sides Pull out the Gear Pull out another c ring with a Loose the inner screw of the screwdriver Flywheel with an Inner Allen Key Screw off the four screws fixing on the Middle Cover the Front Lower Transfer Mechanism on the right and left sides Unclench the threads fixed pAQyErrits rI Take off the Transmitter Counting Sensors Part No 56 from the Front Lower Transfer Mechanism QTY Front Upper Transfer Mechanism SIA l 015A 52A Front Lower Transfer Mechanism S 016 Transmitter Counting Sensors Li a Front Lower Transfer Mechanism Take off the Front Lower Transfer Part No 52A Mechanism 15 17 The Disassembly of Middle Cover and Transfer Roller Assembly Screw off the four screws fixing Take out the Middle Cover Middle Cover the Middle Cover on the right and left sides Pull out the c ring on the right Push the bearings on both sides Transfer Roller Assembly and left sides out and then take off the Transfer Roller Assembly QTY 4 Middle Cover Transfer Roller Assembly 45 One way Bearing amp Gear 46 Flywheel O13A 14 4A 45 46 47 AT Bearing 688 with wrap 18 The Disassembly of Stacker Plate amp Sensors ap Screw off the four screws fixing Stacker Plate Stacker Sensors the Stacker Plate on the right and left sid
5. i ise r aris ED RR A oe RRzo y Rusja is N s LEV REV Points amp Ground Point GND EVRI amp EVR2 Potentiometers 21 2 Change the Sensitivity of Hopper Sensor To change the sensitivity of Hopper Sensor gt dams X Using a screwdriver adjust VR1 potentiometer the first potentiometer on the Main PCB to get a proper voltage with the Multi Meter s red pen touching the first point and the black pen touching Ground Point The range of the voltage is 0 1 2V the higher voltage means the sensibility of the Hopper Sensor is higher Normally for USD the voltage is around 1 0V Adjust clockwise to reduce the voltage or counter clockwise to increase the voltage 22 please adjust the VR1 potentiometer on the Main PCB 3 UV ADJUSTMENT Pull out the right side cover Count genuine Count a white paper or UV Detect Paper The banknotes and press key 9 then press key last two digits of H 2 data should be above 45 ADD twice H 2 data the last two digits should If not adjust VR2 potentiometer be 0 If not adjust VR2 potentiometer the second potentiometer on the Main PCB Adjust the VR2 potentiometer to increase counter clockwise or reduce clockwise the UV sensitivity 23 4 MR ADJUSTMENT Take off the Signal Board Cover Press key Count fake banknotes without magnetic 9 then press key ADD three times to ink The last four digits should be all
6. on the right and left sides Pond Thickness Adjusmen Rab 1 002 5 TopCover 1f 6 TopCoverFixerShat 1 3 The Disassembly of Rear Cover Screw off two screws fixing the Disconnect the connector on Screw off the three screws Rear Cover on the right and left the Rear Cover fixing the Power Supply sides Cover on Bottom Plate y Take out the Power Supply Rear Cover Assembly Cover a little so as to pull off the Power Wire Rear Cover d o 82 Power Wire ai ooo USB 2 0 SERIAL a Screw off the four screws fixing Pull upwards to take off the Note Guider Assembly the Note Guide Plate on the left Note Guider Assembly Front Picture and right sides _ 003 Note Guider Assembly Back Picture 7 Note EntryCover 1f o gt o 003 8 NoteGuiderpart 2 S O 9 Middle Note Guide Plate 1 gt S Pull out the C Ring fixing the Gear Screw off the four screws fixing Disconnect the 16 PIN Connector Take off the Display Panel the Display Panel on the right and left sides Screw off the four screws fixing LCD amp LCD Board the LCD Board Screw off the four screws fixing Use a sleeve barrel to screw Keyboard PCB the two Keyboard PCBs off the four screws fixing the two Keyboard PCBs 6 er He iy hi Use a screwdriver to unclench the clasp A and clasp B will get Pull out the Hopper Sensor Hopper Sensor released
7. right side right side and take off the CIS with Right Bracket Screw off the two small screws on CIS CIS Right Bracket 0 CIS E a 10 The Disassembly of Image PCB ie He a E a ie i Screw off the two screws fixing Disconnect the CIS connector Take off the Image PCB the Image PCB 2 al Image PCB 25 Image PCB outerPCB 1 11 The Disassembly of Main PCB Doai thik Gf Disconnect all the connectors Screw off the four screws fixing Main PCB on the Main PCB the Main PCB 24 MainPCB GinnerPCBY 1 11 LCD Board Signal PCB Power Supply PCB Transmitter Counting Sensors Image PCB Stacker Motor Ey a 4 24V Power Supply pe im es A Bau Main Motor erin Pas ATA Na K a R Interface Blank E UV Sensor Assembly stacker Sensors 12 The Disassembly of Encoder Sensor tes Cut off the plastic wrappers Screw off the two screws fixing Encoder Sensor and disconnect the connector the Encoder Sensor and take out the Encoder Sensor QTY pf 6 Encoder Sensor 1 13 The Disassembly of Kicker Roller Assembly Pull out the c ring on the right Push the bearings on both sides Kicker Roller Assembly and left sides out and then take off the Kicker Roller Assembly 1 QTY Kicker Roller Assembly 011 3 7 Gear MXL Bearing
8. 688 with wrap 14 The Disassembly of Gap Adjustment Assembly gt hS s we t l K E gi p 5 iz a e d i a 4 f f q o s Screw off the four screws fixing Loose the two springs and take Pull out the c ring on the right the Gap Adjustment Fixer Plate out the Gap Adjustment Fixer and left sides on the right and left sides Plate 005 oe al hy ih i A AEEA V Push out the bearings on both Gap Adjustment Assembly sides and then take off the Gap Adjustment Assembly Part s name QTY QTY 15 1 Gap Adjustment Fixer Plate 1 00 2 ustment F T 5 e Spring 2 17 Gap Adjustment Assembly 1 15 The Disassembly of Feed Roller Assembly Pull out the c ring Encoder Disk amp Gear on the left side a Pull out the inside c ring Push the bearing out and do Take out the Feed Roller with a screwdriver the same thing on the other Assembly by pushing the side Roller Assembly towards left 01 2 and pull it out Feed Roller Assembly 3 Timing Belt S _ i fo ooo 0o10 34 TimingBotM 1 35 TimingBtO ot foo o o 36 Encoder Disk amp Gear 1 40 FeedRoller Assembly 1 on A Gear BM J a o o a2 Gear MXL 2 J 43 Bearing 688 with wrap 2 16 The Disassembly of Front Transfer Mechanism 015A Screw off the four screws fixing Front Upper Transfer Mechanism Pull out the
9. SERVICE MANUAL For D 100 USD October 10 Edition CONTENTS CHAPTER DESCRIPTION PAGE Necessary Tools amp Measuring Instruments The Disassembly of Each Part 5 Daily Maintenance 28 Troubleshooting 29 Function Adjustment CHAPTER I NECESSARY TOOLS amp MEASURING INSTRUMENTS 1 2 5 Screwdriver 2 5 Cross point Screwdriver 65 mm insulated instrument Screwdriver Inner Allen Key Nylon faced Hammer Insulated tweezers Ring Spanner Multi meter O Wo NY Wo Aa Se WC WN Sleeve Barrel 10 Needle File Set 11 Miniature Soldering Iron 12 Narrow Nose Pliers CHAPTER 2 THE DISASSEMBLY OF EACH PART Caution Before you disassemble or assemble the machine please make sure that you have disconnected the Power Cord 1 The Disassembly of Side Covers Screw off the four screws Screw off the two screws on the Screw off the two screws on the fixing the Side Covers Bottom Plate fixing the Side Side Plates fixing the Side Covers Covers Pull out the Side Covers Left Side Cover Right Side Cover QTY on Left Side Cover 1f Right Side Cover 1 2 The Disassembly of Top Cover Screw the inside screw Screw off the two screws Loose the two screws on the counter clockwise to loose and fixing the Top Cover Rear Cover with your fingers take off the Thickness Adjustment and take off the Top Cover Knob Screw off the two screws fixing Top Cover Assembly the Top Cover Fixer Shaft
10. d ERROR DENOM FACE ERROR DENOM ORIENT 1 Remove all the notes from the Stacker 2 Press START ENTER key to resume counting REMOVE NOTES FROM STACKER There are notes in the STACKER Remove all the notes from the Stacker 30
11. e last note from the Stacker 2 Press START ENTER key 3 If false alarm occurs recount the last note removed from the Stacker CHANGE OF IN SORT MODE denomination is Remove all notes from the Stacker and machine changed continues counting automatically DENOM IN SINGLE MODE banknote is Remove the last note from the Stacker and DENOM ERROR not equal to the denomination continue counting by pressing START ENTER information key IN FACE MODE banknote is not Remove the last note from the Stacker and equal to the denomination or face continue counting by pressing START ENTER information key IN FACE ALL MODE banknote Remove the last note from the Stacker and FACE ERROR is not equal to the face continue counting by pressing START ENTER information key IN ORIENT MODE banknote is Remove the last note from the Stacker and not equal to the denomination continue counting by pressing START ENTER face or direction information key IN ORIENT ALL MODE Remove the last note from the Stacker and ORIENT ERROR banknote is not equal to the face continue counting by pressing START ENTER or direction information key 1 Press Denomination key to enter banknote value to current total Machi h f NO ID iene cantread the value of io press START ENTER to resume counting l 3 OR remove the note from Stacker and place to Hopper to recount When STACKER is full with 200 STACKER IS FULL notes START ENTER is presse
12. es Then take off the Stacker Sensors from the Plate TIA Stacker Plate 1 72 LowerPressRoller 2 6 amp 2 StackerSensors 1 Screw off the three screws Pull off the Power Wire and Screw off the two nuts with a fixing the Power Supply take out the Power Supply sleeve barrel Cover on Bottom Plate Cover Take out the Power Power Supply Assembly Supply 27 PowerSupply Cover 1 f 28 PowerSupplyPCB 1 A Main PCB 3 f Power Supply N a i A co C 2 gt ww n gt wer connector Main PCB 24V Power Supply w Screw off the four screws Cut off the plastic wrappers Stacker Motor amp Stacker Wheel fixing the Stacker Motor and take out Stacker Motor amp Stacker Wheel Part s name 017 68 Stacker Motor 69 Stacker Wheel Screw off the four screws fixing the Left Side Plate and take off the Plate Rip off the two adhesive tapes Take off the steel cylinders from the Main Motor E r i Se ar Ad Screw off the four screws Take out the Main Motor Main Motor fixing the Main Motor 019 Screw off the four screws Left Side Plate Right Side Plate fixing the Right Side Plate and take off the Plate Bottom Plate 70 Main Motor S oo B Lef SidePlate 1 74 RightSidePlate 1 f o o 75 BottomPite 1 CHAPTER3 FUNCTION ADJUSTMENT 1 1 Double Detection Adjustment For USD factory adjusted Do
13. rast as below 1 Turn on the machine in MIXED mode 2 Count anew bill of 1 circulated condition Its Rear Face should be above and the forward direction point at the Note Guide Plate should be as shown in the first picture below Press 9 and then ADD key five times to check H 5 data The suggested CIS contrast is when the first two digits inside the red circle of H 5 data are around 75 among the range of 60 80 as in the second picture below 3 If the CIS contrast is lower than 60 or higher than 80 please adjust VR2 potentiometer clockwise counter clockwise to reduce increase the contrast Note If the machine counts well with CIS contrast not among 60 80 there is no need to adjust to 60 Count a stack 7 or 8pcs of circulated bills of 1 one by one to make sure the CIS contrast value first two digits of H 5 data is always correct 4 Count batches of mixed denomination notes If the machine works well with notes of every denomination then the CIS Contract is suitable 5 Press CLEAR to escape the H 5 page and return to normal counting mode 23 CHAPTER4 SETTINGS Main Menu Press START key while turning on the machine Press corresponding numeric key into submenu and press PRINT key to exit from the submenu 1 SPEED TRIAL Press key 2 into speed trial of 6 seconds 1min OFF Press GT key to choose the speed class you want to test ADD key is used to switch bet
14. uble Detection Voltage is around 1 10V If single bills in DARK Contrast get Double Notes error please reduce the Double Detection Voltage by 0 05 0 1V by adjusting the VR4 potentiometer the fourth one on the right side of the Main PCB with the Multi Meter s red pen touching the forth point and the black pen touching GND point If double notes in LIGHT or NORMAL Contrast can t be detected please increase the Double Detection Voltage by 0 05V 0 1V 20 1 2 Counting Sensors Adjustment It is recommended after changing to new counting sensors or after using for a long time Take off the Signal Board Cover Press key 5 to choose Put a white paper on the Hopper and press START key while COUNTER E VOLT turning on Power Turn the Kicker Rollers to roll the paper inside until it covers the Counting Sensors TE a screwdriver adjust EVR1 and EVR2 potentiometers until the voltages of LEV and REV points are both around 1 7V with the Multi Meter s red pen touching LEV REV Point and its black pen touching Ground Point Adjust clockwise to increase the voltages or counter clockwise to reduce the voltages Note 1 7V is suitable for the factory white paper With your local white paper the DEN voltage could be a little higher or lower so it s better to find out the voltage on a new machine with your local white paper se Ea agy 4 ANER e UO RES 4 amo Nel LS Ss PEF RRi pm x aciz
15. ween 6s trial and 1 min trial 2 SETTING TIME Reference Reversal Time 15 SPEED 1 15 SPEED 2 15 SPEED 3 Put notes on Hopper and press START key Machine will count notes and stop in 6 seconds automatically Press key 3 into time setting Press ADD key to choose the speed class whose time you want to change Press numeric keys to set the time you want 26 Press START key and then enter password 9572 Press START key again to save the setting 3 SETTING SPEED Reference Rotation Speed 1850 SPEED 1 2800 SPEED 2 3100 SPEED 3 Press key 4 into speed setting Press ADD key to choose the speed class whose rotation speed you want to change Press START key and machine will auto Press ADD key and then enter password test To exit press ESC key 2759 Press START key to save the setting 21 CHAPTERS _ DAILY MAINTENANCE CIS Sensor amp Counting Sensor Clear Open the Rear Cover by Press two tabs on the left and right as loosening the two screws with shown by the arrow sign and the your fingers Cover will pop up a little Use dry clean cloth or with alcohol to clean the CIS Sensor and Counting Sensors Receiver Counting Sensors Transmitter Counting Sensors Feed Gap Adjustment Adjust the Thickness Adjustment Knob towards to increase the Feed Gap towards
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