Model 4095 TABLE OF CONTENTS SECTION 1:OPERATING INSTRUCTIONS SECTION 2: DIAGNOSTICS OPERATION SECTION 3:MECHANICAL ADJUSTMENTS SECTION 4:TEST POINTS

Transcription

1 TABLE OF CONTENTS SECTION 1:OPERATING INSTRUCTIONS SECTION 2: DIAGNOSTICS OPERATION SECTION 3:MECHANICAL ADJUSTMENTS SECTION 4:TEST POINTS SECTION 5:PARTS SECTION 6: COMMUNICATION PACKAGE Rev. 1 05/01 Form Number TOC-1.

2 WARRANTY Cummins-Allison Corporation Warrants all Cummins JetScan and JetCount Currency Counting Machines to be free of defects in material and workmanship under normal use for a period of one (1) year from date of receipt. Labor to repair any failure due to defects is limited to ninety (90) days from date of receipt, and is the responsibility of either the Cummins factory branch office or Cummins authorized dealer. If any such defects occur, your Cummins-Allison Service Representative should be contacted immediately. This Warranty does not include service or replacement parts necessitated by accident, misuse, alterations, acts of God, war, fire, water, sabotage, adverse environmental conditions ( temperatures below 50 F or above 90 F, humidity below 20% or above 80% without condensation, poor or fluctuating electrical power ( 115, 220 or 240 Volt A.C. +/- 10% based on country)), or repairs performed by any person not authorized by Cummins-Allison Corporation. This Warranty does not include consumable items such as Rubber Feed Inserts and Drum rollers nor supplies. This Warranty is the sole Warranty given regarding Cummins JetScan and JetCounts, and is in lieu of all other Warranties, express or implied, including the implied Warranties of merchantability and fitness for a particular purpose. The customer s remedy is limited to repair or replacement, as outlined above. In no event shall Cummins be liable under this Warranty for incidental, special or consequential damages. The Warranty for all replacement parts is limited to ninety (90) days, or the balance of the New Machine One Year Parts Warranty, which ever is longer. The exceptions are Rubber Feed Inserts and Drum Rollers. Warranty for labor to effect repairs is thirty (30) days, or the balance of the New Machine Ninety (90) Days Labor Warranty, which ever is longer. The information in this manual has been carefully checked, and is believed to be entirely reliable; however, no responsibility is assumed for inaccuracies. Cummins-Allison Corporation reserves the right to make changes at any time without notice, in order to improve design and supply the best product possible. FCC COMPLIANCE This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Rev. 1 05/01 Form Number Page 1.

3 Rev. 1 05/01 Form Number Page 1.

4 DIAGNOSTICS OPERATION You can enter diagnostics operation by pressing on the upper right corner of the display screen for three to four seconds. This display appears if your unit has Revision 7 (and up) Software installed and the Password option activated: ENTER PASSWORD CLEAR ENTER EXIT Enter the Password you selected in Setup and press the ENTER key. Please Note: Default Permanent Password is If you entered the correct Password and pressed the ENTER key this display appears: SPECIAL MODE MENU * SETUP * DIAGNOSTICS * DEFAULT EXIT Pressing the DIAGNOSTICS key will prompt the first DIAGNOSTICS screen menu. Rev. 1 05/01 Form Number Page 2-1.

5 This display appears: DIAGNOSTICS MAIN MENU 1 * EPROM DATA * FACTORY ADJUST * SENSORS STATUS * READ HEAD STATUS MORE * UV SENSOR STATUS EXIT Pressing the EPROM DATA key will prompt the EPROM DATA screen menu. This display appears: EPROM DATA CODE PROM r07 CHECKSUM: D686 CHECKSUM: 5C28 MEMORY MODULE ID: 0 EXIT The first line shows the part number and the software level for the two EPROM s mounted on the CPU Board. We use a 16 bit data bus in this JetScan so we need two eight bit EPROM s for addressing purposes. The EPROM s are divided into two parts. The first part contains a basic program that allows the unit to be upgraded with a Flashcard. The second part contains machine operation information. The checksum will change when the unit is upgraded with a new Flashcard. We will inform you of the new checksum when we issue a new Flashcard. Page 2-2. Form Number Rev.1 05/01

6 The checksum for the EPROM for the upper eight bits for the data bus is displayed on the second line. The checksum for the EPROM for the lower eight bits for the data bus is displayed on the third line. The fourth line indicates Memory Module 0. The EEPROM now contains the Communication Option so the JetScan will work without Memory Module. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 1. Pressing the FACTORY ADJUST key will prompt the FACTORY ADJUSTS MENU screen. This display appears: FACTORY ADJUST MENU * PRECHECK * DENSITY SENSOR * STACKER SENSOR * READ HEAD SENSORS MORE * FINE LINE SENSORS EXIT Pressing the PRECHECK key will prompt the PRECHECK menu screen. This display appears: PRECHECK TARGET CURRENT UPPER LINE VOLTAGE: V UPPER DATA VOLTAGE: V LOWER LINE VOLTAGE: V LOWER DATA VOLTAGE: V ADJUST WITH WHITE PAPER UNDER SENSORS EXIT Rev. 1 05/01 Form Number Page 2-3.

7 Insert one white Test Paper ( Part Number ) manually between the Upper and Lower Read Heads. On the Upper Read Head adjust the R1 potentiometer until ULine reads 2.50v +/- 0.25v and the R2 potentiometer until UData reads 4.00v +/- 0.25v on the display. On the Lower Read Head adjust the R1 potentiometer until LLine reads 2.50v +/- 0.25v and the R2 potentiometer until LData reads 4.00v +/- 0.25v on the display. Pressing the EXIT key returns the machine to the FACTORY ADJUST MENU. Pressing the DENSITY SENSOR key will prompt the DENSITY SENSOR screen. This display appears: DENSITY SENSOR LEFT SENSOR VOLTAGE: 0.27v LEFT SENSOR MULTIPLIER: 1.40 RIGHT SENSOR VOLTAGE: 0.25v RIGHT SENSOR MULTIPLIER: 1.44 TARGET VOLTAGE: 0.30v PRESS < CALIB > KEY TO ADJUST TO TARGET + - CALIB EXIT If the TARGET VOLTAGE does not read 0.30v then press either the + or - key until it reads 0.30v. Press the CALIB key to calibrate both Left and Right Density Sensors at the same time. NOTE: Do not insert the Density Gage over the Left or Right Density Sensor when you do this calibration. The calibration is done electronically. Page 2-4. Form Number Rev.1 05/01

8 This display appears: DENSITY SENSOR LEFT SENSOR VOLTAGE: 0.30v LEFT SENSOR MULTIPLIER: 1.40 RIGHT SENSOR VOLTAGE: 0.30v RIGHT SENSOR MULTIPLIER: 1.44 TARGET VOLTAGE: 0.30v PRESS < SAVE > KEY TO SAVE ABOVE SETTINGS SAVE + - CALIB EXIT Press the SAVE key to save the calibration. Pressing the EXIT key returns the machine to the FACTORY ADJUST MENU. Pressing the STACKER SENSOR key will prompt the STACKER SENSOR screen. This display appears: STACKER SENSOR STACKER SENSOR VOLTAGE 1: 2.22v STACKER SENSOR 1 THRESHOLD: 1.70v STACKER SENSOR VOLTAGE 2: 2.35v STACKER SENSOR 2 THRESHOLD: 2.01v FLOW CONTROL VOLTAGE 1: 3.25v FLOW CONTROL 1 THRESHOLD: 2.70v FLOW CONTROL VOLTAGE 2: 2.75v FLOW CONTROL 2 THRESHOLD: 2.30v CALIB STOP EXIT Press the CALIB key to calibrate the stacker sensors. Rev. 1 05/01 Form Number Page 2-5.

9 This display appears: STACKER SENSOR STACKER SENSOR VOLTAGE 1: 2.22v STACKER SENSOR 1 THRESHOLD: 1.70v STACKER SENSOR VOLTAGE 2: 2.35v STACKER SENSOR 2 THRESHOLD: 1.80v FLOW CONTROL VOLTAGE 1: 3.25v FLOW CONTROL 1 THRESHOLD: 2.70v FLOW CONTROL VOLTAGE 2: 2.75v FLOW CONTROL 2 THRESHOLD: 2.30v EMPTY STACKERS AND PRESS < CALIB > KEY SAVE CALIB STOP EXIT Empty both stackers and press the CALIB key. This display appears: STACKER SENSOR STACKER SENSOR VOLTAGE 1: 2.50v STACKER SENSOR 1 THRESHOLD: 2.00v STACKER SENSOR VOLTAGE 2: 2.10v STACKER SENSOR 2 THRESHOLD: 1.68v FLOW CONTROL VOLTAGE 1: 3.25v FLOW CONTROL 1 THRESHOLD: 2.70v FLOW CONTROL VOLTAGE 2: 2.75v FLOW CONTROL 2 THRESHOLD: 2.30v PRESS < SAVE > KEY TO SAVE ABOVE SETTINGS SAVE CALIB STOP EXIT Press the SAVE key to save the calibration. Page 2-6. Form Number Rev.1 05/01

10 Maximum Stacker and Flow Control Sensor Voltage is 4.00v. Minimum Stacker and Flow Control Sensor Voltage is 0.50v. All Stacker and Flow Control voltages are usually in the 2 to 3v range. The sensors might still be good, even if the voltages are not between 2 to 3v. The Stacker Sensor Threshold should be at 80% of the Stacker Sensor Voltage ( i.e. voltage is at 2.50v - threshold should be 2.00v or voltage is at 1.50v - threshold should be at 1.20v ). The display will show STACKER 1 ERROR and/or STACKER 2 ERROR if you do not have the proper voltages in calibration. The display will show FLOW CONTROL 1 ERROR and/or FLOW CONTOL 2 ERROR if one or both Flow Control Sensors are out of calibration. The voltage will drop from the displayed Stacker Sensor Voltage to below the Stacker Sensor Threshold Voltage (usually quite a bit below) when a document is put in the stacker. Pressing the EXIT key returns the machine to the FACTORY ADJUST MENU. Pressing the READ HEAD SENSORS key will prompt the READ HEAD CALIBRATION screen. This display appears: READ HEAD CALIBRATION UPPER LINE VOLTAGE : v UPPER DATA VOLTAGE: v LOWER LINE VOLTAGE: v LOWER DATA VOLTAGE: v UPPER LINE OFFSET: 80 UPPER LINE GAIN: 104 LOWER LINE OFFSET: 85 LOWER LINE GAIN: 58 PUT WHITE PAPER IN HOPPER, PRESS < CALIB > CALIB STOP EXIT Put one white Test Paper (Part Number ) in the Hopper and press the CALIB key. The test paper will feed through the JetScan and then stop. Rev. 1 05/01 Form Number Page 2-7.

11 This display appears: READ HEAD CALIBRATION UPPER LINE VOLTAGE : v UPPER DATA VOLTAGE: v LOWER LINE VOLTAGE: v LOWER DATA VOLTAGE: v UPPER LINE OFFSET: 80 UPPER LINE GAIN: 104 LOWER LINE OFFSET: 85 LOWER LINE GAIN: 58 PRESS <SAVE> KEY TO SAVE ABOVE SETTINGS SAVE CALIB STOP EXIT Any voltage between.3 to.7v is acceptable for the Upper and Lower Line Voltages. Manually insert one Test Paper (Part Number ) between the Upper and Lower Read Heads. Upper and Lower Line Voltages should read 3.5v or higher. Upper and Lower Data Voltages should be at 4.00v (as adjusted in PRECHECK, refer to page 4-4). Moving the paper slightly back and forth using the Feed Rollers will make the tenth and hundredth digit fluctuates slightly. If the voltages are so high that it stays locked at 5.00v when you move the paper back and forth, then you need to readjust the Line and Data sensors using the FACTORY ADJUST - PRECHECK (refer to page 4-4). UPPER LINE OFFSET, UPPER LINE GAIN, LOWER LINE OFFSET and LOWER LINE GAIN are used in the factory and can be ignored. Press the SAVE key to save the calibration. Pressing the EXIT key returns the machine to the FACTORY ADJUST MENU. Pressing the FINE LINE SENSOR key will prompt the FINE LINE CONSTANT screen. This display appears: FINE LINE CONSTANT FINE LINE OFFSET GAIN: 80 PUT WHITE PAPER IN HOPPER, PRESS < CALIB > CALIB STOP EXIT Page 2-8. Form Number Rev.1 05/01

12 Put one white Test Paper (Part Number ) in the Hopper and press the CALIB key. The test paper will feed through the JetScan and then stop. This display appears: FINE LINE CONSTANT FINE LINE OFFSET GAIN: 80 PRESS <SAVE> KEY TO SAVE ABOVE SETTINGS SAVE CALIB STOP EXIT The Upper and Lower Read Head Line Sensors will detect the leading edge of the paper and display the number of encoder pulses between them. Any number between 60 and 90 is acceptable. Press the SAVE key to save the calibration. Pressing the EXIT key returns the machine to the FACTORY ADJUST MENU. Press the MORE key to get to the second screen of the FACTORY ADJUST MENU. Pressing the SUSPECT DOCUMENT CALIBRATION key will prompt the SUSPECT DOCUMENT CALIBRATION screen. This display appears: SUSPECT DOCUMENT CALIBRATION MAGNETIC MULTIPLIER: 1.61 UV MULTIPLIER: 0.50 BLUE MULTIPLIER: 0.22 BASE VOLTAGE: 0.64v CALIBRATED BASE VOLTAGE: 0.66v BILL COUNT: 0 PUT 10 NEW $1 BILLS IN HOPPER, PRESS CALIB CALIB STOP EXIT Rev. 1 05/01 Form Number Page 2-9.

13 Obtain 10 new (or almost new) $1 bills with known high magnetic readings (4500 to 5000) and place them all face down (green side up) head first (the ONE on the bill should be legible - not upside down) in the center of the hopper. Press the CALIB key. The Drive Motor will start and feed all ten bills one at a time. The Drive Motor will stop when the tenth bill is fed and display the newly calibrated multipliers and voltages. NOTE: The count from one to ten will be displayed by BILL COUNT. This display appears: SUSPECT DOCUMENT CALIBRATION MAGNETIC MULTIPLIER: 1.61 UV MULTIPLIER: 2.59 BLUE MULTIPLIER: 0.34 BASE VOLTAGE: 0.64v CALIBRATED BASE VOLTAGE: 0.66v BILL COUNT: 10 PRESS <SAVE> KEY TO SAVE ABOVE SETTINGS SAVE CALIB STOP EXIT The acceptable range for the Magnetic Multiplier is 0.25 through 4. The acceptable range for the UV Multiplier is 0.25 through 2.0 for new machines and 0.25 through 3.9 for aged machines. The acceptable range for the Blue Multiplier is 0.05 through 0.75 for new machines and 0.05 through 1.9 for aged machines. Calibrated base Voltage (previous UV base voltage) indicates the intensity of the UV light when the UV sensors were last calibrated. Base Voltage (current UV base voltage) indicates the intensity of the UV light at the current moment. The acceptable range for the Base Voltage is 0.40 through By comparing Base Voltage to Calibrated Base Voltage one can determine the amount of UV light degradation that has occurred since the last UV sensor calibration procedure. The UV base voltage is determined using the internal reflections from the UV window when no document is present. (NOTE: Base Voltage is only valid if there is no document in front of the UV sensors. If a document is blocking the UV sensors, then Base Voltage is an indication of the level of UV light that is being reflected from that document). Page Form Number Rev.1 05/01

14 Base Voltage and Calibrated Base Voltage should be within when the JetScan is just calibrated. Press the SAVE key to save the calibration. Pressing the EXIT key returns the machine to the FACTORY ADJUST MENU. Pressing the SOLENOID SETUP key will prompt the SOLENOID SETUP screen. This display appears: SOLENOID SETUP LEFT BASELINE: 5 RIGHT BASELINE: LEFT RIGHT SAVE EXIT You do not have to perform the Solenoid Setup if you replace the Left Hand Linear Solenoid Assembly (Part Number ) or Right Hand Linear Solenoid Assembly (Part Number ). The Solenoid Setup sets up the holding current for the solenoids and this is held in memory in the three PC Boards (I.O.Board, M.P.Board and S.I.O. Board) mounted in the back of the JetScan. You do have to perform the Solenoid Setup if you replace either the I.O. Board, M.P Board and/or S.I.O. Board. Perform Solenoid Setup as follows: Left Solenoid: 1. Turn the power OFF on the JetScan. 2. Remove the Rear Cover. 3. Locate Connector J23 on the lower right hand side of the I/O Board and disconnect Connector J Connect the female end of the Adjustment Cable Connector J23 on the I/O Board. Connect the male end of the same Adjustment Cable to the wire connector J23. Rev. 1 05/01 Form Number Page 2-11.

15 5. Connect the two open wires of the Adjustment Cable to your VoltMeter (Fluke 77 or similar) leads. Insert the VoltMeter leads between the 10A and COM connectors on the VoltMeter. Set the VoltMeter to A DC (DC Ampere). 6. Enter Diagnostics Operations/Factory Adjust/Solenoid Setup. This display appears: SOLENOID SETUP LEFT BASELINE: 5 RIGHT BASELINE: LEFT RIGHT SAVE EXIT 7. Press the LEFT key. 8. Press either the + or - key under LEFT BASELINE until the Volt Meter reads 0.5A (500 ma). 9. Press the SAVE key to save the calibration. 10. Turn power OFF on the JetScan and remove the Adjustment Cable from Connector J23 and reconnect Connector J23 to the I/O Board. Repeat the above steps for the right solenoid as follows: 1. Locate Connector J24 on the lower right hand side of the I/O Board and disconnect Connector J Connect the female end of the Adjustment Cable to Connector J24 on the I/O Board. Connect the male end of the same Adjustment Cable to the wire connector J Connect the two open wires of the Adjustment Cable to your VoltMeter (Fluke 77 or similar) leads. Insert the VoltMeter leads between the 10A and COM connectors on the VoltMeter. Set the VoltMeter to A DC (DC Ampere). 4. Enter Diagnostics Operations/Factory Adjust/Solenoid Setup. Page Form Number Rev.1 05/01

16 This display appears: SOLENOID SETUP LEFT BASELINE: 5 RIGHT BASELINE: LEFT RIGHT SAVE EXIT 5. Press the RIGHT key. 6. Press either the + or - key under RIGHT BASELINE until the Volt Meter reads 0.5A (500 ma). 7. Press the SAVE key to save the calibration. 8. Turn power OFF on the JetScan and remove the Adjustment Cable from Connector J24 and reconnect Connector J24 to the I/O Board. Pressing the EXIT key returns the machine to the FACTORY ADJUST MENU. If your unit has Revision 7 (and up) Software installed then you have a key to compensate for motor drift. Pressing the DRIFT ADJUST key will prompt the DRIFT ADJUST MENU. This display appears: DRIFT ADJUST DRIFT ADJUST: 132 PRESS <SAVE> KEY TO SAVE ABOVE SETTINGS SAVE + - START EXIT You need to find a mid point between the motor drifting forward and backward. Press the + key until the motor starts creeping backwards. Remember that number. Press the key until the Rev. 1 05/01 Form Number Page 2-13.

17 motor starts creeping forward. Subtract the smaller number from the bigger number and divide it by two. Add this number to the smaller number or subtract it from the bigger number (i.e =12 divided by 2=6. The drift adjustment should be set to 129). Press the SAVE key. Note: Each time the number is changed the START key must be pressed to look for creeping. Pressing the EXIT key twice returns the machine to DIAGNOSTICS MAIN MENU 1. Pressing the SENSORS STATUS key will prompt the MACHINE SENSOR DATA menu screen. This display appears: MACHINE SENSOR DATA LEFT SENSOR VOLTAGE: 5.00v RIGHT SENSOR VOLTAGE: 5.00v FLOW CONTROL 1 VOLTAGE: 3.50v FLOW CONTROL 2 VOLTAGE: 3.25v HOPPER STACKER STATUS: CLEAR STACKER 1 STATUS: CLEAR STACKER 2 STATUS: CLEAR EXIT LEFT and RIGHT SENSOR VOLTAGE should read a minimum of 4 (volts) without anything covering the Density Sensors. Insert the window of the Density Gauge (part number ) over the Left Density Sensor. You should read 0.30v using a density gauge calibrated to 0.75v. You can still use the old Density Gauge. All you need to do is to convert the calibration number for the 9700 series JetScan as follows: Density Gauge Present Calibration Number 9700 Series Calibration Number Page Form Number Rev.1 05/01

18 Example #1: The number written on your Density Gauge is The 9700 Series calibration number is Example #2: The number written on your Density Gauge is The 9700 Series calibration number is Repeat the above steps for the Right Density Sensor. FLOW CONTROL 1 and 2 VOLTAGE should be Maximum 4.00v and Minimum 0.50v unblocked. If you block the FLOW CONTROL 1 and 2 sensors by either placing a document over the sensors or by just opening up the Pivot Assembly the voltage will go to almost 0v. Put a bill in the Hopper and HOPPER STACKER STATUS: Put a bill in the Upper Stacker and STACKER 1 STATUS: Put a bill in the Lower Stacker and STACKER 2 STATUS: CLEAR should switch to BLOCKED. CLEAR should switch to BLOCKED. CLEAR should switch to BLOCKED. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 1. Pressing the READ HEAD STATUS key will prompt the READ HEAD STATUS menu screen. This display appears: READ HEAD STATUS TARGET CURRENT UPPER LINE VOLTAGE: v UPPER DATA VOLTAGE: v LOWER LINE VOLTAGE: v LOWER DATA VOLTAGE: v EXIT Any voltage between 0.3 to 0.7v is acceptable for the Upper and Lower Line Sensors. Manually insert one white test paper (part number ) between the Upper and Lower Read Heads. Upper and Lower Line Voltages should read 3.5v or higher. Upper and Lower Data Voltages should be at 4.00v ( v). Moving the paper slightly back and forth using the Rev. 1 05/01 Form Number Page 2-15.

19 Feed Rollers will make the tenth and hundredth digit fluctuates slightly. If the voltage is so high that it stays locked at 5.00v when you move the paper back and forth, then you need to readjust the Line and Data sensors using the FACTORY ADJUST - READ HEAD CALIBRATION mode (Refer to page 4-7 ). Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 1. Pressing the UV SENSOR STATUS key will prompt the UV SENSOR STATUS menu screen. This display appears: UV SENSOR STATUS UV SENSOR VOLTAGE: 0.56v BLUE SENSOR VOLTAGE: 0.43v UV MULTIPLIER: 2.59 BLUE MULTIPLIER: 0.34 EXIT The UV Sensor Voltage should be between 0.3v and 2.0v when there is no document in front of the UV Sensor. The Blue Sensor Voltage should be between 0v and 2.0v when there is no document in front of the Blue Sensor. UV Multiplier is the adjusted UV Multiplier. The acceptable range is 0.25 through 2.0 for new machines and 0.25 through 3.9 for aged machines. Blue Multiplier is the adjusted fluorescence multiplier. The acceptable range is 0.05 through 0.75 for new machines and 0.05 through 1.9 for aged machines. If the UV sensors have just been calibrated then the UV Multiplier and Blue Multiplier will be identical to the calibration multipliers (refer to Suspect Document Calibration Procedure on pages 4-9 and 4-10). However, if several days or weeks have transpired since calibration, the adjusted multipliers may differ from the calibration multipliers depending upon how much the UV tube light output has degraded. For example: If the Calibrated Base Voltage is 0.5v and the Base Voltage is 0.4v a UV light intensity degradation of 20% would be indicated. A UV Multiplier of 4 will display a warning message during operation. A 5.0 or higher will indicate a Fail message. Page Form Number Rev.1 05/01

20 A Blue Multiplier of 2.0 or higher will display a warning message during operation. A 2.5 will indicate a Fail message. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 1. Pressing the MORE key will prompt the DIAGNOSTICS MAIN MENU 2 menu screen. This display appears: DIAGNOSTICS MAIN MENU 2 * MOTOR SOLENOID TEST * SKEW TEST * SINGLE BILL BACK * MULTIPLE BILL MORE * BILL THRUPUT EXIT Pressing the MOTOR SOLENOID TEST key will prompt the Motor and Solenoid test. This display appears: ACTUATOR DIAGNOSTIC SPEED STOP * UPPER MOTOR: 0 IN/S 1.60 IN LOWER MOTOR 0 IN/S * UPPER STACKER MANUL SOLENOID * LOWER STACKER AUTO SOLENOID EXIT Pressing the UPPER MOTOR key will start up the Upper and Lower Drive Motors. Rev. 1 05/01 Form Number Page 2-17.

21 This display appears: ACTUATOR DIAGNOSTIC SPEED STOP * UPPER MOTOR: 83 IN/S 1.60 IN LOWER MOTOR 83 IN/S * UPPER STACKER MANUL SOLENOID * LOWER STACKER AUTO SOLENOID EXIT The speed for the Upper and Lower Motors should be 83 inch/ second plus or minus 2 inch/ second. The Upper and Lower Motors will run until the UPPER MOTOR key is pressed again. Both motors will stop and the display will indicate 0 inch/ second motor speed and 1.60 inch stopping distance. Stopping distance should not be higher than 2.0 inches. Pressing the UPPER STACKER key will start the Upper Stacker Motor. Pressing the UPPER STACKER key again will stop the Upper Stacker Motor. Pressing the LOWER STACKER key will start the Lower Stacker Motor. Pressing the LOWER STACKER key again will stop the Lower Stacker Motor. Pressing the MANUL key will manually activate the Linear Diverter Solenoid once. Pressing the AUTO key will continuously activate the Linear Diverter Solenoid. Pressing the AUTO key again will stop the Linear Solenoid activations. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 2. Pressing the SKEW TEST key will prompt the SKEW TEST menu. This display appears: SKEW TEST LAST SKEW: AVERAGE SKEW: MAXIMUM SKEW: -0 deg 0 deg -0 deg PUT BILLS IN HOPPER, PRESS START START STOP EXIT Page Form Number Rev.1 05/01

22 Place a stack of bills in the Hopper and press the START key. The bills will pass over the Left and Right Density Sensors. Allow all the bills to feed until Hopper is empty Pressing the STOP key will stop the motor and display LAST, AVERAGE and MAXIMUM SKEW data. LAST SKEW: Indicates the skew of the last document processed. Negative (-) indicates that the document passed over the Left Density Sensor before it passed over the Right Density Sensor, indicating that the right side of the feeder is too tight. Positive (+) indicates that the document passed over the Right Density Sensor before it passed over the Left Density Sensor, indicating that the left side of the Feeder is too tight. AVERAGE SKEW: Indicates the average skew for all the documents processed. You should be able to get +1 to -1 with a properly adjusted feeder section. MAXIMUM SKEW: Indicates the maximum skew, of one bill, for all the documents processed. This test is very useful when checking if the Retard Roller height adjustment is correct. Refer to Retard Roller Height adjustment in the Mechanical Adjustment section. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 2. Pressing the SINGLE BILL key will prompt the SINGLE BILL TEST menu. This display appears: SINGLE BILL TEST CORRELATION: 0 MAGNETIC SUM: 0 CLOSEST DENOM MATCH: $1 PUT BILL IN HOPPER, PRESS START START STOP EXIT Put a teller quality $1 bill in the Hopper, with the green side up, and press the START key. The green side of the bill will pass over the Lower Read Head Sensor. Rev. 1 05/01 Form Number Page 2-19.

23 This display appears: SINGLE BILL TEST CORRELATION: 975 MAGNETIC SUM: 1000 CLOSEST DENOM MATCH: $1 PUT BILL IN HOPPER, PRESS START START STOP EXIT You should read between 950 and 1020 on the correlation and 800 to 1200 on the magnetism (using a bill with known low magnetic ink). Put a new $1 bill in the Hopper with green side down and press the CONT key. The green side of the bill will pass under the Upper Read Head Sensor. You should get approximately the same display as above. If one read head gives you a noticeably lower correlation than the other read head then you may have an electronic problem with that read head. If both read heads give you a low correlation then the problem could be either mechanical, electrical or both. Be sure to check all Allen screws on pulleys and rollers for tightness, encoders, connector s etc. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 2. Pressing the MULTIPLE BILL keys will prompt the MULTIPLE BILL TEST menus. This display appears: PUT BILLS IN HOPPER, PRESS START MULTIPLE BILL TEST MINIMUM CORRELATION: 0 MINIMUM MAGNETIC SUM: 0 START STOP EXIT Put a stack of at least 100 bills of teller quality $1 bills in the Hopper with the green side up and press the CONT key. The bills will pass over the Lower Read Head Sensor and the Magnetic Read Head. Page Form Number Rev.1 05/01

24 This display appears: PUT BILLS IN HOPPER, PRESS START MULTIPLE BILL TEST MINIMUM CORRELATION: 975 MINIMUM MAGNETIC SUM: 1000 START STOP EXIT MINIMUM CORRELATION indicates the minimum correlation in the stack of bills. MINIMUM MAGNETIC SUM indicates the minimum magnetic bill in the stack of bills. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 2. Pressing the BILL THRUPUT key will prompt the BILLS PER MINUTE TEST menu. This display appears: BILLS PER MINUTE TEST BILLS PER MINUTE: 0 PUT 100 BILLS IN HOPPER, PRESS START START STOP EXIT This diagnostic test is designed to give an indication of the number of bills processed per minute. Place a stack of at least 100 bills in the Hopper and press the START key. The JetScan will process 100 bills and stop. This display appears: BILLS PER MINUTE TEST BILLS PER MINUTE: 1000 PUT 100 BILLS IN HOPPER, PRESS START START STOP EXIT Rev. 1 05/01 Form Number Page 2-21.

25 If the Feeder Assembly is set properly (refer to the retard roller height adjustment) then the bill thruput should be between 950 and If you get lower than 950, then your Feeder Assembly is set too tight and needs to be readjusted. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 2. Pressing the MORE key will prompt the DIAGNOSTICS MAIN MENU 3 menu screen. This display appears: * UV TEST * COMM PORT TEST DIAGNOSTICS MAIN MENU 3 * KEYBOARD TEST BACK * TOTAL SUSPECT DOC COUNTS MORE * PIECE AND ERROR COUNTS EXIT Pressing the UV TEST key will prompt the UV test menu screen. This display appears: UV TEST UV AVERAGE VOLTS: 0.00v UV ADJUSTED MULTIPLIER: 0.00 BLUE AVERAGE VOLTS: 0.00v BLUE ADJUSTED MULTIPLIER: 0.00 PUT BILL IN HOPPER, PRESS START START STOP EXIT Obtain a brand new $1 bill and place it face down (green side up) head first (the ONE on the bill should be legible - not upside down) in the center of the Hopper. Press the START key. The Drive Motor will start and feed the bill over the UV sensor. Page Form Number Rev.1 05/01

26 This display appears: UV TEST UV AVERAGE VOLTS: 1.31v UV ADJUSTED MULTIPLIER: 2.59 BLUE AVERAGE VOLTS: 0.04v BLUE ADJUSTED MULTIPLIER: 0.34 PUT BILL IN HOPPER, PRESS START START STOP EXIT UV ADJUSTED MULTIPLIER is the adjusted UV multiplier used for determining UV Average Volts. BLUE ADJUSTED MULTIPLIER is the adjusted fluorescence multiplier used for determining Blue Average Volts. UV AVERAGE VOLTS indicates the UV reading for the $1 bill. Verify that the UV AVERAGE VOLTS reading are between and If it is not between and then you have to perform the UV sensor calibration procedure. (NOTE: Make sure you have a correct test bill. You may want to use more than one bill to obtain an average). BLUE AVERAGE VOLTS indicates the Fluorescent reading for the $1 bill. Verify that the BLUE AVERAGE VOLTS reading are between and If it is not between and then you have to perform the UV sensor calibration procedure. (NOTE: Make sure you have a correct test bill. You may want to use more than one bill to obtain an average). Repeat the above test using one white test paper (Part Number ) and verify that the UV AVERAGE VOLTS reading is between 1.10 and 4.0 and the BLUE AVERAGE VOLTS reading is between 1.30 and 4.0. Repeat the above test using a new $2 bill placed in the center of the Hopper face down (green side up) head first. UV AVERAGE VOLTS should be no higher than Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 3. Pressing the COMM PORT TEST key will prompt the Communications Ports Test. Rev. 1 05/01 Form Number Page 2-23.

27 This display appears: COMMUNICATIONS PORTS TEST PRESS <START> KEY TO START TEST P1<>P2 P2<>P1 P3<>P4 P4<>P3 START EXIT Install the Communication Test Cable Assembly (Part Number ) between Port 1 and Port 2 or Port 3 and Port 4. Press the START key. This display appears: COMMUNICATIONS PORTS TEST PRESS <START> KEY TO START TEST P1<>P2 P2<>P1 P3<>P4 P4<>P3 PASS PASS PASS PASS START EXIT This indicates that Port 1 and 2 or Port 3 and 4 are communicating properly. If you do not get PASS (a FAIL message is displayed) then either the I/O Board (Part Number ), the Micro Processor Board (Part Number ) is bad or the SIO Board (Part Number ) is bad or not installed. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 3. Pressing the KEYBOARD TEST key will prompt the Keyboard Test menu screen. Page Form Number Rev.1 05/01

28 This display appears: KEYBOARD TEST - Press a key EXIT Press any key. The key you press will light up and the message KEYBD TEST - Touch key pressed is lit. is displayed. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 3. Pressing the TOTAL SUSPECT DOC COUNTS key will prompt the Suspect Document Error Count menu screen. This display appears: SUSPECT DOCUMENT ERROR COUNT UV: 0 BLUE: 0 UV AND BLUE: 0 MAGNETIC: 0 UV AND MAGNETIC: 0 BLUE AND MAGNETIC: 0 UV AND BLUE AND MAGNETIC: 0 CLEAR EXIT UV: BLUE: UV AND BLUE: Indicates the number of suspect documents detected by the UV light only. Indicates the number of suspect documents detected by the fluorescent light only. Indicates the number of suspect documents detected by the combination of the UV and fluorescent lights. Rev. 1 05/01 Form Number Page 2-25.

29 MAGNETIC: UV AND MAG: BLUE AND MAG: UV,BLUE AND MAG Indicates the number of suspect documents detected by the magnetic read head only. Indicates the number of suspect documents detected by the combination of the magnetic read head and the UV light. Indicates the number of suspect documents detected by the combination of the magnetic read head and the fluorescent light. Indicates the number of suspect documents detected by the combination of the magnetic read head, UV and the fluorescent lights. Pressing the CLEAR key clears all Suspect Document Error Counts back to zero. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 3. Pressing the PIECE AND ERROR COUNTS key will prompt the Error Piece Count menu screen. This display appears: ERROR PIECE COUNT TOTAL NO CALLS: 0 SUSPECT DOCUMENTS: 0 DOUBLES: 0 CHAINS: 0 SPACING ERRORS: 0 TRANSPORT JAMS: 0 TOTAL BILLS SCANNED: 0 TOTAL BILLS COUNTED: 0 PROGRAM RESET 1: 0 PROGRAM RESET 2: 0 VAULT DEFAULTS: 0 CLEAR EXIT TOTAL SCANNED indicates the total number of bills scanned (bills processed in count mode are not counted in total scanned) and NO CALLS indicates the number of NO CALL's recorded for the scanned documents. The NO CALL percentage should not be higher than 0.75%. SUSPECT DOCUMENTS indicates the number of suspect documents detected. Page Form Number Rev.1 05/01

30 DOUBLES indicates the number of double feeds that have been detected. CHAINS indicates the number of chaining errors that have been detected. A CHAIN is detected when two documents are edge to edge or up to a 5/8 overlap. SPACING ERRORS indicates number of spacing errors that have been detected. A SPACING ERROR is called when two documents have less than a 1.5 distance between them, but not edge to edge, when they pass over the Density Sensors. TRANSPORT JAMS indicates total number of transport jams that have been detected. PROGRAM RESET 1 indicates number of times a reset has occurred and the total checksum matches. The program continues as if nothing has happened. PROGRAM RESET 2 indicates number of times a reset has occurred and the total checksum does not match but the user setup checksum does. The JetScan will display PROGRAM RESET. All totals will be reset but the user settings will not be affected. Pressing any key resumes operation. You have to rerun the last batch. VAULT DFLTS indicates the number of times a reset has occurred and both the total checksum and the user setup checksum do not match. The JetScan will VAULT DEFAULT and the user settings must be reprogrammed. Pressing the CLEAR key once clears all ERROR PIECE COUNT back to zero. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 3. Pressing the MORE key will prompt the DIAGNOSTICS MENU 4 menu screen. This display appears: DIAGNOSTICS MAIN MENU 4 * BILL FLIP TEST VOLTMETER DIAG * COUNTS DIAG BACK * ENTER SERIAL NUMBER MORE * PRINT STATUS REPORT EXIT Pressing the BILL FLIP TEST key will prompt the Bill Flip Test menu screen. Rev. 1 05/01 Form Number Page 2-27.

31 This display appears: BILL FLIP TEST PLACE BILL STACK IN HOPPER THEN PRESS START TO BEGIN TEST START STOP EXIT Place a stack of bills in the Hopper and press the START key. The JetScan will put all odd number bills in the top pocket and even number bills in the bottom pocket. Press the STOP key to stop the test. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 4. The VOLTMETER DIAG screen is not used by us. If your unit has Revision 7 (and up) Software installed then you have the next four diagnostics Pressing the COUNTS DIAG key will prompt the SORT ERROR FLIPPER COUNT menu. This display appears: SORT ERROR FLIPPER COUNT LEFT FLIPPER: 0 RIGHT FLIPPER: 0 TOTAL SORT ERRORS: 0 CLEAR EXIT LEFT FLIPPER indicates number of activation s of the left solenoid. RIGHT FLIPPER indicates number of activation s of the right solenoid Page Form Number Rev.1 05/01

32 TOTAL SORT ERRORS indicates the number of times a document has sorted to the wrong pocket (i.e. a document should have been sorted in to pocket 1 but was erroneously sorted in to pocket 2). Pressing the CLEAR key clears all Sort Error Flipper Counts. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 4. Pressing the ENTER SERIAL NUMBER key will prompt the Serial Number menu screen. This display appears: SERIAL NUMBER: CLEAR 0 BKSP EXIT The machine Serial Number can be entered and it will be saved in memory and used with the Status Print Report or Status Flash Card Report. Pressing the EXIT key returns the machine to DIAGNOSTICS MAIN MENU 4. Pressing the PRINT STATUS REPORT key prints a status report to an external printer. While it is printing this display appears: STATUS REPORT Printing When it finished printing the Status Report, which consists of all voltages, multipliers, piece and error counts and total suspect document counts, it will return to DIAGNOSTICS MAIN MENU 4. Pressing the MORE key will prompt the DIAGNOSTICS MAIN MENU 5 Rev. 1 05/01 Form Number Page 2-29.

33 This display appears: DIAGNOSTICS MAIN MENU 5 COMM TRACE OFF ON BACK EXIT Press the ON key. The Computer Communication Trace can only be used if one of the ports is configured as a computer (COMP, CISS or CISS+ST) port and another port is configured as a printer port. Exit DIAGNOSTICS OPERATION back to the Main Screen Press the MENU key. This display appears: MAIN SUB MENU * SUSPECT DOC * BATCH * DENSITY * DAY * COMM TRACE UNIT EXIT Press the COMM TRACE key. Page Form Number Rev.1 05/01

34 This display appears: COMPUTER COMMUNICATION DIAGNOSTIC TRACE COMM TRACE OFF ON PRINT PRINT COMM TRACE REPORT EXIT Press the ON key on Comm Trace. Exit COMPUTER COMMUNICATION DIAGNOSTIC TRACE display back to the Main Screen. Run a couple of bills through the unit and wait until the motor has stopped. Remove the bills from the stacker and wait until the external printer has stopped printing. Press the MENU key. This display appears: MAIN SUB MENU * SUSPECT DOC * BATCH * DENSITY * DAY * COMM TRACE UNIT EXIT Press the COMM TRACE key. Rev. 1 05/01 Form Number Page 2-31.

35 This display appears: COMPUTER COMMUNICATION DIAGNOSTIC TRACE COMM TRACE OFF ON PRINT PRINT COMM TRACE REPORT EXIT Press the PRINT key on PRINT COMM TRACE REPORT. The printer will print the Communication Trace. Press the EXIT key twice to return to the Main Screen. Page Form Number Rev.1 05/01

36 DRUM ROLL / FEED ROLL TIMING ADJUSTMENT Timing adjustment of the Drum Roll (part number ) and the Feed Rollers (part number ) with removable Insert (part number ). 1. Turn the power off and unplug the JetScan from the wall outlet. 2. Remove Left Hand Stationary Cover. 3. Loosen the two set screws for the Feed Roll Shaft Pulley. 4. Position the Drum Roll so that the leading edge of the rubber sections are visible at the front edge of the Feeder Plate. 5. Position the Feed Rollers so that two to three teeth of the rubber inserts are visible above the Feeder Plate. 6. Tighten the two set screws for the Feed Roll Shaft Pulley making sure that there is no sideways play. RETARD ROLLER HEIGHT ADJUSTMENT The height adjustment between the Retard Rollers and the Drum Roll is very critical for proper feeding of the documents and elimination of skew. Adjust as follows: 1. Remove Left and Right Hand Stationary Covers. 2. Remove the two screws holding the Feeder Cover and remove the Feeder Cover. 3. Adjust the Thickness Dial so that the Retard Rollers penetrate into the Drum Roll Assembly and verify that the Retard Rollers are centered in the groove. Align them if they are not. 4. Adjust the Thickness Dial up so that the Retard Rollers are now slightly above the Drum Roll Assembly. 5. Turn the Drum Roller until you have the rubber facing the Retard Rollers. 6. Insert the Feeler Gage (Part Number ) between the Right Retard Roller and the Right Drum Roll Assembly. Rev. 1 05/01 Form Number Page 3-1.

37 7. Move the Feeler Gauge slowly from side to side (left to right) while you turn the Thickness Dial towards the negative numbers, adjusting the Retard Rollers down, until you feel a slight drag on the Feeler Gauge. 8. Insert the Feeler Gauge (Part Number ) between the Left Retard Roller and the Left Drum Roll Assembly and verify that you have the same amount of drag on the Feeler Gauge. If you do, skip to step 12 adjustment. If you do not, please continue to step 9 adjustment. 9. Locate the two socket head cap screws for the Support Shaft penetrating through the Left and Right Stationary Side Plates. 10. Loosen one of the socket head cap screws on the Support Shaft and move the Support Shaft up or down until you have the same drag on the feeler gauge on both the left and right side. 11. Secure the socket head cap screw and repeat steps 6 through Reinstall the Feeder Cover. 13. Turn the power ON. 14. Put a strap of bills in the Hopper. 15. When the bills start feeding through the JetScan tap lightly on top of the bills right over the Feed Rollers. NOTE: Do not tap between or on the side of the Feed Rollers. 16. Turn the Thickness Dial towards the negative numbers every time the JetScan stops for a chain*, chain or double. If no chains occur, turn the Thickness Dial toward the positive numbers until you get a chain, then go back to the negative numbers until there are no alarms, as you tap on the stack of bills. Re-calibrate the Thickness Dial at that setting to 0 by loosening the Allen screw holding the dial. Note: Push the Thickness Dial back as far as you can otherwise it is going to touch the Feeder Cover. Continue to adjust the thickness dial until you can tap on the bills without getting an alarm. 17. Enter Diagnostics Operation Skew Test (see page 2-17). Process a stack of bills or documents. You should be able to get +1 to -1 on Ave. with a properly adjusted feeder section. If you do not get +1 to -1 then repeat steps 6 through Enter Diagnostics Operation Bills Per Minute Test (see page 2-20). Process a stack of 100 bills. You should be able to get a bill thruput of 1150 to 1200 with a properly set feeder. If you do not get 950 to 1000 then repeat steps 14 through 16. Page 3-2. Form Number Rev. 1 05/01

38 LOWER TRANSPORT PLATE ADJUSTMENT PRESSURE ROLLER TEST 1. Cut one test paper (Part Number ) in half lengthwise. 2. Inspect and clean Drive Rollers (Part Number ) and Encoder Shaft (Part Number With the JetScan off and all Pulley Belts on, insert the test paper (half) lengthwise between the Pressure Rollers and the Encoder Shaft and the Drive Rollers on the right side. 4. Once the paper is positioned between the Rollers, slowly begin to pull the paper out. As the paper is pulled out, both the Drum Shaft and Encoder Shaft should rotate. They should continue to rotate until the test paper is released by the Drive Rollers. Once the test paper is released from under the Drive Rollers, both shafts may stop turning. As you continue to pull the test paper out you should feel a drag. The drag is created by the pressure between the Pressure Rollers and the Encoder Shaft. The drag may cause the Shaft to rotate slightly and should continue until the test paper is clear of the Encoder Shaft. 5. Repeat this test for the left side Rollers. If you have no drag on either the left or right side then you have to perform the Transport Plate Adjustment ( See page 3-4 ). 6. Verify that the Magnetic Read Head (Part Number ) is adjusted properly with spacing between the magnetic read head and the O ring. ( Refer to Magnetic Read Head Adjustment on page 3-6 ). 7. Insert the test paper (half) lengthwise between the O rings and the Read/Magnetic Heads from the Stacker side. 8. You should be able to move the test paper back and fourth without feeling any drag. If you do feel a drag then you have to readjust the Magnetic Read Head and/or the Transport Plate. ( Refer to Transport Plate Adjustment on page 3-4 ). If the JetScan functions as described in the pressure roller test, continue to the Upper Read Head Spacing Adjustment. If not, continue to Transport Pressure Roller Inspection And Adjustment. TRANSPORT PRESSURE ROLLER INSPECTION AND ADJUSTMENT Lack of proper pressure roller pressure can be caused by several things. With the JetScan unplugged, open the back of the machine and perform the following procedure: Rev. 1 05/01 Form Number Page 3-3.

39 1. Remove the two screws securing the Pressure Roller Spring (Part Number ). 2. Remove the Roller Assemblies (Part number ) and check for the following: a. Distorted spring (All four points should touch the table). b. Bad bearing. 3. Clean the Roller Assemblies and replace them, making sure that they are aligned against the transport plate alignment edge and that the screws are tight. 4. Replace the Bottom Plate and repeat the pressure roller test previously described in Pressure Roller Test on page 3-3. If the machine fails the pressure roller test after all steps have been followed under transport pressure roller inspection and adjustment, the Transport Plate has to be adjusted as described below under Transport Plate Adjustment. TRANSPORT PLATE ADJUSTMENT 1. Remove Left and Right Stationary Covers. 2. Loosen the four screws that hold the Lower Transport Plate. 3. Insert one of the two Pin Assembly Gauges ( Part Number ) into the two square holes on the Right Hand Side Plate and the other one into the square holes on the Left Hand Side Plate. Secure the two Pin Assembly Gauges using the screws that come with the Pin Assembly Gauges. 4. Press down on the Lower Transport Plate until it touches the Pin Assembly gauges evenly and secure the four screws that hold the Lower Transport Plate. 5. This adjustment will only put you into the ballpark. You need to perform Pressure Roller Test as described in Pressure Roller Test page 3-3. UPPER READ HEAD SPACING ADJUSTMENT 1. Remove Left and Right Side Covers. 2. Remove Feeder Cover (Part Number ). Page 3-4. Form Number Rev. 1 05/01

40 3. Push the Feeder Assembly back while you move the two outer O rings out of their grooves towards the outside of the machine. 4. Insert the gauge (Part Number ) between the two Read Heads. NOTE: Make sure the O rings do not interfere with the gauge and that the gauge is flat against the Transport Plate. You should be able to move the gauge back and forth without feeling any drag from the Upper Read Head or Transport Plate. If you do feel a drag - add shims. (Part Number for shim, for shim and for shim). NOTE: Make sure that you have the same amount of shims on both sides. 5. If you can move the gauge back and forth without friction then insert the gauge (Part Number ) together with the gage (0.026 total) between the two Read Heads. Make sure the O rings do not interfere with the gauges and that the gauges are flat against the Transport Plate. You should not be able to move the gauges back and forth without some drag. If you have a lot of drag then add one shim to both sides and repeat steps 4 and 5. You should have a slight drag with gauges and fairly loose with gauges. NOTE: You will increase the risk of jams if you adjust to a tight 0.020, because there will not be enough space between the Read Heads for the bills to pass. You will increase the risk of NO CALL s if you have too much space (more than.026 ). 6. Return the two O rings to its two grooves. 7. Replace the Feeder Cover. 8. Replace left and Right Side Covers. ENCODER REMOVAL The Encoder is secured to the Encoder Shaft with a set screw. The Allen wrench for this set screw is secured to the Right Side Plate, under a screw, below the Encoder. Remove the Encoder as follows. 1. Remove the Encoder Dust Cover. 2. Turn the center of the Encoder, with a slotted screw driver to the unlock position (one dot). 3. Place the Allen wrench into the small hole in the lower bottom right side of the housing. Turn the Transport Roller slowly while holding wrench against Encoder disk to find the set screw. Rev. 1 05/01 Form Number Page 3-5.

41 4. Loosen the set screw and pry housing from plastic back plate with a small screw driver using slots in the housing. 5. The Encoder is centered at the factory so do not remove the plastic back plate from the aluminum mounting plates. We use an Encoder Centering Tool (Part Number ) on the production line but it is not necessary to order this. 6. To re-assemble reverse the process. Remember to lock the slotted center (two dots). MAGNETIC READ HEAD ADJUSTMENT 1. Remove the two screws holding the Rear Cover and remove it. 2. Insert two each Feeler Gauges (Part Number ) between the center "O" ring on the encoder shaft and the Magnetic Read Head. 3. Adjust the Nylok socket head cap screw on the Magnetic Read Head Assembly until you just touch the feeler gauge (This will give you a distance between the Magnetic Read Head and the O ring) 4. Reassemble the Rear Cover. 5. Enter Diagnostics Operation and perform the FACTORY SUSPECT DOCUMENT CALIBRATION adjustment on page Verify all tests in Diagnostics Operation. UPPER AND LOWER FIXED TRANSPORT PLATE ADJUSTMENT 1. Remove Left and Right hand Stationary Covers. 2. Open up the Pivot Assembly. 3. Loosen the four screws attaching each Transport Plate to the Stationary Plates. 4. Insert a screwdriver or Allen wrench into the outer slots on the end of the Transport Plate (between the mounting screws), and pull each plate down and out as far as you can, making sure you do not pinch any of the Transport Shafts. 5. Tighten the four screws for each Transport Plates. TOP AND BOTTOM FOLLOWER PLATE ADJUSTMENT 1. Remove Left and Right Hand Pivot Cover Page 3-6. Form Number Rev. 1 05/01

42 2. Open up the Pivot Assembly. 3. Affix two Upper Gages (Part Number ) to the Top Transport Plate, in the middle, close to the Stationary Plates. 4. Affix two Lower Gages (Part Number ) to the Bottom Transport Plate, in the middle, close to the Stationary Plates. 5. Close the Pivot Assembly. 6. Push the Bottom Follower Plate on the Pivot Assembly down towards the Transport Plate. Tighten the four screws. 7. Push the bottom of the Top Follower Plate down towards the Transport Plate and tighten the two bottom screws. 8. Open up the Pivot Assembly. 9. Pull back on the top of the Top follower plate and tighten the two top screws. 10. Remove the four gages. DIVERTER ADJUSTMENT 1. Remove Left and Right Hand Pivot Cover. 2. Loosen the two Socket Cap Screws securing the Left and Right Linear Solenoid Coupling Assembly to the Diverter. 3. Open up the Pivot Assembly. Place the Up Pos. Diverter Spacer Tool ( Part Number ) on the upper right side of the Lower Fixed Transport Plate ( Part Number ) with the thicker part of the gauge pointing upwards resting against the bottom of the Upper Fixed Transport Plate ( Part Number ) 4. Close the Pivot Assembly. Press down on the Diverter against the gauge and push the Solenoid Plunger up as far as it goes. Tighten the two Socket Cap Screws securing the Linear Solenoid Coupling to the Diverter. 5. Open up the Pivot Assembly and remove the Up Pos. Diverter Spacer Tool. 6. Place the Down Pos. Diverter Spacer Tool ( Part Number ) on the upper left side of the Lower Fixed Transport Plate ( Part Number ) with the thicker part of the gauge pointing upwards, resting against the bottom of the Upper Fixed Transport Plate ( Part Number ) Rev. 1 05/01 Form Number Page 3-7.

43 7. Close the Pivot Assembly. Press down on the Diverter against the gauge and push the Solenoid Plunger up as far as it goes. Tighten the two Socket Cap Screws securing the Linear Solenoid Coupling to the Diverter. 8. Open up the Pivot Assembly and remove the Down Pos. Diverter Spacer Tool. 9. Enter Diagnostics Operation - Factory Adjust - Solenoid Setup. Pressing the LEFT and RIGHT keys should move the Diverter freely up and down if the Left and Right Linear Solenoids have been aligned properly. You have to realign the Left and Right Coupling and Solenoid Assemblies if the Diverter is not moving freely. Page 3-8. Form Number Rev. 1 05/01

44 TEST POINTS IO P.C.BOARD Part Number TP1 = Common. TP2 = PFI ( Power Failure Interupt ). 5v with power on. 0v when power is off. TP3 = +20v. TP4 = -20v. TP5 = VSOL. 40v + or - 5v. TP6 = +12v. TP7 = -12v. TP8 = +5v. TP9 = -15v. TP10 = Encoder Test for Upper Encoder: 0 or +5v with Upper Motor at rest. ( Channel A ): 2.5v with the Upper Motor running. TP11 = Encoder Test for Upper Encoder: 0 or +5v with Upper Motor at rest. ( Channel B ): 2.5v with the Upper Motor running. TP12 = Encoder Test for Lower Encoder: 0 or +5v with Lower Motor at rest. ( Channel A ): 2.5v with the Lower Motor running. TP13 = Encoder Test for Lower Encoder: 0 or +5v with Lower Motor at rest. ( Channel B ): 2.5v with the Lower Motor running TP14, TP15 TP16, TP17 TP18 = M1, M2. Not used Ramp and Sen. Not used. DS1. Left Density Sensor. Enter Diagnostics Operation - Factory Adjust - Density Sensor Menu. Record the left multiplier. Enter Diagnostics Operation - Sensor Status. Insert the window of the density gauge (part number ) over the left density sensor. Multiply the left multiplier with the voltage shown on your volt meter. The result should be very close to the data shown on the display. Rev. 1 05/01 Form Number Page 4-1.

45 (ie. Multiplier is Voltmeter reading is 0.229v DC. Density reading is.35. Multiply 1.57 x = 0.35 which matches the density reading of 0.35). TP19 = TP20,TP21 TP22 = TP23 = TP24 = TP25 = TP26 = DS2. Right Density Sensor. Enter Diagnostics Operation - Factory Adjust - Density Sensor Menu. Record the right multiplier. Enter Diagnostics Operation - Sensor Status. Insert the window of the density gauge (part number ) over the right density sensor. Multiply the right multiplier with the voltage shown on your volt meter. The result should be very close to the data shown on the display. (ie. Multiplier is Voltmeter reading is 0.229v DC. Density reading is.35. Multiply 1.57 x = 0.35 which matches the density reading of 0.35). Not used. STR. Magnetic Sensor. 2.5v at rest. LL1. Lower Read Head raw line voltage. Not Used. LL2. Amplified lower read head line voltage. You should measure approximately 2.5v in Factory Adjust Precheck with a white test paper over the lower read head. LD1. Lower read head raw data voltage. You should measure approximately 3.5v in Factory Adjust Precheck with a white test paper over the lower read head. UL1. Upper Read Head raw line voltage. Not used. TP27 = UL2. Amplified upper read head line voltage. You should measure approximately 2.5v in Factory Adjust Precheck with a white test paper under the upper read head. TP28 = UD1. Upper read head raw data voltage. You should measure approximately 3.5v in Factory Adjust Precheck with a white test paper under the upper read head. TP29, TP30, TP31 IC1, IC2 and IC3. Not used. TP32 = TP33 = TP34 = UV. 0.3v through 2.0v. BLUE. 0v through 2.0v. LED. Not used Page 4-2. Form Number Rev. 1 05/01

46 Rev. 1 05/01 Form Number Page 4-1.

47 P.C. BOARDS AND CABLES A.C. ON/OFF Switch Line Filter Microprocessor P.C. Board SIO P.C. Board CPU I/O P.C. Board Upper Read Head P.C. Board Lower Read Head P.C. Board Transformer Assembly Fan Assembly, Heat Sink Touch Screen Keyboard Interface P.C. Board Touch Screen Cable Assembly, Encoders Cavble Assembly, Hopper Sensor Cable Assembly, Stacker Sensors Cable Assembly, Flow Control Sensors Cable Assembly, Upper Read Head Cable Assembly, AC Cable Assembly AC Ground Wire Assembly, AC Line ( Brown ) Wire Assembly, AC Line ( Blue ) Cable, Display Cable Assembly, UV P.C. Board Right Solenoid Wire (long) Left Solenoid Wire (short). Rev. 1 05/01 Form Number Page 5-1.

48 CABINET ASSEMBLY Page 5-2 Form Number Rev. 1 05/01

49 CABINET ASSEMBLY ITEM NO PART NUMBER QTY DESCRIPTION Left Hand Pivot Cover Left Hand Stationary Cover Screw, #4-40 x 3/8 Phil Washer Hd Feeder Capacity Extension Right Hand Stationary Cover Screw, #4-40 x 3/8 Phil Washer Hd Right Hand Pivot Cover. The following items are not shown: Stationary Cover Standoff Screw, #6-32 x 3/8 Phil Truss Hd Pivot Cover Standoff Screw, #6-32 x 3/8 Phil Truss Hd Power Cord Machine Dust Cover Flash Card Sleeve Rear Cover Screw, #6-32 x 3/8 Phil Truss Hd. Rev. 1 05/01 Form Number Page 5-3.

50 BASIC MACHINE ASSEMBLY 1 Page 5-4 Form Number Rev. 1 05/01

51 BASIC MACHINE ASSEMBLY 1 ITEM NO PART NUMBER QTY DESCRIPTION Right Hand Stationary Sideplate Push Mount Cable Tie A.C. ON/OFF Switch Line Filter Nut, #8-32 Hex ( Keps ) Plastic Cable Clamp Tie Nut, #8-32 Hex ( Keps ) Right Hand Linear Solenoid Plate Plastic Cable Clamp Tie Nut, #8-32 Hex ( Keps ) Pivot Pin E-Ring, O 3/ Left Hand Linear Solenoid Plate Left Hand Stationary Sideplate. Rev. 1 05/01 Form Number Page 5-5.

52 BASIC MACHINE ASSEMBLY 2 Page 5-6 Form Number Rev. 1 05/01

53 BASIC MACHINE ASSEMBLY 2 ITEM NO PART NUMBER QTY DESCRIPTION Microprocessor P.C. Board Screw, #2-56 x 3/16 Phil Int Sems Flashcard Sleeve CPU I/O P.C. Board Screw, #6-32 x 3/8 Pan Hd ( sems ) Bottom Door Screw, #6-32 x 3/8 Pan Hd ( sems ) Washer,.156 x.312 x Push Rivet Foot SIO P.C. Board Screw, #2-56 x 3/16 Phil Int Sems. Rev. 1 05/01 Form Number Page 5-7.

54 PIVOT ASSEMBLY 1 Page 5-8 Form Number Rev. 1 05/01

55 PIVOT ASSEMBLY 1 ITEM NO PART NUMBER QTY DESCRIPTION Touchscreen Display Assembly Screw, Phil Wshr Hd #4-40 x 3/ Washer,.252 x.312 x.030. The following four items are for the adjustable display and are not shown: Left Hand Upper Bracket Right Hand Upper Bracket Top Cover (mounted to Top Follower Plate Assembly) Cover Plate Right Hand Lin Sol Pivot Plate Screw, #6-32 x 1/4 Int Sems Washer,.156 x.312 x Right Hand Roller Latch Assembly Roller, Latch Spring Acorn Nut, #4-40 ( Nylon ) Right Hand Linear Solenoid Assembly Nut, #6-32 x Hex Keps ( 3/64 Thk ) Right Hand Stacker Bushing, Snap - in Plastic Bottom Pocket Stacker Assembly. ( Refer to pages 5-34 and 5-35 for parts breakdown ) Left Hand Lin Sol Pivot Plate Stacker Motor Assembly Screw, Pan Hd Int Sems #4-40 x 1/ Top Pocket Stacker Assembly. ( Refer to pages 5-32 and 5-33 for parts breakdown ) Left Hand Stacker. The following item is not shown: Rev. 1 05/01 Form Number Page 5-9.

56 Stacker Shaft. PIVOT ASSEMBLY 2 Page 5-10 Form Number Rev. 1 05/01

57 PIVOT ASSEMBLY 2 ITEM NO PART NUMBER QTY DESCRIPTION Bracket, Linear Solenoid Coupling Assembly, Lin Sol. This Assembly consists of the following parts: Linear Solenoid Coupling Linear Solenoid Flange Linear Solenoid Pin E ring Screw, #2-56 x 3/8 Skt Cap Washer, #2 Lock Nyliner Bushing Left Hand Linear Solenoid Assembly Left Hand Roller Latch Assembly Roller, Latch Spring Acorn Nut, #4-40 ( Nylon ). Rev. 1 05/01 Form Number Page 5-11.

58 PIVOT ASSEMBLY 3 Page 5-12 Form Number Rev. 1 05/01

59 PIVOT ASSEMBLY 3 ITEM NO PART NUMBER QTY DESCRIPTION Top Follower Plate Assembly. ( Refer to pages 5-28 and 5-29 for parts breakdown ) Diverter, Linear Solenoid Coupling Assembly Lin Sol Bearing Diverter Shaft Ball Bottom Follower Plate Assembly. ( Refer to pages 5-30 and 5-31 for parts breakdown ) E-Ring, Shaft o 3/ Washer,.187 x.375 x Pin, Linear Solenoid Link E-Ring, Shaft o Nut, #6-32 Hex Keps ( 3/64 Thk ) Rev. 1 05/01 Form Number Page 5-13.

60 SIDEPLATE ASSEMBLY 1 Page 5-14 Form Number Rev. 1 05/01

61 SIDEPLATE ASSEMBLY 1 ITEM NO PART NUMBER QTY DESCRIPTION Feeder Assembly. ( Refer to pages 5-42 through for parts breakdown ) Feeder Cover Screw, #4-40 x 1/4 Phil Truss Hd Right Hand Stationary Sideplate Screw, #6-32 x 3/8 Phil Pn Hd Washer,.156 x.312 x Stud, Feeder Plate Mounting ( Front ) Washer,.129 x.312 x Spacer, Feed Shaft Washer,.252 x.312 x Nut, Locater Washer,.129 x.250 x Nut, #5-40 Hex A/R Grease Conductive Stud, Feeder Plate Mounting ( Rear ) Washer,.129 x.312 x Washer, Nylon Shoulder Washer,.252 x.312 x Washer, Spec. Flat Platic Nut, #5-40 Hex A/R Grease Conductive Screw, #5-40 x 3/8 Skt Hd Cap Washer, #5 Split Lock Washer,.156 x.312 x Screw, #5-40 x 3/8 Skt Head Cap Washer, #5 Split Lock Washer, Plain Steel Washer, Bearing Spacer Screw, #6-32 x 1/2 Skt Head Cap Washer, #6 Split Lock Washer,.156 x.312 x.050. Rev. 1 05/01 Form Number Page 5-15.

62 SIDEPLATE ASSEMBLY 2 Page 5-16 Form Number Rev. 1 05/01

63 SIDEPLATE ASSEMBLY 2 ITEM NO PART NUMBER QTY DESCRIPTION Screw, #8-32 x 3/8 Phil Int Sems Nut, #6-32 Keps ( 7/64 Thk. ) Bracket, Right Hand Upper Read Encoder Encoder Dust Cover Washer, Bearing spacer Shims, Ring E Plate, Encoder Mounting Screw, #4-40 x 3/8 Phil Pan Hd Screw, #2-56 x 1/4 Phil Pn Hd Bearing, Transport Screw, #5-40 x 3/8 Skt Head Cap Washer, #5 Split Lock Washer, Plain Steel Washer, Bearing Spacer Screw, #6-32 x 1/4 Phil Int Sems Washer,.156 x.312 x Screw, #6-32 x 3/8 Phil Pn hd Washer,.156 x.312 x Screw, #6-32 x 1/4 Phil Int Sems Washer,.156 x.312 x Switch, A/C Power Line Filter Screw, #5-40 x 1/2 Phil Flat Hd Nut, #5-40 Hex Keps ( 9/64 Thick ). Rev. 1 05/01 Form Number Page 5-17.

64 SIDEPLATE ASSEMBLY 3 Page 5-18 Form Number Rev. 1 05/01

65 SIDEPLATE ASSEMBLY 3 ITEM NO PART NUMBER QTY DESCRIPTION Grommet, 7/16 ID Rubber Plate, Lower Fixed Transport Sensor Assembly, Flow Control Nut, Special 2-56 Hex Strip, Wear Screw, #6-32 x 3/8 Phil Pn Hd Washer,.156 x.312 x Tie Bar Door Assembly, Bottom Bottom Door Transformer Assembly Screw, #8-32 x 3/8 Phil Ph Int Sems Washer, Plain.191-I.D..050W Push Rivet Foot Bottom, Front Shield Shaft, Transport w/o Encoder Shaft, Transport w/o Encoder ( Short ) Plate, Upper Fixed Transport Sensor Assembly, Flow Control Nut, Special 2-56 Hex Shaft, Transport Without Encoder Transport Assembly Right Hand Spacer Left Hand Spacer #6-32 x 1 Round Head Screw O - Ring. Encoder Shaft. Rev. 1 05/01 Form Number Page 5-19.

66 SIDEPLATE ASSEMBLY 4 Page 5-20 Form Number Rev. 1 05/01

67 SIDEPLATE ASSEMBLY 4 ITEM NO PART NUMBER QTY DESCRIPTION Feeder Shaft Upper Read Head Bracket, Left Hand Feed Roll Feed Roll Insert Screw, #8-32 x 3/16 Skt Set Brass Feeder Plate Assembly T - Handle Shaft Upper Read Head Bracket, Right Hand Compression Spring Spring Retainer A/R.005 Shim A/R.010 Shim A/R.020 Shim Upper Read Head Assembly. Rev. 1 05/01 Form Number Page 5-21.

68 SIDEPLATE ASSEMBLY 5 Page 5-22 Form Number Rev. 1 05/01

69 SIDEPLATE ASSEMBLY 5 ITEM NO PART NUMBER QTY DESCRIPTION Encoder Shaft Drum Roller Shaft Drive Roller Screw, #8-32 x 3/16 Set. Brass Tip Drum Roll Assembly Feeder Assembly. ( NOTE: Do not order this part. Refer to pages 5-42 through 5-45 for parts breakdown ) Pulley Center Roller Drive Tire Screw, #8-32 x 3/16 Set. Brass Tip O Ring O Ring. Rev. 1 05/01 Form Number Page 5-23.

70 SIDEPLATE ASSEMBLY 6 Page 5-24 Form Number Rev. 1 05/01

71 SIDEPLATE ASSEMBLY 6 ITEM NO PART NUMBER QTY DESCRIPTION Screw, #6-32 x 3/8 Phil Pn Hd Washer,.156 x.312 x Stud, Feeder Plate Mounting ( Front ) Washer,.129 x.312 x Spacer, Feed Shaft Washer,.252 x.312 x Nut, Locater Washer,.129 x.250 x Nut, #5-40 Hex ( Spec ) A/R Grease, Conductive Belt, 3MMp/50T x 6 MM ( HTD ) Screw, #5-40 x 3/8 Skt Head Cap Washer, #5 Split Lock Washer,.156 x.312 x Belt,.080P/165 Grooves Timing Belt,.080P/203 Grooves Timing Belt,.080P/90 Grooves Timing Screw, #6-32 x 1/4 Phil Int Sems Motor Assembly. Lower Drive Screw, #6-32 x 3/8 Phil Pn Hd Washer,.156 x.312 x Motor assembly, Upper Drive Screw, #6-32 x 3/8 Phil Pn Hd Washer,.156 x.312 x Transformer Screw, #8-32 x 3/8 Phil Ph Int Sems Washer, Plain I.D..050W. Rev. 1 05/01 Form Number Page 5-25.

72 SIDEPLATE ASSEMBLY 7 Page 5-26 Form Number Rev. 1 05/01

73 SIDEPLATE ASSEMBLY 7 ITEM NO PART NUMBER QTY DESCRIPTION Washer, Wave Spring Washer, Spec Flat Pulley, 3MMP/18T x 6MM ( HTD ) Pulley, 3MMp/18T x 6MM ( HTD ) Screw, #6-32 x 1/8 Set ( Brass Tip ) Pulley,.080P/80T Screw, #8-32 x 3/16 Set Pulley,.080P/56T Screw, #8-32 x 3/16 Set Gear, 108 Teeth ( 48 Pitch ) Spur Washer,.252 x.312 x Gear, 100 Teeth ( 48 Pitch ) Spur Spacer Pulley,.080P/60T Timing Screw, #8-32 x 3/16 Set Pulley,.080P/32T Timing Screw, #8-32 x 3/16 Set Pulley,.080P/32T I Flange Timing Screw, #8-32 x 3/16 Set Bearing, Transport Washer, Bearing Spacer. The following items are not shown: Pulley,.080P/24T Timing ( Motor ) Screw, #6-32 x 1/8 Set ( Brass Tip ). Rev. 1 05/01 Form Number Page 5-27.

74 TOP FOLLOWER Page 5-28 Form Number Rev. 1 05/01

75 TOP FOLLOWER ITEM NO PART NUMBER QTY DESCRIPTION Bearing Assembly Spring Hex Nut #2-56 x 3/16 Thk Spacer, Plastic Housing Reflector Assembly Hex Nut #2-56 x 3/16 Thk Screw, #2-56 x 3/16 Long, Pan Hd Int Sems Washer, #2 Flat ( Brass ) Top Follower Plate Spring, Pressure Roller Hex Nut #2-56 x 3/16 Thk Spacer, Plastic. The following items are not shown: Top Follower Cover Screw, #6-32 x 3/8 Lg Phil Truss Hd. Rev. 1 05/01 Form Number Page 5-29.

76 BOTTOM FOLLOWER Page 5-30 Form Number Rev. 1 05/01

77 BOTTOM FOLLOWER ITEM NO PART NUMBER QTY DESCRIPTION Bearing Assembly Spring Hex Nut, #2-56 x 3/16 Thk Spacer, Plastic Housing Reflector Assembly Hex Nut, #2-56 x 3/16 Thk Screw, #2-56 x 3/16 Long, Pan Hd Int Sems Bottom Follower Plate. Rev. 1 05/01 Form Number Page 5-31.

78 TRAY ASSEMBLY, TOP POCKET STACKER Page 5-32 Form Number Rev. 1 05/01

79 TRAY ASSEMBLY, TOP POCKET STACKER ITEM NO PART NUMBER QTY DESCRIPTION Stacker Sensor PC Board Assembly Nut, #4-40 x 3/32 Thk Hex ( Keps ) Dust Shield Stacker Sensor Filter Top Stacker Tray Reflective Surface Label Clip, Low Profile Wire. Rev. 1 05/01 Form Number Page 5-33.

80 TRAY ASSEMBLY, BOTTOM POCKET STACKER Page 5-34 Form Number Rev. 1 05/01

81 TRAY ASSEMBLY, BOTTOM POCKET STACKER ITEM NO PART NUMBER QTY DESCRIPTION Stacker Sensor PC Board Assembly Nut, #4-40 x 3/32 Thk Hex ( Keps ) Dust Shield Stacker Sensor Filter Bottom Stacker Tray Reflective Surface Label Clip, Low Profile Wire. Rev. 1 05/01 Form Number Page 5-35.

82 TOUCHSCREEN ASSEMBLY Page 5-36 Form Number Rev. 1 05/01

83 TOUCHSCREEN ASSEMBLY ITEM NO PART NUMBER QTY DESCRIPTION Touchscreen/Display bracket Front Panel Gasket Touch Screen ( Large ) Circuit Board Standoff Display with Headers Touch Screen Keyboard Int.P.C.Board Screw, #6-32 x 5/8 Long, Phil Pan Int Sems Display Shield Screw, #6-32 x 1/4 Long, Phil Pan Int Sems. The following item is not shown: Display Cable Plastic Cable Tie. Rev. 1 05/01 Form Number Page 5-37.

84 TRANSPORT ASSEMBLY Page 5-38 Form Number Rev. 1 05/01

85 TRANSPORT ASSEMBLY Part Number ITEM NO PART NUMBER QTY DESCRIPTION Lower Read Head PC Board UV PC Board Seal Read Head Dust Cover backing Read Head Dust Shield Screw, #2-56 x 12/4 Phil Ph Int Sems Static Clip. parts: Roller Assembly. This assembly consists of the following Ball Bearing Bearing Mounting Stud Transport Tire Lower Transport Plate Photodiode Sensor Assembly Clamp Screw, #2-56 x 12/4 Phil Ph Int Sems Glass Pressure Roller Spring Screw, #2-56 x 3/8 Phil Ph Int Sems. parts: Magnetic Sensor Assembly. This assembly consists of the following Extension Spring Screw, #6-32 x 7/8 Shcs Self-lock Magnetic Sensor Magnetic Sensor Mount Pivot Block Dowel Pin,.125OD x 1.00LG Screw, #4 Self Tapping 5/8LG. The following parts are not shown: Window, UV, Glass Mask Rev. 1 05/01 Form Number Page 5-39.

86 Shield, Glass Dust. UPPER READ HEAD ASSEMBLY Page 5-40 Form Number Rev. 1 05/01

87 UPPER READ HEAD ASSEMBLY Part Number ITEM NO PART NUMBER QTY DESCRIPTION Spring Retainer Glass Mask Shield Screw, #0-80 x 3/16 Fl Hd Screw, #2-56 x 0.25 Pn Hd Upper Read Head PC Board A/R RTV, GE 160 White Self Levl Seal Dust Shield Offset Latch Screw, #2 x 1/4 Phil Pan Hh Type B. The following items are not shown: Cover, Scraper Plain Washer Screw, #2-56 x 1/4 Phil Ph Int Sems. Rev. 1 05/01 Form Number Page 5-41.

88 FEEDER ASSEMBLY Page 5-42 Form Number Rev. 1 05/01

89 FEEDER ASSEMBLY Part Number ITEM NO PART NUMBER QTY DESCRIPTION Screw, #6-32 x 7/8 Lg Bd Hd Retard Roller Shaft Ratchet Arm Assembly E Ring Washer Ball Bearing Retard Roller Bracket Retard Roller Set Screw, #5-40 x 1/4 S.H. Set Cup Pt Picker Roller Assembly AR Shim,.256 ID x.372 OD x Dial Adjustment Screw Set Screw, #5-40 x 0.13 Lg Rocker Arm Spring. Rev. 1 05/01 Form Number Page 5-43.

90 FEEDER ASSEMBLY Page 5-44 Form Number Rev. 1 05/01

91 FEEDER ASSEMBLY Part Number ITEM NO PART NUMBER QTY DESCRIPTION Pressure Roller Assembly Pressure Roller Spring Screw, #5-40 x 1/2 Rd Hd Mach Washer, #5 Split Medium Lock Leaf Spring Friction Bumper Screw, #2-56 x 1/4 Phil Pn Hd E Ring Washer Spacer Ratchet Arm with Sleeve Washer Support Shaft Screw, #5-40 x 3/8 Skt Hd Cap Lock Washer, #5 Split Plain Washer,.156 ID.050 THK Wave Washer. Rev. 1 05/01 Form Number Page 5-45.

92 TABLE OF APPENDIXES APPENDIX A: MACHINE SPECIFICATIONS APPENDIX B: REQUIRED TOOLS APPENDIX C: RECOMMENDED SPARE PARTS APPENDIX D: DAILY MAINTENANCE ROUTINE APPENDIX E: THEORY OF OPERATION APPENDIX F: SCHEMATICS Rev. 1 05/01 Form Number TOA-1.

93 MACHINE SPECIFICATIONS Dimensions: 16" Depth. 18" Height Width. 42lb Weight. Speed: 1000 Bills per minute. Denominations scanned: $1, $2, $5, $10, $20, 50, $100. Scanning Accuracy: 99.99%. Display: Touch Screen. Document size: Height: 2.56" to 3.66". Length: 5.12" to 8.75". Power requirement: Environmental: Communication Ports: 115v %, 50/60 Hz. (Dedicated line recommended). 230v %, 50/60 Hz. (Dedicated line recommended). Humidity: 20 to 80% (without condensation). Temperature: 50 to 90 Degree Fahrenheit. Four RS232 ports (female Modular Telephone Connector). Rev. 1 05/01 Form Number Page A 1.

94 REQUIRED TOOLS To properly service the Cummins-Allison JetScan you must have the following tools (one of each unless specified) in addition to the standard tool box compliment. 1. Test paper. Part Number Density gauge. Part Number Drum Roll/Retard Roller height adjustment, Magnetic Head adjustment feeler gage. Part Number (2 each needed). 4. Communication Test Cable. Part Number Digital Voltmeter. (Fluke 77 or similar). 6. Transport Plate Height Adjustment Gage/Pin Assembly gage. Part Number (2 each needed. One set includes two). 7. Encoder Centering Tool. Part Number Upper Read Head Gage ( ). Part Number Upper Read Head Gage ( ). Part Number Top Follower Plate Adjustment Gage. Part Number Bottom Follower Plate Adjustment Gage. Part Number Diverter Adjustment Gage - Up Position. Part Number Diverter Adjustment Gage - Down Position. Part Number Lock Collar Adjustment Tool. Part Number Solenoid Connecting Cable. Part Number Rev. 1 05/01 Form Number Page B 1.

95 DAILY MAINTENANCE ROUTINE The following maintenance procedure should be performed every day: 1. Remove the Feeder Plate Assembly. Use a soft pencil eraser to remove all ink buildup on the aluminum rollers. 2. Use a pressurized aerosol duster, such as Tech Spray Precision Duster (Cummins Part Number ), to blow the dust off the hopper side of the currency path. 3. Blow the dust from the area around the aluminum rollers. 4. Blow the dust out of the stacker area. 5. Pump a small amount of roll cleaner on a rag and clean the retard and drum rollers. (Cummins Part Number Roll Cleaner 4 Oz 12 Pack). 6. Open up the Pivot Assembly. Pump a small amount of roll cleaner on a rag and clean all the rollers on the five Transport Shafts. 7. Replace the Feeder Plate Assembly and blow out any dust in the hopper area. 8. Clean the glass and the metal reflector in the stacker. Rev. 1 05/01 Form Number Page D 1.

96 THEORY OF OPERATION When you place a document on the feeder plate, the hopper sensor will detect it. The JetScan will automatically start the main motor and the stacker motor. The feed roll inserts will push the document slightly up in the air, making a more direct pass in between the drum roll and the retard rollers. The two outside rubber parts on the drum roll will start feeding the document in while the retard rollers above will stop all documents, except the bottom document. The retard rollers do not move in the counter clockwise direction, thus allowing friction to separate the documents. The document is fed only when the two outside rubber parts on the drum roll are facing the retard rollers which allow the bills to be spaced about 1.5" apart. An encoder mounted to the end of the encoder shaft, also starts turning when the main motor starts. The encoder wheel has 512 slots per revolution making it possible to accurately determine where the document is in relation to sensors located in the JetScan. The first sensors the document reaches are the UV and Blue Sensors. These two sensors will determine the quality of the paper in the document, stopping the JetScan if the paper is not of the proper quality. The second set of sensors the document reaches are the two density sensors (Left and Right). The density sensors determine the density of the document, stopping the JetScan when a double is detected. They also count the documents in count mode and determine the amount of skew in diagnostics operation. There has to be a set number of pulses between two documents detected by the two density sensors. If there are no pulses detected between documents then a chain will be indicated. Too few pulses between documents will be indicated as a chain*, which indicates that the documents are too close. The line and data sensors are the next sensors the document reaches. The line sensors will detect the picture outline of the bill and will trigger the data collection via the data sensors. One of the two data sensors will read the green side of the bill and an algorithm will determine the correlation result indicating the bill's denomination. This correlation should never be lower than 800 and will never be higher than The electronics determines if the document shall be placed in the top or the bottom stacker and it controls the diverter to route the document to the top or bottom stacker according to the mode settings. The document is now fed into the transport section. The top flow control sensor will always be activated by the document. The bottom flow control sensor will only be activated if the document is going to the bottom stacker. The document is now fed into the stacker wheels and into the stacker where the stacker sensor light beam is interrupted by the document. When you remove the document, for example, because a strap limit has been reached, the light beam will be allowed to reflect back to the sensor indicating that the stacker is empty and that any remaining documents in the hopper can be fed. Rev. 1 05/01 Form Number Page E 1.

97 RECOMMENDED SPARE PARTS LIST PART NUMBER DESCRIPTION Microprocessor Board IO P.C. Board CPU I/O Board Upper Read Head Assy Lower Read Head Board Fan Assy Touch Screen Touch Screen Int. Board Encoder Flow Control Sens.Assy Feeder Plate Assy Drum Roll Assy O Ring O Ring Upper Drive Motor Assy Lower Drive Motor Assy Stacker Sensor Board Photodiode Sensor Assy Transport Tire Retard Roller Feed Roll Insert Feed Roll Insert. Rev. 1 05/01 Form Number Page C 1.

98 Rev. 1 05/01 Form Number Page C 1.

99 SCHEMATICS Part Number Description Pages MP PC Board Assembly. F2 F SIO PC Board Assembly F5 F IO PC Board Assembly F7 F Upper Read Head PC Board Assembly F13 F Lower Read Head PC Board Assembly F15 F16. Rev. 1 05/01 Form Number Page F 1.

100 MP PC BOARD ASSEMBLY Page F 2. Form Number Rev. 1 05/01.

101 MP PC BOARD ASSEMBLY Rev. 1 05/01 Form Number Page F 3.

102 MP PC BOARD ASSEMBLY Page F 4. Form Number Rev. 1 05/01.

103 SIO PC BOARD ASSEMBLY Rev. 1 05/01 Form Number Page F 5.

104 SIO PC BOARD ASSEMBLY Page F 6. Form Number Rev. 1 05/01.

105 IO PC BOARD ASSEMBLY Rev. 1 05/01 Form Number Page F 7.