Diebold 5500 Front-load Cash Dispenser On-site

Component Removal and Replacement Manual

Copyright ©Diebold, Incorporated
TM-000538-001A PD 7327
November 2014

CONFIDENTIAL - Trade Secret Material

Only Diebold and entities granted an express written license by Diebold may possess or use
this material. Unauthorized possession or use is illegal and is punishable by fine and/or
imprisonment.

Important - click here for terms and conditions governing the use of this document.

Document History
Document Number Date Remarks
TM-000538-001A 11/2014 Original edition

Section 1
Personal Safety

1.1 Warning and Caution Labels

The terminal might have any of the warning or caution labels shown below. Strictly observe the
following safety information to reduce the risk of severe personal injury, or death.

Label Definition Safety Concern

Electrical shock An electrical shock hazard exists in the area of the label. Do not remove
hazard covers. Remove power before servicing.

Warning or A personal injury can occur. Look for nearby warning label (electrical
danger shock, pinch point, moving machinery, high temperature hazard) or
refer to the module or ATM operating guide for the specific hazard.
Pinch point An area that can pinch (or cut) you exists in the area of this label. Keep
your hands and fingers clear of pinch points.

Moving Moving parts that can snag or pull clothing, hair, skin, or jewelry into the
machinery mechanism are present in the area of this label. Keep clothing, hair,
hazard skin, and jewelry out of the mechanism.
High High temperatures that can cause pain or burns are present in the area
temperature of this label. Do not touch until cooled.
hazard

1.2 Safely Servicing the Terminal

Strictly observe the following safety warning when servicing the terminal to reduce the risk of
damage to the equipment and personal injury.

WARNING

Voltages inside the terminal can cause bodily injury or death from electrical shock. To
prevent bodily injury or death from electrical shock, follow the steps in Section 4.3 or
Section 4.5 to remove AC power from the terminal before attempting any of the procedures
in this manual, unless instructed otherwise.

CAUTION

 Disconnecting cables without first turning off the power to the terminal can damage
the module or the terminal. DO NOT disconnect or reconnect any module cables
without first turning off the power to the terminal, as described in Section 4.
 The modules and devices are sensitive to electrostatic discharge. Use proper
personal grounding and anti-static handling procedures when working with the
modules and devices. Failure to comply could permanently damage the component.

Section 2
Introduction
Description
The model 5500 terminal is a full-service, drive-up, island terminal that is serviced from the front of
the terminal.

This document describes how to remove and replace the major components of the terminal, shown
in Figure 2-1 through Figure 2-3.

Figure 2-1 Components of the Fascia

 Component Refer to
1 Fascia mirror Section 16
2 Cash pocket camera Section 8
3 All-in-one module Section 7
4 Function key CCA Section 15
5 Contactless card reader Section 9
6 Speakers Section 14
7 EPP module Section 10
8 2D barcode scanner Section 11
9 Fingerprint reader Section 12
10 Headphone jack CCA Section 13

Figure 2-2 Components of the Top Housing and Safe

 Component Refer to
1 All-in-one module Section 7
2 Receipt printer module Section 21
3 Cable retractor Section 4.8
4 TMD modules Section 20
5 UCC (Upper Control Card) module Section 18
6 AC/DC power module Section 19
7 BAI (Basic Alarm Interface) Section 29
7 LCC (Lower Control Card) Section 30
8 DC/DC (Smart Power Module) and battery module Section 31
9 Activdispense Section 28
10 Dip card reader Section 25
11 Active edge card reader Section 24
12 Motorized card reader Section 23

Figure 2-3 Lower Door Component

Component Refer to
1 Lower door - cash pocket camera installed Section 27
2 Lower door service key and lock Section 27
3 Lower door assembly Section 27

Figure 2-4 Fascia Bezels

 Component Refer to
1 Front fascia bezel Section 17
2 Fingerprint reader bezel Section 17
3 Receipt printer and 2D barcode scanner bezel Section 17
4 Card reader bezel Section 23 - Motorized Card Reader
Section 24 - Active Edge Card Reader
Section 25 - Dip Card Reader
5 Activdispense bezel Section 26
6 Contactless card reader bezel Section 17

Section 3
Accessing the Terminal
This section provides information about accessing different parts of the cash dispenser.
Section 4
Terminal Start-up and Shut-down Procedures
This section describes how to start up and shut down the terminal before servicing most
components in the terminal. Refer to the appropriate sections of this document for more information
about removing and replacing each component.

WARNING

Voltages inside the terminal can cause bodily injury or death from electrical shock. To
prevent bodily injury or death from electrical shock, follow the steps in Section 4.3 to
remove DC power, or follow the steps in Section 4.5 to remove AC power, from the terminal
before attempting any of the procedures in this manual, unless instructed otherwise.

CAUTION

 Disconnecting cables without first turning off the power to the terminal can damage
the module or the terminal. DO NOT disconnect or reconnect any module cables
without first turning off the power to the terminal, as described in Section 4.3.
 The modules and devices are sensitive to electrostatic discharge. Use proper
personal grounding and anti-static handling procedures when working with the
modules and devices. Failure to comply could permanently damage the component.
 An "orderly shutdown" of the terminal, including the software operating system,
must be performed as part of the terminal shut down procedure. Failure to comply
could cause unrecoverable errors when the terminal is restarted.

See Table 4-1 and Figure 4-1 for an overview of each of the shut-down and start-up procedures in
this section.

Table 4-1 Description for Start-up and Shut-down Procedures

Shut-down
and Start-up
Procedure Description Use For
Devices-only Removes 24V DC power from 24V DC power supply by Servicing a terminal
pressing the idle power switch located on the front device without shutting
fascia cover of the UCC module. down the processor and
the alarm modules.
This removes all 24V DC or 5V DC USB devices.

The terminal processor, fans (if present), and alarm

components are not affected.
Functional An orderly shut-down of the terminal processor. Processor maintenance,
maintenance on devices
Disconnect the 24V DC power cable from the connected to fascia
processor. Removes 24V DC power from 24V DC control hub.
power supply by pressing main power switch located on
 the front fascia cover of the UCC module. (This totally
removes DC power to fascia control hub.)

This power on/off all modules including processor

connected to the fascia control hub.
Electrical Performs the following operations: Performing maintenance
on any terminal
 Same as functional procedure. component or device.

 Removes all AC power to the terminal (at

breaker or wall outlet).

Removes all power to the terminal.

Figure 4-1 Power Switches

1 USB port 2.0

2 Dual USB port 2.0
3 Maintenance mode switch
4 Idle power (on/off) switch
5 Main power (on/off) switch
6 All in one module - consumer display (with touch screen)
7 DC 1 output (15 pin)
8 DC 2 output (16 pin)
9 DC 3 output (14 pin)
10 DC 4 output (18 pin)
11 AC output
12 100 to 240 V AC input

4.1 Devices-only Shut-down Procedure

Perform the following steps to shut down the terminal devices.

WARNING

You must perform the procedures in Section 4.5 before servicing any components using AC
power. This includes, but is not limited to, the power supply for the alarms interface.

CAUTION

 Disconnecting device cables without first turning off the terminal's AC power can
damage the device or the terminal. DO NOT disconnect or reconnect any device
cables without first performing either the devices-only (Section 4.1), functional
(Section 4.3), or electrical (Section 4.5) shut-down procedure.
 The modules and devices are sensitive to electrostatic discharge. Use proper
personal grounding and anti-static handling procedures when working with the
modules and devices. Failure to comply could permanently damage the component.

NOTE

For this procedure, devices refers to the terminal DC power supply and all of the +24V DC /
5V DC USB devices (except processor) that it powers.

The terminal processor and alarm components are not affected by this procedure.

1. Remove the terminal from consumer service and follow the institution's procedures to place
the terminal in service mode.
2. Have someone from the institution remove all currency, ATM cards, deposits, and cassettes
from the terminal.
3. Press the idle power (on/off) switch located on the front fascia cover of the UCC module to
power off the +24 VDC power (see Figure 4-1).

4.2 Devices-only Start-up Procedure

Perform the steps in this section to start up the terminal devices.

1. Press the idle power (on/off) switch to power on 24 VDC (see Figure 4-1).
 2. Run the appropriate diagnostics to test new components.
3. Have someone from the institution install media (currency) and cassettes into the terminal.
4. Follow the institution's procedures to return the terminal to consumer service.
5. Run several transactions at the terminal to verify that it operates correctly.

4.3 Functional Shut-down Procedure

Perform the following steps for a functional shut-down at the terminal.

WARNING

You must perform the electrical shut-down procedure (Section 4.5) before servicing any
components directly connected to the AC line. This includes, but is not limited to, the power
supply for the alarms interface.

CAUTION

 Disconnecting device cables without first turning off the terminal's AC power can
damage the device or the terminal. DO NOT disconnect or reconnect any device
cables without first performing either the devices-only (Section 4.1), functional
(Section 4.3), or electrical (Section 4.5) shut-down procedure.
 The modules and devices are sensitive to electrostatic discharge. Use proper
personal grounding and anti-static handling procedures when working with the
modules and devices. Failure to comply could permanently damage the component.

1. Remove the terminal from consumer service and follow the institution's procedures to place
the terminal in service mode.
2. Have someone from the institution remove all currency, ATM cards, deposits, and cassettes
from the terminal.

NOTE

Go to Step 3 to initiate a functional shutdown of the terminal.

Go to Step 4 to initiate a shutdown of the terminal using the processor operating

system or the Agilis ® maintenance mode.

3. Perform an orderly shutdown of the following items:

o All customer software applications
o The ATM software operating system
o Devices connected to the fascia control hub
4. Perform an orderly software shutdown of the following items:
o All customer software applications
o The ATM software operating system
o The processor
d. Select shutdown from the processor operating system or log on to the Agilis ®

maintenance mode.
 e. Follow the appropriate steps to initiate a software shutdown.
5. Press the main power switch located on front fascia cover of the UCC module to power off
all modules including processor.

WARNING

o The DC power supply has residual power after its AC power is removed. The
residual power is dangerous and can cause bodily injury from electrical
shock or damage to the terminal. To prevent bodily injury or damage to the
terminal, make sure the power supply's fans have all stopped rotating before
disconnecting any device cables.
o After an orderly shutdown (Step 3 or Step 4) is completed, AC power is still
present in the terminal. You must perform the procedure in Section 4.5 before
servicing any components directly connected to the AC line. This includes,
but is not limited to, the power supply for the alarms interface.

4.4 Functional Start-up Procedure

Perform the following steps to initiate a functional start-up of the terminal.

1. Press the main power switch located on front fascia cover of the UCC module to power on
all the modules including the processor.
2. Connect the +24 VDC power cable to the processor.
3. The terminal operating system and software applications will continue to load.
4. The terminal will go into service after all the software has loaded.
5. Run the appropriate diagnostics to test new components.
6. Have someone from the institution install currency and cassettes into the terminal.
7. Follow the institution's procedures to return the terminal to consumer service.
8. Complete several transactions to verify how the terminal is operating.

4.5 Electrical Shut-down Procedure

WARNING

You must perform the electrical shut-down procedure (Section 4.5) before servicing any
components directly connected to the AC line. This includes, but is not limited to, the power
supply for the alarms interface.

1. Perform the functional shut-down procedure (Section 4.3).

2. Remove the incoming AC power to the terminal (at the AC power receptacle or disconnect
and tag the institution's circuit breaker).

4.6 Electrical Start-up Procedure

1. Restore incoming AC power to the terminal (at the AC power receptacle or institution's
circuit breaker).
2. Perform the functional start-up procedure (Section 4.4).

4.7 Troubleshooting
Refer to Table 4-2 to diagnose problems on function keypads and consumer keypads.

NOTE

Refer to the Encrypting PIN Pad (EPP7) On-site Repair Manual (TM-000485-001B) for more
information about troubleshooting the consumer keypad.

Table 4-2 Troubleshooting the Shut-down Procedures

Problem Probable Cause Corrective Action
No response or Disconnected or Check keypad cable connections for damage and tight fit.
display when damaged keypad Check cable for continuity. Replace cable if defective. Refer to
key is pressed cables. the Diebold 5500 Front-load Lobby Cash Dispenser On-site
Cabling Repair Manual (TM-000539-001A) for information
about keypad cabling.
Defective keypad Replace keypad.
 For the function keypad, refer to
 For the consumer keypad, refer to

Stuck key on Dirt or other Clean keypad with mild solution of soap and water. Wipe
keypad contaminants on keypad dry. Replace keypad if key remains stuck.
keypad
 For the function keypad, refer to
 For the consumer keypad, refer to

4.8 Cable Retractor - Removal, Replacement, and Parts

Perform the procedures in Section 4.8.1 to remove the cable retractor for the top chassis.

Perform the procedures in Section 28.2 to remove the cable retractor for the dispenser of the
ActivDispense.

4.8.1 Removing the Top Chassis Cable Retractor

Perform the following steps to remove the top chassis cable retractor.

CAUTION

The mounting brackets for the cable retractor can break if it is stressed or if excessive force
is used. Be careful not to use excessive force on the mounting brackets during any of the
following steps.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Remove the two nuts that secure the cable retractor mounting bracket to the upper fascia
(Figure 4-2).
3. Remove the cable retractor mounting bracket engaged with upper cable retractor end
connector from upper fascia (Figure 4-2).
4. Carefully disengage the cable retractor end connector (upper one) out of upper retractor
mounting bracket (Figure 4-2).
 5. Disengage the cable retractor end connector (lower one) away from the lower mounting
bracket (Figure 4-2).

Figure 4-2 Removing the Top Chassis Cable Retractor

1 The locking tab fully engaged

2 Locking tab
3 Cable retractor end connector (upper)
4 Upper mounting bracket
5 Mounting nuts (quantity 2)
6 Cable retractor
7 Cable retractor end connector (lower)

4.8.2 Replacing the Top Chassis Cable Retractor

Reverse the steps in Section 4.8.1 to replace the cable retractor.

4.8.3 Removing and Replacing the Cable Retractor of the ActivDispense

Refer to Section 28.2.

4.8.4 Cable Retractor Parts Information

Table 4-3 provides the part numbers for the two types of cable retractors used in the terminal.

Table 4-3 Cable Retractor Part Numbers

Part Number Description Where Used
49-250948-000C Chain-type cable retractor, large Top chassis
49-250942-000A Cable retractor end connector, large Top chassis
49-204314-000B Chain-type cable retractor, small Activdispense
49-203098-000A Cable retractor end connector, small Activdispense

Section 5
Upper Fascia - Fascia Control Hub
This section describes how to remove and replace the fascia control hub.

5.1 Removal

Perform the following steps to remove the fascia control hub that is mounting to the back of the all-
in-one module.

1. Insert the fascia key into the fascia lock.

2. Turn the key clockwise and pull the top chassis out to the fully extended service position.

Figure 5-1 Opening the Top Chassis

 1 Insert the key and turn it clockwise
2 Pull out the top chassis to the fully extended service position

3. Perform the terminal functional shut-down procedure (Section 4.3)

4. Disconnect all the cables connected to the fascia control hub. (Refer to the Diebold 5500
Front-load Lobby Cash Dispenser On-site Cabling Repair Manual [TM-000539-001A])
5. Remove the four mounting screws that fasten the fascia control hub cover to the module.
6. Remove the fascia control hub cover.
7. Remove the two mounting screws that secure the fascia control hub to the all-in-one
module, then remove the fascia control hub.
8. Remove the four mounting screws that secure the fascia control hub mounting bracket to
the all-in-one module, then the mounting bracket could be removed.

Figure 5-2 Removing the Fascia Control Hub

1 All-in-one module
2 Fascia control hub mounting bracket
3 Mounting screws for mounting bracket (4)
4 Fascia control hub
5 Mounting screws for fascia control hub (2)
6 Fascia control hub cover
7 Mounting screws for cover (4)

5.2 Replacement

Reverse the steps in Section 5.1 to install the fascia control hub.
Section 6
Upper Fascia - Touch Screen CCA Assembly
This section describes how to remove and replace the touch screen CCA.

6.1 Removal

Perform the following steps to remove the CCA:

1. Open the top chassis to the fully extended service position.

2. Perform the terminal functional shut-down procedure (Section 4.3).
3. Remove the fascia control hub (Section 5.1).
4. Disconnect the touch screen cable. For the detailed cabling, refer to the Diebold 5500
Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-000539-001A).
5. Remove the two mounting screws that secure the touch screen CCA assembly to the upper
fascia.
6. Remove the touch screen CCA assembly away from the upper fascia.
7. Remove the two mounting screws that secure the touch screen CCA to the mounting
bracket.
8. Remove the touch screen CCA away the mounting bracket.

Figure 6-1 Removing the Touch Screen CCA Assembly

1 Mounting screws for the CCA

2 Touch screen CCA
3 Mounting bracket
4 Mounting screws for the mounting bracket
6.2 Replacement

Reverse the steps in Section 6.1 to install the touch screen CCA.

Section 7
Upper Fascia - All-in-one Module
This section describes how to remove and replace the all-in-one module.

7.1 Removal

Perform the following steps to remove the module:

1. Open the top chassis to the fully extended service position.

2. Perform the terminal functional shut-down procedure (Section 4.3).
3. Remove the fascia control hub (Section 5.1).
4. Remove the touch screen CCA assembly (Section 6.1).
5. Disconnect the cables connected to the all-in-one module (Refer to the Diebold 5500 Front-
load Lobby Cash Dispenser On-site Cabling Repair Manual [TM-000539-001A]).
6. Remove the four mounting nuts and remove the cable ties.
7. Remove the six mounting screws that secure the all-in-one module mounting bracket.
8. Remove the module mounting bracket.
9. Remove the all-in-one module from the upper fascia.
10. After the all-in-one module is removed from the terminal, be noted that carefully remove the
following module components:
a. Remove the privacy filter gasket;
b. Remove the privacy filter;
c. Remove the touch screen side gasket;
d. Remove the touch screen gasket;
e. Remove the touch screen.

Figure 7-1 Removing the All-in-one Module

1 Module mounting bracket
2 Mounting nuts for mounting bracket and cable tie
3 Mounting screws
4 Gasket for touch screen
5 Side gasket for touch screen
6 Touch screen
7 Privacy filter
 8 Gasket for privacy filter
9 All-in-one module

7.2 Replacement

Reverse the steps in Section 7.1 to replace the all-in-one module.

Section 8
Upper Fascia - Cash Pocket Camera
This section describes how to remove and replace the cash pocket camera.

8.1 Removal

Perform the following steps to remove the modules:

1. Open the top chassis to the fully extended service position.

2. Perform the terminal functional shut-down procedure (Section 4.3).
3. Disconnect the cables connected to the cash pocket camera (Refer to the Diebold 5500
Front-load Lobby Cash Dispenser On-site Cabling Repair Manual [TM-000539-001A]).
4. Remove each camera by removing the two mounting screws. The camera with mounting
bracket assembly is removed away from the upper fascia (Figure 8-1).
5. After the camera with mounting bracket is removed, perform the following steps to remove
the camera away from the mounting bracket (Figure 8-1):
a. Remove the mounting screw that secure the camera to the mounting bracket.
b. Carefully disentangle the camera USB and logic cable.
c. Remove the camera from the mounting bracket.

Figure 8-1 Removing the Cash Pocket Camera

 1 Mounting screw for camera (1)
2 Mounting bracket
3 Camera
4 Camera USB and logic cable
5 Mounting screws for two mounting brackets (total 4)

8.2 Replacement

Reverse the steps in Section 8.1 to replace the cash pocket camera assembly.

Section 9
Upper Fascia - CCR (Contactless Card Reader) Assembly
This section describes how to remove and replace the CCR.

9.1 Removal
Perform the following steps and refer to Figure 9-1 to remove the CCR.

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Make a note of the cable connections to the CCR. Refer to the Diebold 5500 Front-load
Lobby Cash Dispenser On-site Cabling Repair Manual (TM-000539-001A).
4. Disconnect the 24 V DC power & USB cable from the CCR.
5. Remove the mounting screws that secure the CCR to the fascia.
6. Remove the CCR out of the terminal.

9.2 Replacement

Reverse the steps in Section 9.1 to replace the CCR.

Figure 9-1 Removing the CCR

1 CCR assembly
2 Mounting screws (2)

Section 10
Upper Fascia - EPP (Encrypting PIN Pad) Module
This section describes how to remove and replace the EPP module.
10.1 Removal

Perform the following steps to remove the EPP module from the terminal.

1. Open the top chassis to the fully extended service position.

2. Perform the functional shut-down procedure (Section 4.3).

Perform Step 3 through Step 5 to remove the EPP light.

3. Disconnect the EPP light cable from the module. Refer to the Diebold 5500 Front-load
Lobby Cash Dispenser On-site Cabling Repair Manual (TM-000539-001A).
4. Remove the two mounting screws that secure the EPP light with mounting bracket to the
module (Figure 10-1).
5. Remove the EPP light and its mounting bracket from the module (Figure 10-1).

Figure 10-1 Removing the EPP Light

1 EPP light mounting bracket

2 Mounting screws (2)
3 EPP light
4 EPP module

Perform the following steps to remove the EPP module:

6. Disconnect all the cables that are connected to the EPP. Refer to the Diebold 5500 Front-
load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-000539-001A).
7. Remove the EPP module mounting bracket by removing the 6 mounting screws (Figure 10-
2).
8. Remove the EPP module away from the upper fascia by removing the four mounting
screws that secure the EPP module to the fascia (Figure 10-2).
9. Remove the EPP module from the fascia (Figure 10-2).

Figure 10-2 Removing the EPP Module

1 EPP (Encrypting PIN pad) module mounting bracket

2 Mounting screws for EPP module (4)
3 Mounting screws for EPP mounting bracket (6)
 4 EPP module

10.2 Replacement

Reverse the steps in Section 10.1 to replace the EPP module.

Section 11
Upper Fascia - 2D Barcode Scanner
This section describes how to remove and replace the 2D barcode scanner.

11.1 Removal

Perform the following steps and refer Figure 11-1 to remove the module:

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Disconnect the USB and logic cable connecting from the fascia control hub to the 2D
barcode scanner. Refer to the Diebold 5500 Front-load Lobby Cash Dispenser On-site
Cabling Repair Manual (TM-000539-001A).
4. Remove the 3 mounting screws that secure the 2D barcode scanner mounting bracket to
the fascia.
5. After the mounting bracket is removed, remove the 2 mounting screws that fasten the 2D
barcode scanner to the mounting bracket.
6. Remove the 2D barcode scanner from the mounting bracket.

Figure 11-1 Removing the 2D Barcode Scanner

 1 2D barcode scanner
2 Mounting bracket
3 Mounting screws for mounting bracket (3)
4 Mounting screws for 2D barcode scanner (2)

11.2 Replacement

Reverse the steps in Section 11.1 to replace the 2D barcode scanner module.

Section 12
Upper Fascia - Fingerprint Reader
This section describes how to remove and replace the fingerprint reader.

12.1 Removal

Perform the following steps shown in Figure 12-1 to remove the fingerprint reader.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
 3. Disconnect the fingerprint reader USB and logic cable connecting to the fascia control hub.
Refer to the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual
(TM-000539-001A).
4. Remove the 4 mounting screws that secure the fingerprint reader assembly to the upper
fascia.
5. After the fingerprint reader assembly is removed, remove the two mounting screws to
disassemble the fingerprint reader away from the mounting bracket.

Figure 12-1 Removing the Fingerprint Reader

1 Mounting screws for fingerprint reader assembly (4)

2 Fingerprint reader cover
3 Fingerprint reader
4 Mounting screws for the mounting bracket
5 Mounting bracket for fingerprint reader

12.2 Replacement

Reverse the steps in Section 12.1 to replace the fingerprint reader.

Section 13
Upper Fascia - Headphone Jack
This section describes how to remove and replace the headphone jack.

13.1 Removal

Perform the following steps shown in Figure 13-1 to remove the head phone jack.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Disconnect the headphone jack logic cable connecting to the fascia control hub. Refer to
the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-
000539-001A).
4. Remove the headphone jack by unfastening the two mounting screws that secure the
headphone jack to the upper fascia.
5. Remove one mounting screw to disassemble the headphone jack away from the mounting
bracket.

Figure 13-1 Removing the Headphone Jack

1 Mounting screw for the mounting bracket (1)

2 Mounting bracket
3 Mounting screws for the headphone jack
4 Headphone jack

13.2 Replacement

Reverse the steps in Section 13.1 to replace the headphone jack.

Section 14
Upper Fascia - Speakers
This section describes how to remove and replace the speakers.

14.1 Removal

Perform the following steps to remove the module (Figure 14-1).

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Disconnect the speaker logic cable. Refer to the Diebold 5500 Front-load Lobby Cash
Dispenser On-site Cabling Repair Manual (TM-000539-001A).
4. Remove the nuts that secure the speakers to the fascia.
5. Remove the speakers from the fascia.

Figure 14-1 Removing the Fascia Speakers

1 Speaker logic cable
2 Speakers
3 Mounting nut

14.2 Replacement

Reverse the steps in Section 14.1 to replace the fascia speakers.

Section 15
Upper Fascia - Function Keypad CCA and the Function Keypad
Keytops
This section describes how to remove and replace the function keypad CCA and keytops.

15.1 Removal

Perform the following steps and refer to Figure 15-1 to remove:

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Disconnect the function keypad cable connecting to the EPP. Refer to the Diebold 5500
Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-000539-001A).
4. Remove 3 mounting screws that fasten each function keypad CCA to the upper fascia.
5. Remove the function keypad CCA away from the fascia.
6. If necessary, remove the defective function keytops by using a small, flat-blade screwdriver
to carefully pry them off the fascia.

Figure 15-1 Removing the Function Keypad CCA and Keytops

1 Function keytops
2 Function keypad CCA cable
3 Mounting screws (total 6)
4 Function keypad CCA

15.2 Replacement

Reverse the steps in Section 15.1 to replace the function keypad CCA.

Section 16
Upper Fascia - Mirror and Lens
This section describes how to remove and replace the fascia mirror and lens.
16.1 Removal

Perform the following steps to remove the mirror and lens.

NOTE

The removal procedure could be operated without moving the terminal from customer
service or shutting down the terminal.

Use a small, flat-blade screwdriver to carefully pry the defective mirror and the lens off the fascia
(Figure 16-1).

Figure 16-1 Removing the Fascia Mirror or Lens

1 Fascia mirror (left)

2 Fascia lens
3 Fascia mirror (right)

16.2 Replacement

Perform the following steps to replace a fascia mirror and lens:

 1. Clean any adhesive residue with isopropyl alcohol (91% or higher concentration) from the
mounting area around the mirror or lens.
2. Use double-sided tape to mount the replacement mirror or lens on the fascia.

Section 17
Upper Fascia - Upper Fascia Assembly, Front Fascia and Receipt
Printer & Card Reader Bezel
This section describes how to remove and replace the whole upper fascia assembly, the front fascia
and the receipt printer & card reader bezel.

17.1 Removal

Perform the following steps to remove the upper fascia and its bezel.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Disconnect all cables connecting to the upper fascia modules in Section 5 through Section
16. For the cabling details, refer to the Diebold 5500 Front-load Lobby Cash Dispenser On-
site Cabling Repair Manual (TM-000539-001A).
4. Cut the cable tie straps that secure the cables to the fascia.
5. Refer to the procedures described in Section 21.1 to remove the receipt printer.
6. Refer to the procedures described in Section 23 through Section 25 to remove the card
readers.
7. Remove the fascia mounting bracket (left and right) by unfastening the 5 mounting screws
each side (Figure 17-1).
8. After the fascia mounting bracket is removed, carefully and strongly lift the entire upper
fascia assembly off the terminal (Figure 17-1).
9. After the entire upper fascia is removed,
o If necessary, use the small, flat-blade screwdriver to carefully pry the CCR cover
and fingerprint reader cover off (Figure 17-1).
o The front fascia and receipt printer bezel could be disassembled (Figure 17-2).

Figure 17-1 Removing the Upper Fascia Assembly

1 CCR cover (optional)
2 Fingerprint reader cover
3 Fascia mounting bracket (right)
4 Mounting screws (total 10)
5 Fascia mounting bracket (left)

Figure 17-2 Disassembling the Front Fascia and Receipt Printer & Card Reader Bezel
 1 Front fascia
2 Receipt printer and card reader bezel

17.2 Replacement

Reverse the steps in Section 17.1 to replace the upper fascia assembly.

NOTE

Carefully ensure that the front fascia and receipt printer bezel (Figure 17-2) are embedded
precisely into the terminal when replacing the new.

Section 18
Top Chassis - UCC (Upper Control Card) Module
This section describes how to remove and replace the UCC module.

18.1 Removal

Perform the following steps to remove the module.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Disconnect the cables from the UCC CCA. For the cabling details, refer to the Diebold 5500
Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-000539-001A).
4. Remove the two mounting screws that secure the UCC module to the terminal.
5. Remove the UCC module away from the terminal.

Figure 18-1 Removing the UCC Module

1 UCC module
2 Mounting screws (quantity 2)

6. After the UCC module is removed, perform the following steps to remove the UCC module
components.
a. Release the locking tabs that secure the UCC cover to the assembly.
b. Disconnect the switch cables that are connected to the UCC CCA.
c. Carefully unplug the following switches from the CCA
 Main power on/off switch
 Idle power on/off switch
 Maintenance switch
d. Remove the three mounting screws that secure the UCC CCA to the module cover.
e. Push the CCA downward then lift it upward to disassemble the UCC CCA away
from the module.
f. If necessary, remove and replace the UCC module label.

Figure 18-2 Removing the UCC Module Components

 1 Locking tabs 7 Disconnect the Idle power (on/off) switch
cable
2 UCC module base 8 Disconnect the maintenance mode switch
cable
3 Main power (on/off) switch 9 UCC CCA
4 Idle power (on/off) switch 10 Mounting screws (quantity 3)
5 Maintenance mode switch 11 UCC module cover
6 Disconnect the main power (on/off) switch
cable

18.2 Replacement

Reverse the steps in Section 18.1 to replace the UCC module.

Section 19
Top Chassis - AC/DC Module
This section describes how to remove and replace the AC/DC module.

19.1 Removal

Perform the following steps to remove the module.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Disconnect the cables that are connected to the AC/DC module. For the cabling details,
refer to the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual
(TM-000539-001A).
4. Remove the two mounting screws that secure the AC/DC module into the top chassis.
5. Remove the AC/DC module from the terminal.

Figure 19-1 Removing the AC/DC Module

1 Mounting screws (quantity 2)

2 AC/DC module
19.2 Replacement

Reverse the steps in Section 19.1 to replace the AC/DC module.

Section 20
Top Chassis - TMD Modules
This section describes how to remove and replace the TMD modules.

20.1 Removal

Perform the following steps to remove the module.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Disconnect all the cable connections to the TMD modules. For the cabling details, refer to
the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-
000539-001A).
4. Perform the following steps to remove the TMD CPK assembly from the top chassis
cabinet.
a. Remove the two mounting nuts that secure the TMD CPK assembly to the terminal.
b. Remove the CPK assembly.
c. Release the CPK cover locking tab that fasten the CPK into the assembly cover.
d. Carefully disengage the CPK module from the cover.
e. Unplug the rocker switch out of the CPK module, if necessary.

Figure 20-1 Removing the TMD CPK Assembly

 1 Mounting nuts for CPK assembly (quantity 2)
2 CPK cover
3 CPK module
4 CPK module locking tabs
5 CPK module mounting bracket
6 Rocker switch

5. Perform the following steps to remove the TMD drive box CCA.
 a. Remove the two mounting screws that secure the drive box CCA assembly to the
card reader bezel.
b. Remove the drive box CCA assembly with its bracket from the terminal.
c. Remove the drive box CCA from its bracket by removing the one mounting screw.

Figure 20-2 Removing the TMD Drive Box CCA Assembly

1 Mounting screw for drive box CCA

2 Drive box CCA
3 Mounting screws for mounting bracket (2)
4 Drive box CCA mounting bracket

6. Perform the following steps to remove the TMD local access keyboard (optional).
a. Remove the four mounting nuts to remove the local access keyboard assembly
from the terminal.
b. Remove the one mounting screw that secure the local access keyboard to the
mounting bracket.
c. Release the locking tab to disengage the keyboard away from the mounting
bracket.
d. Remove the local access keyboard away from the mounting bracket.
 Figure 20-3 Removing the TMD Local Access Keyboard

1 Local access keyboard

2 Local access keyboard mounting bracket
3 Mounting screw for mounting bracket
4 Mounting nuts for local access keyboard assembly (4)

20.2 Replacement

Reverse the steps in Section 20.1 to replace the TMD module.

Section 21
Top Chassis- Receipt Printer
This section describes how to remove and replace the receipt printer.
21.1 Removal

Perform the following steps to remove the module.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform the functional shut-down procedure (Section 4.3).
3. Make a note of the cable connections on the printer control CCA. For the cabling details,
refer to the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual
(TM-000539-001A).
4. In front of the terminal upper fascia, carefully remove the receipt printer indicator.
5. Disconnect the power and USB cables from the printer control board.
6. Remove the two rear mounting screws.
7. Slide the printer backwards until the printer frame clears the front hold down tabs.
8. Lift the printer out of the terminal.

Figure 21-1 Removing the Receipt Printer

1 Receipt printer slot
2 Printer indicator
3 Receipt printer
4 Mounting screws (2)

21.2 Replacement

1. Reverse the steps in Section 21.1 to replace the receipt printer.

2. Make sure the front of the receipt printer frame goes underneath the locking tabs.

21.3 Docking the Receipt Printer

Perform the following steps to verify and adjust the docked position of the receipt printer.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Make sure that the receipt printer is securely docked to the fascia.
4. Inspect the opening in the fascia for the following conditions:
o The front of the receipt printer should protrude slightly out of the opening.
o The receipt printer bezel should be flat and not visibly bowed outward.
o Apply moderate pressure to the front of the receipt printer. The printer should not
move back (away) from the receipt printer bezel or move only slightly (maximum of
0.1 mm [0.004 inch]).

Figure 21-2 Checking the Docking Position of the Receipt Printer

1 Incorrect - printer does not protrude out of fascia opening

2 Correct - printer should protrude slightly out of fascia opening
 5. If all of the conditions in Step 4 are met, no adjustment is necessary. Perform either the
functional start-up procedure (Section 4.4) or the devices-only start-up procedure (Section
4.2) to return the terminal to service.
6. If any of the conditions in Step 4 are not met, perform the following steps to adjust the
receipt printer.
a. Open the top chassis.
b. Loosen the rear mounting screw. If necessary, remove the paper roll from the
receipt printer to access the mounting screw.
c. Move the receipt printer in the direction necessary to correct the docking position,
either toward or away from the terminal fascia.
d. Hold the receipt printer in this position and tighten the rear mounting screws.
e. Push the receipt printer back into the terminal and make sure that the slide release
for the receipt printer is securely engaged.
f. Close the top chassis.
g. Repeat Step 3 through Step 6 as necessary until the receipt printer is properly
adjusted.

21.4 Removing and Replacing the Receipt Printer Bezel

Perform the following steps to remove and replace the receipt printer bezel.

1. Remove the receipt printer from the terminal (Section 21.1).

2. Remove the printer bezel. Refer to the One-sided Graphical Thermal Receipt Printer (49-
240508-000A) On-site Repair Manual (TM-000527-001A) for information about removing
and replacing the printer bezel.
3. Reinstall the receipt printer into the terminal (Section 21.2).

Section 22
Top Chassis - Journal Printer
This section describes how to remove and replace the journal printer.

22.1 Removal

Perform the following steps to remove the module.

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Disconnect the cables that are connected to the journal printer. For the cabling details, refer
to the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-
000539-001A).
4. Remove the mounting screws and the washer.
5. Remove the journal printer out of the terminal.

Figure 22-1 Removing the Journal Printer

 1 Mounting screw and washer
2 Journal printer

22.2 Replacement

Reverse the steps in Section 22.1 to replace the journal printer.

Section 23
Top Chassis - Motorized Card Reader
This section describes how to remove and replace the motorized card reader, the card retain bin
and how to dock the card reader on the fascia.

23.1 Removing the Motorized Card Reader and the Card Retain Bin

Perform the following steps to remove the motorized card reader.

NOTE

Someone from the institution should have already removed any captured cards from the
retained card bin.

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Disconnect the cables connected to the motorized card reader. For the cabling details, refer
to the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-
000539-001A).
4. Remove one mounting screw to remove the lockable bin.
5. Remove the two mounting screws that secure the motorized card reader to the mounting
base.
6. Lift the card reader up of the terminal.
7. Remove the two mounting screws that secure the mounting base to the top chassis.
Remove the card reader mounting base.
8. After the motorized card reader is removed, stand in the front of the terminal and perform
the following steps to remove the motorized card reader bezel:
a. Remove the four mounting screws that secure the bezel mounting bracket to the
fascia.
b. Remove the bezel mounting bracket.
c. Remove the four mounting screws that secure the reader bezel to the fascia bezel.
d. Remove the motorized card reader bezel from the front of the terminal.

Figure 23-1 Removing the Motorized Card Reader

1 Motorized card reader bezel 6 Lockable bin
2 Bezel mounting bracket 7 Mounting screws (quantity 2)
 3 Mounting screws for bezel mounting 8 Motorized card reader
bracket
4 Mounting screws for bezel 9 Mounting screws for reader mounting
base
5 Mounting screws for lockable bin 10 Mounting base

23.2 Docking the Motorized Card Reader

Perform the following steps to verify and adjust the docked position of the motorized card reader.

1. Open the top chassis to the fully extended position.

NOTE

Someone from the institution should have already removed any captured cards or
the retained card cassette.

2. Make sure that the motorized card reader is securely engaged through the reader bezel
opening.
3. Inspect the card reader for the following conditions:
o The front of the card reader should protrude slightly past the surrounding bezel.
o Apply moderate pressure to the front of the card reader. The card reader should not
move back (away) from the bezel.

Figure 23-2 Docking Position of the Motorized Card Reader

 1 Incorrect - card reader does not protrude past bezel opening
2 Correct - card reader protrudes slightly past bezel opening

4. If all the conditions in Step 3 are met, no adjustment is necessary. Return the terminal to
consumer service.
5. If any of the conditions in Step 3 are not met, continue with the following steps to adjust the
card reader.
a. Loosen the two mounting screws for the card reader.
b. Move the card reader in the direction necessary to correct the docking position,
either toward or away from the terminal fascia.
c. Hold the card reader in this position and tighten the mounting screws.
d. Repeat Step 2 through Step 5 as necessary until the card reader is properly
adjusted.

Section 24
Top Chassis - Active Edge Card Reader (optional)
This section describes how to remove and replace the active edge card reader.

24.1 Removal
Perform the following steps to remove the active edge card reader and its bezel.

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Disconnect the cables connected to the active edge card reader. For the cabling details,
refer to the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual
(TM-000539-001A).
4. Remove the active edge card reader by removing the two rear mounting screws that secure
the reader to the holder bracket.
5. Remove the reader holder mounting bracket by removing the two mounting screws that
fasten the holder to the terminal.
6. After the active edge card reader is removed, stand in the front of the terminal and perform
the following steps to remove the active edge card reader bezel.
a. Remove the two mounting screws that secure the bezel mounting bracket to the
bezel.
b. Remove the bezel mounting bracket.
c. Remove the four mounting screws that secure the bezel to the fascia.
d. Remove the reader bezel from the fascia.

Figure 24-1 Removing the Active Edge Card Reader

1 Active edge card reader bezel
2 Active edge card reader bezel mounting bracket
3 Mounting screws for the card reader bezel
 4 Mounting screws for the mounting bracket
5 Active edge card reader
6 Mounting screws for the card reader
7 Mounting screws for the holder mounting bracket
8 Holder mounting bracket

24.2 Replacement

Reverse the steps in Section 24.1 to replace the active edge card reader.

Section 25
Top Chassis - Dip Card Reader (optional)
This section describes how to remove and replace the dip card reader.

25.1 Removal

Perform the following steps to remove the dip card reader and its bezel

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Disconnect the cables connected to the dip card reader. For the cabling details, refer to the
Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-
000539-001A).
4. Remove the dip card reader assembly from the terminal by removing the three mounting
screws.
5. Remove the one mounting screw that secure the dip card reader into the reader cover.
6. Remove the dip card reader from the reader cover.
7. Remove the four mounting screws that secure the dip card reader bezel to the terminal
8. Slightly disengage the dip card reader bezel away from the terminal.

Figure 25-1 Removing the Dip Card Reader

1 Dip card reader bezel
2 Dip card reader
3 Dip card reader bezel mounting screws (total 3)
4 Dip card reader cover
5 Dip card reader cover mounting screw (total 1)
6 Dip card reader bezel mounting screws (total 4)

25.2 Replacement

Reverse the steps in Section 25.1 to replace the dip card reader.

Section 26
Lower Door - ActivDispense Bezel
This section describes how to remove and replace the activdispense bezel.
26.1 Removal

Perform the following steps shown in Figure 26-2 to remove the activdispense bezel.

1. Open the lower door to the fully extended service position, refer to the procedures in Figure
26-1.

Figure 26-1 Opening the Lower Door

1 Insert the key and turn it clockwise

2 Open the lower door to the fully service position

2. Remove the 6 mounting screws that secure the activdispense bezel to the mounting
bracket.
3. Remove the mounting bracket and bezel away the lower door.
4. The entire bezel could be disassemble from the lower door. Carefully remove the indicator
lens from the bezel.

Figure 26-2 Removing the Activdispense Bezel

 1 Activdispense bezel
2 Activdispense bezel mounting bracket
3 Mounting screws (total 6)
4 Bezel tab
5 Dispenser indicator

26.2 Replacement

Reverse the steps in Section 26.1 to replace the activdispense bezel.

Section 27
Lower Door - Lower Door, Lower Door Service Lock, Cash Pocket
Camera (optional)
This section describes how to remove and replace the entire lower door assembly, lower door
service lock and the optional cash pocket camera module.

27.1 Removal

Perform the following steps to remove the lower door assembly.

1. Open the lower door to the fully extended service position, refer to the procedures in Figure
26-1.
2. Remove the five mounting screws that fasten the lower door assembly to the terminal.
3. Remove the lower door assembly from the terminal.

Figure 27-1 Removing the Lower Door Assembly

1 Lower door
 2 Mounting screws (quantity 5)

Step 4 describes how to remove the lower door service lock and its component.

4. Remove the mounting screw that secure the following components:

o Star washer
o Guide bracket
o Mounting nut
o Service lock
o Service key

Figure 27-2 Removing the Lower Door Service Lock

 1 Service key 4 Guide bracket
2 Service lock 5 Mounting screw
3 Mounting nut 6 Star washer

If the cash pocket camera is installed in the lower door, perform the following steps to
remove the camera assembly.

5. Disconnect the camera USB and power logic cables.

6. Remove the four mounting screws that secure the camera module to the lower door.
7. Remove the camera module from the lower door.
8. Separate the camera module from the mounting bracket.

Figure 27-3 Removing the Cash Pocket Camera (optional)

 1 Camera module
2 Mounting bracket
3 Mounting screws (quantity 4)

27.2 Replacement

Reverse the steps in Section 27.1 to replace the lower door assembly and its service lock.

Section 28
Safe- ActivDispense
28.1 Removal

This section describes how to remove and replace the acivedispense and its slide.

28.1.1 Removing the ActivDispense

Perform the following steps to remove the dispenser from the terminal.

NOTE

Someone from the institution should have already opened the safe door to remove currency,
deposits, and cassettes before the terminal is serviced.

1. Open the top chassis to the fully extended service position (Figure 5-1).
2. Perform either the functional shut-down procedure (Section 4.3) or the electrical shut-down
procedure (Section 4.5).
3. Close the top chassis.
4. Open the safe door. Refer to the Diebold 5500 Front-load Lobby Cash Dispenser Operating
Guide (TP-821763-001A).
5. Pull the blue dispenser handle outward and fully extend to the outside of the safe.
6. If present, remove the two mounting screws that secure the shipping bracket to the
dispenser.
7. Remove the shipping bracket from the dispenser.
8. Make a note of the cable connections to the dispenser control CCA.
9. Disconnect the USB and power cables from the dispenser control CCA.

Figure 28-1 Disconnecting the Cables from the ActivDispense

 1 DC power cable connector
2 USB cable connector
3 Mounting screws (quantity 2)
4 Shipping bracket

The following steps describe how to remove the dispenser of the ActivDispense.

10. Remove the front two mounting screws and washers.

11. Do not remove the two rear mounting screws located the tail place of the dispenser, but
cautiously pull and drag the dispenser forwarding along the arrow direction shown in Figure
28-2, then to disengage the dispenser out of the two rear mounting screws.
12. Grasp the front of the dispenser weldment and pull it towards you to separate it from the
mounting tray.

Figure 28-2 Removing the ActivDispense

 1 Front mounting screws (quantity 2)
2 Front mounting washers (quantity 2)
3 Rear mounting screws for fastening the dispenser into the tray
4 Pushing and lifting the dispenser along the arrow direction

WARNING

An empty dispenser with no cassettes weighs approximately 102.5 pounds (46.5

kilograms) and can cause bodily injury or equipment damage if it falls. To prevent
bodily injury or damage to the equipment, use care when handling the dispenser.

13. Carefully remove the dispenser from the terminal.

28.1.2 Replacing the ActivDispense

Perform the following steps to replace the dispenser in the terminal.

1. Slide the mounting tray completely into the terminal until it latches securely in place.
2. Reverse the steps in Section 28.1.1 to install the dispenser in the terminal.

NOTE

Make sure the dispenser release tabs engage the locking tabs on the mounting tray.

If necessary, extend the dispenser out of the terminal far enough to access the
relocking aid and use a screwdriver in the relocking aid to help move the dispenser
forward until the release tabs engage the locking tabs.

3. Reset the communication security after the dispenser is installed.

Figure 28-3 Using the Dispenser Relocking Aid

1 Dispenser module
2 Screwdriver
3 Re-locking aid
4 Mounting tray locking tab
5 Dispenser release tab
28.2 ActivDispense Slides and Cable Retractor

28.2.1 Removing the Dispenser Slides and Cable Retractor

Perform the following steps to remove the dispenser slides and cable retractor.

1. Remove the dispenser (Section 28.1.1).

2. Slide the tray out of the safe. Remove the ground cable from the tray, if present.
3. Remove the three mounting screws that secure the tray to the slides.
4. Lift the tray up and away from the dispenser install kit.

Figure 28-4 Removing the Mounting Tray

1 Mounting screws (three each side)

2 Mounting tray
5. Access the cable retractor inward in the safe. Remove the mounting screws (total two) that
secure the cable retractor end connectors (upper one and lower one) into the safe.
6. Remove the cable retractor.

Figure 28-5 Removing the Cable Retractor

1 Mounting screw for upper end connector of the cable retractor

2 Cable retractor
3 Mounting screw for lower end connector of the cable retractor

7. Push the slides back into the slides mounting bracket.

8. Perform the following steps to remove the entire activdispense slides with its mounting
bracket from the safe:
a. Keep the mounting screws not removed (item 1 in Figure 28-6).
b. Remove the mounting screw (item 7 shown in the Figure 28-6).
c. Loosen but do not remove the screw 2 in Figure 28-6.
d. Push the slides inward to the middle position, then disengage the slides up.
e. Lift and remove the slides out of the slides mounting bracket.

Figure 28-6 Removing and Replacing the ActivDispense Slides with Mounting Bracket
 Item Part Number Description
1 --- Keep the mounting screws not removed
2 --- Loosening the screw but not remove
3 49-252827-000B Slide mounting bracket (right)
4 49-218237-000A Slide (right)
5 49-218238-000A Slide (left)
6 49-252826-000B Slide mounting bracket (left)
7 --- Removing the screw

9. After the slides with its mounting bracket is removed from the safe, perform the following
steps to remove the slide from the mounting bracket.
a. Remove the mounting screws (2 screws each side) that secure the slides to the
mounting bracket.
b. Disengage the slides away the mounting bracket, and lift the slides up out of the
mounting bracket.

Figure 28-7 Removing the ActivDispense Slides from the Mounting Bracket
 1 Slides
2 Mounting screws (each two)

28.2.2 Replacing the Dispenser Slides and Cable Retractor

Reverse the steps in Section 28.2.1 to replace the dispenser slides.

Section 29
Safe - Basic Alarm Interface (BAI)
This section describes how to remove and replace the basic alarm interface.

29.1 Removal

Perform the following steps to remove the basic alarm interface.

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Close the top chassis.
4. Open the safe door. Refer to the Diebold 5500 Front-load Lobby Cash Dispenser Operating
Guide (TP-821763-001A).
5. Refer to the steps described in the Section 28 to remove the dispenser, the cable retractor
and the slides of the activdispense.
6. After the dispenser is removed, disconnect the cables that are connected to the basic alarm
interface. For the cabling details, refer to the Diebold 5500 Front-load Lobby Cash
Dispenser On-site Cabling Repair Manual (TM-000539-001A).
7. Remove the two mounting screws that secure the basic alarm interface to the CCA
mounting bracket.
8. Remove the basic alarm interface from the mounting bracket.
9. Remove the switch bracket by removing the two mounting nuts, then unplug the switch out
of the bracket.
10. After the BAI and the switch bracket are removed, remove the two mounting screws and
two mounting washers that secure the BAI mounting bracket to the safe.
11. Remove the BAI mounting bracket from the safe.

Figure 29-1 Removing the Basic Alarm Interface

1 Mounting nuts for switch mounting bracket
2 Switch mounting bracket
3 Switch
4 Mounting screws for BAI mounting bracket
 5 BAI mounting bracket
6 Mounting washers for BAI mounting bracket
7 BAI
8 Mounting screws for BAI

29.2 Replacement

Reverse the steps in Section 29.1 to replace the basic alarm interface.

Section 30
Safe - Lower Control Card (LCC)
This section describes how to remove and replace the LCC.

30.1 Removal

Perform the following steps to remove the LCC.

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Close the top chassis.
4. Open the safe door. Refer to the Diebold 5500 Front-load Lobby Cash Dispenser Operating
Guide (TP-821763-001A).
5. Refer to the steps described in the Section 28 to remove the dispenser, the cable retractor
and the slides of the activdispense.
6. After the dispenser is removed, disconnect the cables that are connected to the LCC. For
the cabling details, refer to the Diebold 5500 Front-load Lobby Cash Dispenser On-site
Cabling Repair Manual (TM-000539-001A).
7. Remove the four mounting screws that secure the CCA cover into the safe.
8. Remove the CCA cover.
9. Remove the four mounting screws that secure the LCC into the safe.
10. Remove the LCC from the safe.
11. Remove the switch bracket by removing the two mounting nuts, then unplug the switch out
of the bracket.

Figure 30-1 Removing the LCC

1 Mounting screws for CCA cover (4)
2 Switch mounting bracket
3 Switch
4 Mounting nuts for switch mounting bracket (2)
 5 Mounting screws for LCC (4)

30.2 Replacement

Reverse the steps in Section 30.1 to replace the LCC.

Section 31
Safe - DC/DC (Smart Power) Module with Battery and Line Filter
This section describes how to remove and replace the DC/DC or smart power module.

31.1 Removal

Perform the following steps to remove the smart power or DC/DC power modules, battery and line
filter.

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Close the top chassis.
4. Open the safe door. Refer to the Diebold 5500 Front-load Lobby Cash Dispenser Operating
Guide (TP-821763-001A).
5. Refer to the steps described in the Section 28 to remove the dispenser, the cable retractor
and the slides of the activdispense.
6. After the dispenser is removed, disconnect the cables that are connected to the DC/DC
power module, battery and line filter. For the cabling details, refer to the Diebold 5500
Front-load Lobby Cash Dispenser On-site Cabling Repair Manual (TM-000539-001A).
7. Remove the four mounting screws that secure the DC/DC power module to the safe.
8. Remove the DC/DC power module from the safe.

Figure 31-1 Removing the DC/DC (Smart Power) Power Module

 1 Mounting screws for the smart power module
2 Smart power module

Perform Step 9 and Step 10 to remove the power module battery.

9. Remove the two mounting screws that secure the power module battery with bracket to the
safe.
10. Remove the power module battery and mounting bracket from the safe.

Figure 31-2 Removing the Power Module Battery

 1 Mounting nuts (quantity 2)
2 Mounting bracket
3 Power module battery

Perform the following steps to remove the line filter assembly.

11. Remove the mounting screw (item 3 in Figure 31-3), meanwhile, loosen but do not remove
the three mounting screws (item 2 in Figure 31-3).
12. Remove the line filter assembly including the line filter module with its mounting bracket
from the safe.
13. Remove the two mounting nuts with washers (item 7 and item 8) that make the line filter
module fastened into the mounting bracket with lock latches.
14. Remove the two bigger mounting nuts (item 5) that fasten the line filter module to the
mounting bracket.
15. Remove the line filter module from its mounting bracket.

Figure 31-3 Removing the Line Filter Assembly

 1 Line filter mounting bracket
2 Mounting nuts for fastening the line filter assembly with mounting bracket
3 Mounting screw for fastening the line filter assembly with mounting bracket
4 Line filter module
5 Mounting nuts for fastening line filter module to the mounting bracket
6 Lock latches
7 Washers for fastening line filter module to the mounting bracket
8 Mounting nuts for fastening line filter module to the mounting bracket

Perform the following steps to remove the smart power module mounting tray from the safe.

16. Remove the front two mounting screws and washers that secure the mounting tray to the
safe.
17. Keep the two rear mounting screws not removed, meanwhile, drag and pull the mounting
tray along the arrow direction shown in the Figure 31-4 to remove it out of the safe.
 Figure 31-4 Removing the Mounting Tray

1 Mounting screws (quantity 2)

2 Mounting washers (quantity 2)
3 Mounting tray
4 Keep the two rear screws not removed

31.2 Replacement

Reverse the steps in Section 31.1 to replace the power module, the power battery and the line filter
assembly.

Section 32
Safe Door - Door Sensor Interface
This section describes how to remove and replace the safe door sensor interface.

32.1 Removal
Perform the following steps to remove the safe door sensor interface.

1. Open the top chassis to the fully extended service position.

2. Perform either the functional shut-down procedure (Section 4.3) or the devices-only shut-
down procedure (Section 4.1).
3. Close the top chassis.
4. Open the safe door. Refer to the Diebold 5500 Front-load Lobby Cash Dispenser Operating
Guide (TP-821763-001A).
5. Disconnect the cables that are connected to the door sensor interface. For the cabling
details, refer to the Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair
Manual (TM-000539-001A).
6. Remove the three mounting screws that secure the door sensor interface to the safe door.
7. Remove the door sensor interface from the safe door.

Figure 32-1 Removing the Door Sensor Interface

1 Door sensor interface

2 Mounting screws (quantity 3)

32.2 Replacement
Reverse the steps in Section 32.1 to replace the safe door sensor interface.

Appendix A
Related Documentation
The following documents provide additional information about the terminal. Refer to the Diebold
web site at http://www.diebold.com/ficcdsvdoc/ to order these documents.

Table A-1 Service Manuals

Manual Title Part Number
ActivDispense On-site Repair Manual TM-000536-
001A
All-in-One Dual Core Processor and Display Module (Standard) On-site Repair TM-000526-
Manual 001A
All-in-One Dual Core Processor and Display Module (Advanced) On-site Repair TM-000513-
Manual 001A
Encrypting PIN Pad (EPP7) On-site Repair Manual TM-000485-
001B
One-sided Graphical Thermal Receipt Printer (49-240508-000A) On-site Repair TM-000527-
Manual 001A
Motorized Card Reader (with chip, 123) On-site Repair Manual TM-000034-
001C
ActivDispense Media Supply Cassette On-site Repair Manual TM-000529-
001A
ActivDispense Plastic Divert/Retract Cassette On-site Repair Manual TM-000528-
001A
Lower Control Card Repair Manual TM-000544-
001A
Upper Control Card Repair Manual TM-000545-
001A
Diebold 5500 Front-load Lobby Cash Dispenser Installation Instructions TM-000537-
001A
Diebold 5500 Front-load Lobby Cash Dispenser On-site Cabling Repair Manual TM-000539-
001A