Partes AFD

Advanced Function Dispenser
On-site Repair Manual

Copyright ©Diebold, Incorporated
TM-000001-001F PD 5173
August 2010
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.
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Document History
Document
Number Date Remarks
TM-000001-001A 3/2003 Initial release
TM-000001-001B 10/2004 Revised
TM-000001-001C 4/2005 Revised
TM-000001-001D 5/2006 Revised (updated information throughout manual, added RoHS parts
information)
TM-000001-001E 5/2010 Revised
TM-000001-001F 8/2010 Revised Table 6-3
Section 1
Introduction
This document discusses on-site repair for the Advanced Function Dispenser (AFD). The Advanced
Function Dispenser is a presenter type dispenser. It picks media from dispense cassettes, stacks the
media, and transports the media stack to the consumer. The media stack is presented to the consumer
through a slot in the terminal fascia.
The main components of the AFD are:
• Picker module(s)
• Stacker module
• Transport module
• CCA
The dispenser may contain from one to five cassettes depending upon the configuration options.
Occasionally, media may be diverted from the picking process or retracted from the presentation slot.
Diverted or retracted media is retained in the divert/retract cassette. For more information about media
cassettes refer to the Advanced Function Dispenser Media Supply Cassette On-site Repair Manual (TM-
000027-001C). For more information about the divert/retract cassette refer to the Advanced Function
Dispenser Divert/Retract Cassette On-site Repair Manual (TM-000052-001C).
The following sections describe the major components that make up the advanced function dispenser
(Figure 1-1).
Figure 1-1 Advanced Function Dispenser Components
1 Transport module
2 Stacker module
3 Control CCA
4 Picker modules
1.1 Transport Module
The transport module is mounted on top of the stacker module. The function of the transport module is to
move the media stack out through the fascia opening to the consumer. After the stacker module lifts the
media stack into the transport path, the transport module push plate and belts move the media stack to
the front of the transport module until it blocks the exit sensor. When the exit sensor is blocked, the push
plate stops, the shutter opens, and the belts push the media stack through the fascia opening to the
consumer. The transport module holds the media in this position until it is removed by the consumer. If
the consumer does not remove the media, the transport module can retract the media stack. Once
retracted, the media stack can be held in escrow or deposited into the retract compartment of the
divert/retract cassette.
There are four versions of the transport module, two front-load version for terminals supplied from the
fascia side, and two rear-load versions for terminals supplied from the non-fascia side.
Figure 1-2 Transport Modules

1 620 mm short, rear-load
2 720 mm long, front-load
3 625 mm short, front-load
4 860 mm long, rear-load
5 620 mm short, rear-load, open
6 625 mm short, front-load, open
1.2 Stacker Module
The stacker module (Figure 1-3) arranges the picked media into a neat stack and lifts the media stack
into the transport. The transport module push plate and belts move the media stack to the front of the
transport module to a calculated position just short of the exit sensor. The gate opens, the push plate and
belts move the stack to a position just inside the fascia opening. Finally the belts push the media stack
through the fascia opening to the consumer. If any questionable media is encountered, a divert door
slides over the stacker tray and diverts the media into the divert compartment of the divert/retract
cassette.
Figure 1-3 Stacker Module
1 Stacker module
1.3 Picker Module
The picker module (Figure 1-4) removes media from the dispense cassette. The major field replaceable
parts that make up the picker module are described in the following sections (Figure 1-5 ).
Figure 1-4 Picker Module
1 Picker module
Feed Shaft Assembly

The feed shaft assembly consists of three plastic feed wheels secured to a feed wheel shaft. Each feed
wheel has a small raised section molded into its circumference. The raised section contains a high friction
rubber surface which picks a media note as the feed wheel rotates and places it in contact with the media
stack.
Stripper Wheel and Fender Assembly

The stripper wheel shaft is clutched so that it will rotate only one-way. The stripper wheel is a high friction
rubber wheel that prevents more than one note of media from being dispensed by the feed wheels. The
wheel is mounted on the end of the stripper wheel shaft and is pressed against the center feed wheel by
the media cassette with a preset force. In the event that the feed wheels pick more than one note from
the media stack, the extra notes will be held back (stripped) by the non-rotating stripper wheel. A fender is
used to cover the stripper wheel to prevent damage to the media by the stripper wheel.
Figure 1-5 Picker Module Major Components
1 Motor coupling 6 Take-away wheel shaft

2 Keyboard assembly 7 Take-away wheel
3 Feed shaft 8 Stripper wheel
4 Feed wheel assembly 9 Stripper wheel shaft
5 Take-away springs 10 Stripper wheel fender
Take-away Wheel Assembly

The take-away wheel shaft can rotate freely in both directions. The take-away wheel, made of rubber,
provides the friction required to drive the note once it is past the stripper wheel. The take-away wheel is
mounted on the end of the take-away shaft and is pressed against the center feed wheel by the media
cassette with a preset force. Once the raised drive sections of the feed wheels lose contact with the
picked note, the take-away wheel forces the note against the recessed rubber section of the center feed
wheel, supplying the friction to drive the note past the stripper wheel.
Take-away Springs
The take-away springs have small, bi-directional rollers that help the outside feed wheels drive the note
out of the feed channel. They are spring loaded against the two outside feed wheels and operate on the
same principal as the take-away wheel. When the note enters between the take-away springs and the
feed wheels, the force of the take-away springs against the feed wheels provides the friction for the feed
wheels to drive the note out of the feed channel.
Stepper Drive Motor

The stepper drive motor (Figure 1-6) is a DC motor used to rotate the feed shaft assembly. The motor is
connected to the feed shaft through a motor coupling.
Keyboard Assembly
The keyboard assembly (Figure 1-6) is a keyboard used to sense cassette presence and configuration.
When a cassette is inserted into the dispenser, buttons on the cassette depress corresponding buttons on
the keyboard assembly. From the buttons depressed, the dispenser determines how the cassette is
configured. The cassette can be configured for media denomination, height, and thickness; or the
cassette can be configured for denomination and currency code. The keyboard also detects if media
parity is required. The keyboard is not field replaceable. If it fails, you must replace the picker module.
Figure 1-6 Picker Stepper Motor
1 Keyboard assembly
2 Stepper drive motor
1.4 Circuit Card Assembly (CCA)
The dispenser control CCA is located on the side of the dispenser. The CCA contains control circuitry and
firmware. The firmware controls the dispenser operations and contains all the dispenser routines to
handle USB communications, mispicks, come-alongs, short notes, doubles, and long notes, as well as
the motor drive pulse sequence commands. The firmware also reads the currency cassette information to
perform and complete a dispense operation. If you replace the AFD control CCA, then you must reset the
AFD communication. If the AFD control CCA is replaced, the sensors must be manually recalibrated.
Refer to Section 2.6 to recalibrate the sensors.
Section 2
Troubleshooting and Diagnostics
Troubleshooting and diagnostics for the advanced function dispenser will be handled through the
terminal's resident interface diagnostic software.
2.1 AFD Communication
There is a USB communication security feature in the terminal processor software. This feature prevents
unauthorized computers from commanding secure terminal devices to operate, such as the advanced
function dispenser (AFD). AFD communication security is set at the factory during assembly. Refer to
Service Considerations (Section 2.2) to determine status, when to update, and when to set the AFD
communication.
2.2 Service Considerations
To determine the status of the AFD communication, perform the steps in Section 2.3
If you perform either of the following repairs, you must update the AFD communication (Section 2.4).
• Replace the processor hard disk drive

• Replace the processor motherboard
If you perform either of the following repairs, you must set the AFD communication (Section 2.5).
• Replace the AFD control CCA

• Replace both the processor hard disk drive and the processor motherboard
2.3 How to Determine Advanced Function Dispenser Communication Status
The AFD communication can have three statuses. Do the following action for the status displayed using
the appropriate diagnostics.
Status Action
OK None required
Communication warning, one of the signatures does not match Update communication (Section 2.4)
Device communication not trusted Set communication (Section 2.5)
Locate "Security result", then read the status in the Status column.
Component Status Action

Security OK None (Section 2.3)
result Communication warning, one of the signatures does Update AFD communication
not match (Section 2.4)
Device communication not trusted Set AFD communication (Section
2.5)
The Set AFD Communication screen appears with the message "AFD communications are secure".
2.4 Updating the Advanced Function Dispenser Communication
To update the AFD communication perform the following steps:
1. Select Advanced Function Dispenser from the appropriate diagnostics.

2. In the Module Test and Commands field select Set AFD Communication.
3. According to the appropriate diagnostics click the Update AFD Communication button.
4. Return to the Status and Tests windows and run the AFD self test to ensure proper operation.
5. Return the terminal to service.
2.5 Setting the Advanced Function Dispenser Communication
To set the AFD communication perform the following steps:
1. Access the AFD by opening the terminal chest door.

2. Select Advanced Function Dispenser from the appropriate diagnostics.
3. In the Module Test and Commands field select Set AFD Communication.
4. As instructed on the Set AFD Communication screen press and hold the AFD CCA Boot Load
button (S1) (Figure 7-1) while clicking the on-screen Set AFD Communication button.
NOTE
Keep the CCA Boot Load button depressed until the communication set is completed.
When communication set is completed, you will see the message "Read Security
Configuration completed" .
5. As instructed on the Set AFD Communication screen, press the AFD CCA Reset button (S2)
(Figure 7-1).
6. Return to the Status and Tests windows and run the AFD self test to ensure proper operation.
7. Return the terminal to service
2.6 Sensor Recalibration
When using AFD firmware version 1.30 and above, transport and stacker sensors must be calibrated if
any of the following modules are replaced.
• Transport
• Stacker
• Control CCA
Sensors are calibrated using the appropriate diagnostics.
NOTE
Before calibrating the sensors, the sensors must be clean and unblocked.
Section 3
Removing the Main Modules
This section describes how to remove and replace field serviceable dispenser modules. The procedures
in this section are based upon the assumption that the advanced function dispenser has already been
removed from the terminal.
This section describes how to remove the four major modules from the dispenser.
3.1 Control Circuit Card Assembly (CCA)
NOTE
• When you replace the AFD control CCA, you must set the AFD communication (Section
2.5).
• When the AFD control CCA is replaced, the sensors must be manually recalibrated. Refer
to Section 2.6 to recalibrate the sensors.
3.1.1 Removal
1. Loosen, but do not remove, the two screws that secure the CCA cover to the stacker module
(Figure 3-1).
2. Slide the CCA cover so that the keyholes align with the screw heads.
3. Remove the CCA cover.
4. Remove cables from CCA connectors. Note cable routing and tag cables if necessary to aid in
CCA installation.
5. Remove the two screws that secure the CCA (Figure 3-2).
CAUTION
6. ESD sensitive components. Use proper ESD handling and storing procedures when
removing the dispenser CCA. Failure to comply may result in permanent damage to the
CCA and operational problems with the dispenser.
7. Rotate the CCA clockwise around the bottom right keyhole standoff, until the top right standoff
aligns with the keyhole. Remove the CCA by tilting the top of the CCA out of the top keyhole
standoff and lifting it off the bottom keyhole standoff.
3.1.2 Replacement
1. To replace the dispenser CCA, reverse the removal procedure.
CAUTION
2. The old CCA cover (49-2000642-000B) can not be used with a stacker with a ribbed cam.
The new CCA cover (49-2000642-000C) can be used with a stacker with either a ribbed or
not ribbed cam.
3. Set the AFD communication (Section 2.5).
4. Make sure that transport and stacker sensors are clean and unblocked.
5. Refer toSection 2.6 to recalibrate the sensors. Sensor calibration data is saved to the control
CCA. When transports are replaced, they may not work until a calibrate command is issued.
Figure 3-1 Removing the CCA Cover

1 Control CCA cover mounting screws (2)
Figure 3-2 Removing the Dispenser CCA
1 Control CCA mounting screws (2)

2 CCA keyhole and mounting standoff (top right keyhole standoff)
3 CCA notch and mounting standoff (bottom right keyhole standoff)

3.2.1 Removal
1. Remove the divert cassette, if present.

2. Remove control CCA cover (refer to Section 3.1.1).
3. Remove the transport module connector from J3 on the CCA (Figure 3-3).
4. On front-load transport modules, unscrew the standoff that secures the gate drive flip gear, then
remove the gear.
5. Remove the four screws (M3-6) that secure the transport.
6. Push the transport from the rear to loosen the stacker-to-transport push plate timing belt.
7. Remove the transport-to-stacker intermodule timing belt and the stacker-to-transport push plate
timing belt.
8. Position the cam so that the stacker tray is in the full down position and the divert tray is over the
stacker tray.
9. Lift the transport at the front and rear and remove it (Figure 3-4).
3.2.2 Replacement
1. To replace the transport module, reverse the removal procedure (Section 3.2.1) and verify the
following alignments:
o Stacker tray is in the full down position with the divert tray over the stacker tray.
o Divert cassette is not present in the module
o On rear-load transports, the finger of the stacker module gate actuator sets in the notch
of the transport module gate actuator
o Edge of the transport frame rests in the groove of the divert door
o Transport mounting holes are on the outside of the stacker module
o Make sure that the stacker frame pins (standoffs) are set in the slots in the transport.
o On front-load transports, make sure that index marks on the gate drive flip gear align with
the arrows on the rack gears (Figure 3-3).
o Make sure that connector J3 is properly seated (Figure 3-5).
NOTE
Lubricate the transport module according to the planned maintenance guide lines.
2. Make sure all sensors on the transport and stacker are clean and unblocked.
3. After replacing the transport, the exit sensor emitter and detector are new, and the stack sensor
detector is new. These sensors must be manually recalibrated. Refer toSection 2.6 to recalibrate
the sensors. Sensor calibration data is saved to the control CCA. When transports are replaced,
they may not work until a calibrate command is issued.
Figure 3-3 Transport Mounting Screws, CCA Connector, and Stacker Push Plate Belt
1 Transport module front mounting screw (2)
2 Inter-module transport-to-stacker timing belt (210-tooth rear-load, or 124-tooth front-load)
3 Transport module rear mounting screw (2)
4 Gear, 30-tooth (front-load only)
5 Standoff, M4 (front-load only)
6 Transport cable connector
7 Cam
8 Stacker-to-transport push plate timing belt (37-tooth on 860 mm rear-load and front-load, or 45-tooth on
620 mm rear-load)
Figure 3-4 Removing the Transport Module

Figure 3-5 Transport and Stacker Module Connector
1 Connector not properly seated

2 Connector properly seated
3.3 Stacker Module
3.3.1 Removal
1. Remove all cassettes if any are present.
2. Remove the transport module (Section 3.2.1).
3. Disconnect the stacker CCA connections as follows:
o J2 - stacker module cable connector
o J1 - brushless DC motor connector. Compress the connector lock latch, then pull the
connector up.
NOTE
Tag connectors J10 and J13 to avoid confusion before removing them from the
CCA.
o J10 - push plate stepper motor connector
o J13 - cam stepper motor connector
4. Lift the non-geared side of the top transport module drive shaft out of the recess in the frame and
lower it to remove the tension on vertical timing belts (Figure 3-6).
5. Remove the three vertical timing belts from the top transport module drive shaft assembly, then
replace the drive shaft assembly in the stacker frame.
6. Remove the shipping screw that secures the stacker to the first picker channel, if present.
7. Release the stacker module latch springs, then slide the stacker module toward the rear and lift
up to remove it (Figure 3-7).
NOTE
To avoid damage when transporting the stacker module, secure the top drive shaft to the
paddle shaft.
3.3.2 Replacement
1. To replace the stacker module, reverse the removal procedure.

2. Make sure that connector J2 is properly seated (Figure 3-5).
3. Verify proper movement of the vertical drive belts. Check that the lower shaft floats freely and the
springs operate properly.
4. If the stacker cam contains a rib to aid service in turning of the cam (49-201057-000B) then the
CCA cover with clearance hole for cam ribs (49-200642-000C) is necessary. Using a cover
without the clearance hole with a ribbed cam will cause improper operation.
5. Make sure all sensors on the transport and stacker are clean and unblocked.
6. After the stacker is replaced, the stacker sensor emitter is new and must be manually
recalibrated. Refer to Section 2.6 to recalibrate the sensor.
Figure 3-6 Transport Module Top Drive Shaft

1 Non-geared side of top transport module drive shaft assembly
Figure 3-7 Stacker Module Latch Springs
1 Latch spring (2), push inward to release
3.4 Picker Module

3.4.1 Removal
To remove either picker module one or two (picker module one is immediately under the stacker module),
it is necessary to remove the CCA, the transport module, and the stacker module. The transport module
and stacker module may be removed as one piece. Step 1 through Step 7 in Section 3.4.1.1 describes
how to do this. For instructions to remove the transport module only, refer to Section 3.2.1. For
instructions to remove the stacker module, refer to Section 3.3.1.
Picker module three, four, and five can be removed without removing the CCA, the transport module, or
the stacker module (refer to Picker Modules Three, Four, and Five Section 3.4.1.2).
3.4.1.1 Picker Module One and Two
1. Remove the control CCA (Section 3.1).

2. Remove the spring and spring holder block from both sides of the lower transport drive shaft
assembly (Figure 3-8).
3. Lift the lower transport drive shaft assembly to free the bearing flanges, then remove the shaft
assembly.
4. Set the shaft assembly aside in a safe place and secure the vertical timing belts to prevent
damage to them.
5. Remove the shipping screw that secures the stacker to the first picker channel, if present.
Release the stacker module latch springs (Figure 3-7) and slide the stacker and transport unit
toward the rear.
6. Remove the shipping screw(s) attached to the picker that you wish to remove.
7. Remove the transport and stacker from the picker module stack.
8. Remove the picker motor cable and the keyboard cable. Save them for use on the replacement
module.
9. On the picker module you wish to remove, release the latch springs (Figure 3-9) and slide the
module toward the rear to disengage it from the pins in the module below it, then lift the module
from the stack.
3.4.1.2 Picker Modules Three, Four, Five and Six
The following steps describe how to remove picker modules three, four, five and six without removing the
CCA, the transport module, or the stacker module.
1. Remove the spring and spring holder block from both sides of the lower transport drive shaft
assembly (Figure 3-8).
2. Lift the lower transport drive shaft assembly to free the bearing flanges, then remove the shaft
assembly.
3. Set the shaft assembly aside in a safe place and secure the vertical timing belts to prevent
damage to them.
4. Disconnect the keyboard cables (Figure 3-10) for picker modules three, four, five and six from the
CCA and remove them from the cable route dressing.
5. Disconnect the motor cables (Figure 3-11) for picker modules three, four, five and six then
remove them from the cable route dressing.
6. Remove the shipping screw(s) attached to the picker that you wish to remove.
7. On the picker module above the one you wish to remove, release the latch springs and slide the
module toward the rear to disengage it from the pins in the module below it (Figure 3-9).
8. Lift the picker module(s) with stacker, CCA, and transport from the stack.
9. On the picker module you wish to remove, release the latch springs and slide the module toward
the rear to disengage it from the pins in the module below it, then lift the module from the stack.
Figure 3-8 Lower Transport Drive Shaft Spring and Spring Holder Block
1 Spring
2 Spring holder block
3 Lower transport drive shaft assembly
4 Vertical timing belts
Figure 3-9 Picker Module Latch Springs, Guide Pins, and Motor Cable Routing for Modules One and Two
1 Picker module pins 4 Picker module two
2 Picker module guides 5 Latch spring
3 Picker module one 6 Picker motor cable connectors
Figure 3-10 Picker Module Three, Four, Five and Six Keyboard Cable Routing
1 Picker module three keyboard connector 5 Picker module three
2 Picker module four keyboard connector 6 Picker module four
3 Picker module five keyboard connector 7 Picker module five
4 Picker module six keyboard connector 8 Picker module six
Figure 3-11 Picker Module Three, Four, Five and Six Motor Cable Routing
1 Picker module six connector
2 Picker module five connector
3 Picker module four connector
4 Picker module three connector
5 Picker module three
6 Picker module four
7 Picker module five
8 Picker module six
3.4.2 Replacement
1. If required, attach a motor cable and keyboard cable to the picker module before assembling the
picker stack.
2. Assemble the picker module stack. Make sure that the picker module guides and pins are
properly engaged (Figure 3-9).
3. If removed separately, attach and secure the transport and stacker module assemblies.
4. Route the motor cables for picker modules one and two as shown in Figure 3-9.
5. Attach the control CCA (Section 3.1.1).
6. Connect the motor cables from picker modules one and two to the CCA.
7. Route and connect the motor cables from picker modules three, four, five and six. Start with the
module that is farthest from the CCA (Figure 3-11).
8. Route and connect the keyboard cables. Start with the module that is farthest from the CCA
(Figure 3-10).
9. Install the vertical timing belts and the lower transport drive shaft assembly, springs, and spring
holder blocks (Figure 3-8). Make sure that the belts are not twisted and are in the pulleys. Make
sure that the wide section of the spring is down.
10. Install the CCA cover. Make sure that no cables are pinched behind the cover.
3.5 Dispenser Module-level Parts List
NOTE
The restriction of hazardous substances (RoHS) directive regulates the use of certain materials in
electrical and electronic equipment placed in the European Economic Area (EEA) market starting
July 1, 2006. Some parts listed in this document have both RoHS compliant and RoHS non-
compliant part numbers.
• RoHS compliant parts can be used in any equipment regardless of the equipment's
location or placed-in-market date.
• RoHS non-compliant parts can only be used in equipment located outside the EEA market
or in equipment placed in the EEA market before July 1, 2006.
Figure 3-12 Dispenser Module-level Parts

WARNING
For continued protection against fire hazard, replace fuses with only the same type and rating as
the original factory installed fuse.
Table 3-1 Rear-load Module-level Parts (860 mm and 620 mm)

Item Description Part Number Quantity
Rear- Rear- Rear-load
RoHS Non- RoHS load 860 load 620 620 mm
[6]
Compliant Compliant mm mm Open
Figure 3-12
1 Transport assembly, rear-load 49-200595- 49-211434- 1 -- --
860 mm 000A 000A
1 Transport assembly, rear-load 49-202795- 49-211436- -- 1 --
620 mm 000A 000A
1 Transport assembly, front-load 49-202775- 49-211435- -- -- --
720 mm 000A 000A
625 mm 000A 000A
625 mm 000A 000B
2 Transport assembly, short, N/A 49-211437- -- -- --
front-load, 625 mm, open 000C
2 Transport assembly, short, N/A 49-211436- -- -- 1
rear-load, 620 mm, open 000B
3 Stacker assembly 49-200596- 49-211433- 1 1 1
000A 000A
4 Gear, flip, 30-tooth, module 49-202778- 49-202778- -- -- --
one, spur, (720 mm transport) 000A 000A
5 Standoff, self-clinching M04.0- 29-009595- 29-009595- -- -- --
0.70-0.20 000A 000A
[1] [2] [2]
6 Picker assembly (aggressive) 49-200000- 49-211432- 1 to 6 1 to 6 1 to 4
000A 000A
[1] [2] [2]
6 Picker assembly 1.5 N/A 49-225262- 1 to 6 1 to 6 1 to 4
(aggressive) 000A
[1] [2] [2]
6 Picker assembly (non- 49-200000- 49-211432- 1 to 6 1 to 6 1 to 4
aggressive) 000B 000B
7 Belt, timing, 45-tooth 49-018410- 49-018410- -- 1 1
000E 000E
7 Belt, timing, M03.0 37-tooth, 49-018410- 49-018410- 1 -- --
transport to push plate 000D 000D
[5]
8 CCA, dispenser 49-204271- 49-208102- 1 1 1
000B 000H
9 Cover, drive side (CCA) 49-200642- 49-200642- 1 1 1
000C 000C
10 Screw, machine, pan head, 29-014330- 29-016399- 6 6 6
M3.0-0.50-06.0, philips, nylock 000B 000B
11 Screw, machine, pan head 19-033427- 29-016253- 2 2 2
M04.0-0.70-006.0, philips 6 000F 000A
(CCA mounting)
[2] [2] [2]
12 Cable, power, motor, (picker 49-202781- 49-207979- 1-3 1-3 1-3
positions 1 and 2 and 3) 385 000A 000A
mm
[2] [2]
13 Cable, power, motor, picker 49-202781- 49-207979- 1-3 1-3 1
(positions 4 and 5 and 6) 670 000B 000B
mm
14 Cable, motor (795 mm) N/A 49-207979- -- 1 --
000D
[2]
15 Cable, logic, dispenser N/A 49-211110- -- 1 --
keyboard, (picker position 6) 000E
695 mm
[2] [2]
16 Cable, logic, dispenser 49-200009- 49-211110- 1 1 --
keyboard, (picker position 5) 000D 000D
575 mm
[2] [2] [2]
17 Cable, logic, dispenser 49-200009- 49-211110- 1 1 1
keyboard, (picker position 4) 000C 000C
455 mm
[2] [2] [2]
keyboard, (picker position 3) 000B 000B
345 mm
[2] [2] [2]
19 Cable, logic, dispenser 49-200009- 49-211110- 1-2 1-2 1-2
keyboard, (picker positions 1 000A 000A
and 2) 160 mm
20 Spring, compression 29-014430- 29-016412- 2 2 2
000B 000A
21 Shaft, transport idler assembly 49-202790- 49-202790- 1 1 1
000A 000A
22 Holder, spring 49-204031- 49-204031- 2 2 2
000A 000A
23 Belt, timing, M3.0P (vertical 49-204013- 49-204013- 3 3 3
transport, one or two picker 000B 000B
modules)
transport, three picker 000C 000C
modules)
transport, four picker modules) 000D 000D
23 Belt, timing, M3.0P (vertical 49-204013- 49-204013- 3 3 --
transport, five picker modules) 000E 000E
23 Belt, timing, M3.0P, dual N/A 49-204013- -- 3 --
urethane (6-high AFD) 000G
24 Belt, timing, M3.0P, 124 tooth 29-008375- 29-008375- -- -- --
00AE 00AE
24 Belt, timing, 210 tooth, 49-018410- 49-018410- 1 1 1
transport to stacker 000F 000F
Not Fuse, F1, CCA (4A, 125V, 19-040585- 19-040585- 1 1 1
[3] [4]
shown slow blow) 000E 000E
[4]
Not Fuse, F2, CCA (5A, 125V, 19-040586- 19-040586- 1 1 1

[3] [4]
shown standard blow) 000A 000A
[4]
[1]
A dispenser can have from one to six picker assemblies
[2]
Quantity depends upon the number of picker assemblies in the dispenser
[3]
For continued protection against fire hazard, replace fuses with only the same type and rating as the
original factory installed fuse.
[4]
See Figure 7-1
[5]
When you replace the dispenser CCA, set the AFD communication (Section 2.5).
[6]
Open transports are not backward compatible with prior AFD modules.
Table 3-2 Front-load Module-Level Parts (720 mm and 625 mm)

Front- Front- Front-load
RoHS Non- RoHS load 720 load 625 625 mm
[6]
Compliant Compliant mm mm Open
Figure 3-12
1 Transport assembly, rear- 49-200595- 49-211434- -- -- --
load 860 mm 000A 000A
1 Transport assembly, rear- 49-202795- 49-211436- -- -- --
load 620 mm 000A 000A
1 Transport assembly, front- 49-202775- 49-211435- 1 -- --
load 720 mm 000A 000A
1 Transport assembly, front- 49-207955- 49-211437- -- 1 --
load 625 mm 000A 000A
1 Transport assembly, front- 49-207955- 49-211437- -- -- --
load 625 mm 000A 000B
2 Transport assembly, short, N/A 49-211437- -- -- 1
front-load, 625 mm, open 000C
2 Transport assembly, short, N/A 49-211436- -- -- --
rear-load, 620 mm, open 000B
3 Stacker assembly 49-200596- 49-211433- 1 1 1
000A 000A
4 Gear, flip, 30-tooth, module 49-202778- 49-202778- 1 1 1
one, spur, 720 mm transport 000A 000A
5 Standoff, self-clinching 29-009595- 29-009595- 1 1 1
M04.0-0.70-0.20 000A 000A
[1] [2] [2]
6 Picker assembly (aggressive) 49-200000- 49-211432- 1 to 6 1 to 6 1 to 4
000A 000A
[1] [2] [2]
6 Picker assembly 1.5 N/A 49-225262- 1 to 6 1 to 6 1 to 4
(aggressive) 000A
[1] [2] [2]
6 Picker assembly (non- 49-200000- 49-211432- 1 to 6 1 to 6 1 to 4
aggressive) 000B 000B
7 Belt, timing, 45-tooth 49-018410- 49-018410- -- -- --
000E 000E
7 Belt, timing, M03.0 37-tooth, 49-018410- 49-018410- 1 1 1
transport to push plate 000D 000H
[5]
8 CCA, dispenser 49-204271- 49-208102- 1 1 1
000B 000H
9 Cover, drive side (CCA) 49-200642- 49-200642- 1 1 1
000C 000C
10 Screw, machine, pan head, 29-014330- 29-016399- 6 6 6
M3.0-0.50-06.0, philips, 000B 000B
nylock
11 Screw, machine, pan head 19-033427- 29-016253- 2 2 2
M04.0-0.70-006.0, philips 6 000F 000A
(CCA mounting)
[2] [2] [2]
12 Cable, power, motor, (picker 49-202781- 49-207979- 1-3 1-3 1-3
positions 1 and 2 and 3) 385 000A 000A
mm
[2] [2] [2]
13 Cable, power, motor, picker 49-202781- 49-207979- 1-3 1 1
(positions 4 and 5 and 6) 670 000B 000B
mm
14 Cable, motor (795 mm) N/A 49-207979- -- -- --
000D
15 Cable, logic, dispenser N/A 49-211110- -- -- --
keyboard, (picker position 6) 000E
695 mm
[2] [2]
16 Cable, logic, dispenser 49-200009- 49-211110- 1 1 --
keyboard, (picker position 5) 000D 000D
575 mm
[2] [2] [2]
keyboard, (picker position 4) 000C 000C
455 mm
[2] [2] [2]
keyboard, (picker position 3) 000B 000B
345 mm
[2] [2] [2]
19 Cable, logic, dispenser 49-200009- 49-211110- 1-2 1-2 1-2
keyboard, (picker positions 1 000A 000A
and 2) 160 mm
20 Spring, compression 29-014430- 29-016412- 2 2 2
000B 000A
21 Shaft, transport idler 49-202790- 49-202790- 1 1 1
assembly 000A 000A
22 Holder, spring 49-204031- 49-204031- 2 2 2
000A 000A
23 Belt, flat, dual urethane 49-204013- 49-204013- 3 3 3
(vertical transport, one or two 000B 000B
picker modules)
(vertical transport, three 000C 000C
picker modules)
(vertical transport, four picker 000D 000D
modules)
23 Belt, flat, dual urethane 49-204013- 49-204013- 3 3 --
(vertical transport, five picker 000E 000E
modules)
23 Belt, timing M3.0 P, dual N/A 49-204013- -- -- --
urethane (6-high AFD) 000G
24 Belt, timing, M3.0P, 124-tooth 29-008375- 29-008375- 1 1 1
00AE 00AE
24 Belt, timing, 210-tooth, 49-018410- 49-018410- -- -- --
transport to stacker 000F 000F
Not Fuse, F1, CCA (4A, 125V, 19-040585- 19-040585- 1 1 1
[3] [4]
shown slow blow) 000E 000E
[4]
Not Fuse, F2, CCA (5A, 125V, 19-040586- 19-040586- 1 1 1

[3] [4]
shown standard blow) 000A 000A
[4]
[1]
A dispenser can have from one to six picker assemblies. Opteva 500 terminals can only have one to 4
pickers.
[2]
Quantity depends upon the number of picker assemblies in the dispenser
[3]
For continued protection against fire hazard, replace fuses with only the same type and rating as the
original factory installed fuse.
[4]
See Figure 7-1
[5]
When you replace the dispenser CCA, set the AFD communication (Section 2.5).
[6]
Open transports are not backward compatible with prior AFD modules.
Section 4
Transport Module Repair
The procedures in this section assume that the dispenser has been removed from the terminal.
CAUTION
Wear a properly grounded anti-static wrist strap when handling CCAs. Use an anti-static carrier to
store CCAs before installation and after removal.
Before removing cable ties or disconnecting cables as part of a procedure, take note of cable
routing or bundling and cable tie locations. If cables are not routed or secured properly, they may
become damaged and affect terminal operation.
NOTE
If you replace the AFD control CCA, then you must reset the AFD communication. If the AFD
control CCA is replaced, the sensors must be manually recalibrated. Refer to Section 2.6 to
recalibrate the sensors.
4.1 Fascia Plate
4.1.1 Removal
1. Remove the transport module from the dispenser assembly (Section 3.2.1).
2. Remove the lead-through indicator from the fascia plate as follows:
a. Remove the two push-in fasteners that secure the lead-through indicator by pushing the
fastener shaft from the front side and then removing it and its insert from the back (Figure
4-2).
b. Remove the lead-through wires and the exit sensor detector wires from the fascia plate,
cut wire ties where required.
3. Remove the two fascia plate extension tension springs (Figure 4-3).
4. Slide the gate actuator so the lock tabs are centered in the fascia slots.
5. Remove the three fascia plate mounting screws that secure the fascia plate to the transport
module.
6. Slightly spring the fascia plate away from the gate lock and remove it from the front.
4.1.2 Replacement
1. Grease the gate with Diebold lubricant (part number 16-003082-000A) before assembly.
Figure 4-1 Lubrication
1 Diebold lubricant (16-003082-000A)
2. To replace the fascia plate, reverse the removal procedure.
Figure 4-2 Removing the Lead-through Indicator and Exit Sensor

1 Lead-through and exit sensor wires
2 Push-in fasteners
3 Lead-through indicator
4 Exit sensor
5 Gate actuator
6 Fascia plate
7 Lock tabs
Figure 4-3 Removing the Fascia Plate
1 Fascia plate mounting screws at sides of transport module (M4-0.7)

2 Fascia plate extension tension spring
3 Fascia plate mounting screw underneath transport module (M3-6)
4.2 Gate
4.2.1 Removal
1. Remove the fascia plate (Section 4.1.1).

2. Remove the two threaded standoffs that secure the gate (Figure 4-4).
NOTE
Use a 5mm (3/16 inch) socket to remove the threaded standoffs.
3. Remove the cable guide. Cut cable ties as required. Slide the cable guide toward the fascia, then
lift it out of the chassis. On a 625 mm front-load transport remove the two screws then remove the
cable guide.
4. Move the gate or the gate actuator so that the bar bushing is in the wide part of the slot in the
gate actuator.
CAUTION
5. The gate may be easily deformed. Do not spring and deform the gate when you remove it.
Failure to comply may result in a defective gate that will not contact the gate switch.
6. Remove the gate from the transport module.
7. Remove the screw, threaded standoff, and the gate bushings from the gate bar. Note the
orientation of the gate bushing for use in replacement.
NOTE
Use a 3/16 inch socket to remove the threaded standoffs that secure the gate bushings.
4.2.2 Replacement
To replace the gate, reverse the removal procedure.
NOTE
Observe the following points during replacement:
• Install the front gate bar bushings before attaching the gate and note the bushing
orientation.
• Make sure that the threaded standoffs are through the hole in the bushings.
• Make sure that the gate switch actuator properly engages the switch.
• Verify that the actuator can move properly to open and close the gate.
Figure 4-4 Removing the Gate

1 Cable guide 5 Gate bushing
2 Switch 6 Threaded standoff (2), gate bushing
3 Gate 7 Bar bushing
4 Threaded standoff (2), gate mounting 8 Screw (2)
4.3 Exit Sensor Bracket
4.3.1 Removal
1. Remove the fascia plate (Section 4.1.1).

2. Remove the gate (Section 4.2.1).
3. If necessary, cut ties that secure the wires of the exit sensor detector.
4. Lift the exit sensor bracket at its rear to free the rear retaining fingers, then slide it toward the rear
to free the front retaining fingers (Figure 4-5).
5. Lift the exit sensor bracket and remove it toward the front of the transport.
6. Remove the push-in fasteners that secure the sensor, then angle the sensor so it can be
removed from the top of the bracket. Note the orientation and keying of the sensor.
Figure 4-5 Removing the Exit Sensor Detector

1 Exit sensor detector 4 Front finger of bracket
2 Push-in fasteners 5 Rear finger of bracket
3 Exit sensor bracket 6 Sensor plate
4.3.2 Replacement
1. Be sure to observe the orientation and keying of the sensor.

2. To replace the exit sensor bracket, reverse the removal procedure.
3. For old sensor plates, make sure that tie wraps are oriented with the knuckle down under the
sensor plate.
4.4 Stacker Sensor Bracket (rear-load 860 mm, 625 mm and 720 mm front-load)
4.4.1 Removal
1. Cut ties that secure the stacker sensor cable (Figure 4-6)
2. Remove the two push-in fasteners that secure the stacker sensor.
3. Remove the stacker sensor and move the cable out of the way.
4. Remove the two screws that secure the sensor bracket.
5. On the rear-load 860 mm transport, lift the stacker sensor bracket at the gate switch side, then
push the bracket toward the opposite side to provide removal clearance. Lift the other side of the
bracket.
On a front-load transport, perform the same step but lift the side opposite the gate switch first.
6. Lift the bracket approximately 45°, then move the bracket to remove the hooks from the transport
frame).
4.4.2 Replacement
To replace the stacker sensor bracket, reverse the removal procedure.
Figure 4-6 Disconnecting the Stacker Sensor Bracket
1 Push-in fasteners
2 Stacker detector sensor and cable
3 Mounting screw, (M3-6)
4 Stacker sensor bracket
5 Bracket hooks
4.5 Stacker Sensor Bracket (rear-load 620 mm)
4.5.1 Removal
1. Cut ties that secure the stacker sensor cable.

2. Remove the two push-in fasteners that secure the stacker sensor (Figure 4-7).
3. Remove the stacker sensor and move the cable out of the way.
4. Remove the nut holding the gate switch and remove the gate switch.
5. Remove the two screws (M3-6) that secure the sensor bracket.
6. Lift the stacker sensor bracket at the side opposite the gate switch, then push the bracket toward
the gate switch side to provide removal clearance. Lift the other side of the bracket.
7. Lift the bracket approximately 45° to enable removing the hooks from the transport frame, then
remove the bracket (Figure 4-8).
4.5.2 Replacement
To replace the stacker sensor bracket, reverse the removal procedure.
Figure 4-7 Removing the Stacker Bracket (620 mm rear-load)
1 Push-in fasteners 5 Hex nut

2 Detector 6 Sensor bracket mounting screw
3 Sensor bracket mounting screw 7 Sensor bracket
4 Sensor cable harness (gate switch)
Figure 4-8 Removing the Stacker Sensor Bracket (rear-load 620 mm)
1 Sensor bracket
2 Sensor bracket hooks
4.6 Gate Actuator
4.6.1 Removal
1. Remove the exit sensor bracket (Section 4.3).

2. Remove the stacker sensor bracket (Section 4.4, rear-load 860 mm and front-load or Section 4.5,
rear-load 620 mm).
3. Remove the 14-tooth pulley from the transport drive shaft assembly (Figure 4-9), rear-load
transports only.
4. Remove the 274-tooth timing belt, rear-load transports only.
5. Remove the two mounting screws that secure the gate actuator.
6. Slide the actuator away from the gate.
7. Remove the four bar bushings. Note the orientation of the bushings for replacement.
8. Align the removal brackets with the threaded mounting standoffs, then remove the gate actuator.
NOTE
On a rear-load 620 mm transport, the removal brackets are on the opposite side from the
rear-load 860 mm transport.
9. Remove the two nylon screw glides from the gate actuator, if present.
4.6.2 Replacement
NOTE
• During replacement, do not damage the gate actuator switch.

• Make sure the 14-tooth pulley lock tab is fully engaged.
To replace the gate actuator, reverse the removal procedure.
Figure 4-9 Removing the Gate Actuator (rear-load 620 mm shown)

1 Gate actuator bracket 5 274-tooth timing belt (rear-load only)
2 Gate actuator nylon screw glide 6 Threaded standoff
3 Mounting screws 7 Gate actuator pulley (14-tooth) (note pulley lock tab)
4 Bar bushings 8 Removal brackets
4.7 Transport Rails and Pinch Roller Removal
4.7.1 Removal
1. Remove the fascia (Section 4.1).

2. Remove the gate (Section 4.2).
4. Remove the stacker sensor bracket (Section 4.4 or Section 4.5).
5. Remove the gate actuator (Section 4.6).
6. To remove the outer rails, squeeze the rails or use a small flat blade screwdriver (or similar
object) to disengage the rail hooks from the transport frame (Figure 4-10). Note the orientation of
the rails for replacement.
7. To remove the center rails, perform the following steps:
a. Squeeze the rails or use a small flat blade screwdriver (or similar object) to disengage the
rail hooks from the transport frame.
b. Lift the rail away from the frame.
c. From the underside of the frame, remove the hook that secures the anti-skew finger
(Figure 4-11), then slide the rail toward the center of the frame until the exit pinch roller is
in the cutout.
d. Remove the rail from the frame.
e. Remove the exit pinch roller and its shaft.
4.7.2 Replacement
To replace the transport rails, reverse the removal procedure.
Figure 4-10 Removing Transport Rails
1 Transport outer rail (2)

2 Rail hooks
3 Transport center rail (2)
Figure 4-11 Transport Center Rail and Anti-skew Finger

1 Center rail anti-skew finger
2 Pinch roller
3 Pinch roller shaft
4.8 Transport Belts (rear-load)
4.8.1 Removal
1. Remove the fascia plate (Section 4.1).

4. Remove the stacker sensor bracket (Section 4.4 or Section 4.5).
5. Remove the gate actuator (Section 4.6). This step is optional, but recommended.
6. Remove the bearing from the end of the transport exit drive shaft assembly (Figure 4-12).
7. Slide the transport exit drive shaft assembly into the frame, toward the center, far enough to
remove the belts.
8. Remove the belts through the guides in the push plate face.
9. Remove the transport drive shaft assembly as follows:
a. Remove the transport cable harness from the cable clamp(s) nearest the transport drive
shaft bearing to provide access to the large cut out.
b. Move the transport drive shaft assembly to the large cut out.
c. Rotate the transport drive shaft assembly away from the frame to provide clearance for
the bearing shoulder through the cut out.
NOTE
On the rear-load 860 mm transport, hold the push plate timing belt away from the
drive shaft assembly to make removal easier.
4.8.2 Replacement
NOTE
Make sure that the belts are threaded through the guides in the push plate face and are not
twisted.
To replace the transport belts, reverse the removal procedure.
Figure 4-12 Removing Belts from the Transport Exit Drive Shaft and Transport Drive Shaft
1 Transport exit drive shaft assembly 4 Transport belts

2 Bearing 5 Transport belt in push plate guides
3 Transport drive shaft assembly 6 Large cut out in frame for bearing removal
4.9 Transport Belts (front-load)
4.9.1 Removal

4. Remove the stacker sensor bracket (Section 4.4, rear-load 860 mm and front-load or Section 4.5,
rear-load 620 mm).
6. Release the latch and remove the 18-tooth pulley from the transport drive shaft assembly (Figure
4-13).
7. Remove the bearing from the transport drive shaft assembly.
8. Remove the transport drive shaft assembly by rotating it away from the frame to provide
clearance for the bearing shoulder through the cut out.
9. Remove the push plate drive shaft as follows:
a. Release the latch and remove the 14-tooth pulley from the push plate shaft assembly.
b. Remove the e-ring that secures the shaft.
c. Slide the shaft toward the center of the frame to remove the shaft from the belts.
10. Remove the belts through the guides in the push plate face (Figure 4-14).
11. Remove the transport exit drive shaft assembly from the frame.
4.9.2 Replacement
To replace the front-load transport belts, reverse the removal procedure.
NOTE
Make sure that the belts are threaded through the guides in the push plate face and are not
twisted.
Figure 4-13 Removing the Belts from the Transport Drive Shaft (front-load)
1 14-tooth pulley 4 Bearing

2 Push plate drive shaft assembly 5 18-tooth pulley
3 E-ring 6 Transport drive shaft assembly
Figure 4-14 Removing the Transport Drive Shaft (front-load)
1 Transport exit drive shaft assembly

2 Transport belts
3 Belt guides in push plate
4.10 Push Plate, Push Plate Face, and Timing Belt
4.10.1 Removal

5. Remove the transport belts and shafts (Section 4.8 or Section 4.9).
6. Release the lock, then remove the 14-tooth pulley (Figure 4-16) from the push plate assembly
shaft. Remove the belt from the idler pulley.
7. Remove the e-ring that retains the push plate assembly shaft.
8. Slide the push plate assembly shaft toward the center of the frame to free the bearing.
9. Remove the push plate assembly shaft and bearing from the frame.
NOTE
On rear-load transports, the push plate shaft assembly may be easier to remove if you
remove the transport harness from the cable clips near the shaft bearing.
10. Slide the push plate with belt out of the frame (Figure 4-17).
11. Remove the timing belt from the push plate (274-tooth belt on 620mm rear-load transports, 529-
tooth belt on the 860mm rear-load transports, and 445-tooth belt on front-load transports).
12. Pry the two plastic lock tabs in the push plate to disengage them from the push plate face (Figure
4-15).
13. Remove the push plate face. Note the orientation for replacement.
4.10.2 Replacement
To replace the push plate, the push plate face, and belts, reverse the removal procedure.
NOTE
After completing the replacement procedure, grease the frame where the push plate makes
contact.
Figure 4-15 Removing the Push Plate Face
1 Push plate
2 Push plate face
3 Push plate lock tab
Figure 4-16 Removing the Push Plate Shaft Assembly

1 14-tooth pulley 4 Transport belts
2 Push plate assembly shaft 5 Screw (M3-6)
3 E-ring (M5) 6 Belt idler bushing
Figure 4-17 Removing the Push Plate and Belt Assembly
1 Push plate timing belt

2 Push plate and timing belt shown upside down
3 Push plate and belt assembly
4.11 Transport Harness
4.11.1 Removal

2. On rear-load transports only, remove the stacker sensor bracket (Section 4.4, rear-load 860 mm
or Section 4.5, rear-load 620 mm).
3. Remove the exit sensor detector from the exit sensor bracket.
4. Remove the exit sensor emitter from the center sensor transport rail (Figure 4-18).
5. Cut all cable ties that secure the harness. Note the location of all cable ties for replacement.
6. For rear-load 860 mm and front-load transports, remove the screw (M3-14) that secures the
actuator switch.
For rear-load 620 mm transports, remove the nut (M3) that secures actuator switch. Slide the
switch off its locating stud.
7. Remove the cable from all cable clips. Note the routing of the cable and stacker sensor breakout
for replacement.
NOTE
To help during replacement, place a non-permanent mark on the frame to indicate the
position of the stacker sensor breakout.
4.11.2 Replacement
1. Place the stacker sensor detector harness breakout in position first when installing the transport
harness.
2. To replace the transport cable harness, reverse the removal procedure.
Figure 4-18 Removing the Transport Cable Harness

1 Exit sensor emitter in center transport rail
2 Non-permanent mark on frame to position the stacker sensor breakout
4.12 Divert Deflector (Rear-load Only)
4.12.1 Removal
1. Remove the transport module from the dispenser (Section 3.2).
NOTE
Be careful when removing the divert deflector because the end latches and top center
hooks are very susceptible to breakage.
NOTE
The static brushes (49-204047-000A) that were attached to the divert door, have been
removed from stacker modules that are at Revision 7 or above and relocated to the
transport.
2. Release the end latches from the frame and move the deflector assembly away from the latch
slots (Figure 4-19).
3. Carefully work the deflector upward to disengage the center hooks.
4. Rotate the deflector assembly away from the frame to remove it.
4.12.2 Replacement
To replace the divert deflector, reverse the removal procedure.
NOTE
Make sure that the alignment fingers are under the frame. After replacement, operate the push
plate to verify proper operation and that there is no interference.
Figure 4-19 Removing the Divert Deflector
1 Divert deflector
2 One center hook
3 Fingers with rounded angles
4.13 Transport Module Illustrated Parts Lists
The illustrations and tables in this section list transport module service parts.
NOTE
• The restriction of hazardous substances (RoHS) directive regulates the use of certain
materials in electrical and electronic equipment placed in the European Economic Area
(EEA) market starting July 1, 2006. Some parts listed in this document have both RoHS
compliant and RoHS non-compliant part numbers.
NOTE
Sheet metal that is gold in color is probably not RoHS compliant. Sheet metal that is silver/blue in
color probably is RoHS compliant.
Table 4-1 Transport Modules

Part Number
RoHS Non- RoHS
Description Compliant Compliant Refer to...
Transport, 860mm long rear-load 49-200595-000A 49-211434-000A Figure 4-20 and Table
4-2
Transport, 620mm short rear-load 49-202795-000A 49-211436-000A Figure 4-21 and Table
4-3
Transport, 620mm short rear-load, N/A 49-211436-000B Figure 4-22 and Table
OPEN 4-4
Transport, 720mm long front-load 49-202775-000A 49-211435-000A Figure 4-23 and Table
4-5
Transport, 625mm short front-load 49-207955-000A 49-211437-000A Figure 4-24 and Table
4-6
Transport, 625 mm, short front-load, N/A 49-211437-000C Figure 4-25 and Table
OPEN 4-7
Figure 4-20 Transport Module, Long, Rear-load 860mm (49-211434-000A)

Table 4-2 Transport Module Parts, Long Rear-load 860 mm (49-211434-000A)
Part Number
RoHS Non- RoHS
Item Description Compliant Compliant Quantity
Figure 4-20
1 Bracket, sensor, 860 mm transport 49-200621-000A 49-200621- 1
000A
2 Clamp, cable 29-014447-000A 29-014447- 14
000A
3 Presenter, sensor cable harness (lead-through 49-200638-000B 49-207982- 1
indicator and gate switch included) 000B
[1]
Detector 49-201054-000A 49-201054-
000A
[1]
Emitter 49-200653-000A 49-200653-
000A
[1]
Switch (gate) 49-202780-000A 49-202780-
000A
[1]
Lead-through indicator 49-202788-000A 49-202788-
000B
4 Screw, self tapping, pan head, M3-6, philips, nylock 29-014333-000C 29-016368- 3
000C
5 Actuator, gate, 860 mm transport 49-200625-000F 49-200625- 1
000G
6 Bracket, exit sensor 49-200618-000E 49-200618- 1
000E
7 Washer, flat M4, reg 19-033445-000A 19-056810- 2
000A
8 Standoff, self clinching, M3 29-009281-000A 29-009281- 2
000A
9 Bushing, gate bar 49-200679-000B 49-200679- 4
000B
10 Gate, rear-load, security 49-200605-000B 49-200605- 1
000E
11 Spring, extension 19-033359-000A 29-016411- 2
000A
12 Shaft, presenter pinch roller 49-202777-000A 49-202777- 2
000A
13 Roller, exit pinch 49-202764-000A 49-202764- 2
000A
14 Fastener, pnl, push-in, roundhead 29-012227-000E 29-012227- 6
000E
15 Plate, Fascia 49-200604-000F 49-200604- 1
000H
16 Screw, machine, pan head, M4-8.0, philips, nylon 29-014331-000C 29-016337- 2
000C
17 Standoff, self clinching, M03.0-0.50-006.0 29-009105-000D 29-009105- 2
000D
18 Bushing, gate bar, large N/A 49-207969- 2
000A
19 Screw, machine, panhead, M3-8, philips 29-014330-000A 29-016399- 3
000B
20 Bushing, idler, ID 5.4 OD 10.3 49-201087-000A 49-201087- 1
000A
21 Shaft, transport exit drive assembly 49-200615-000C 49-200615- 1
000C
22 Belt, flat, 0.250, semi-stretch 29-008482-000J 29-008482- 3
000J
23 Cabling guide 49-202761-000B 49-202761- 1
000B
24 Screw, self tapping, pan head, M3-14, 29-014333-000B 29-016368- 1
000B
25 Screw, machine, SEMS, pan hd, square dome, M3-8 29-013932-000B 29-016398- 1
000B
26 Nut, SEM, M3, helical conical 29-009778-000A 29-016303- 1
000A
27 Pin, dump, open 39-009224-000C 39-009224- 1
000C
28 Shaft, transport drive assembly 49-200630-000B 49-200630- 1
000C
29 Bearing, ball, radial, M6 49-201066-000A 49-201066- 3
000A
30 Clamp, cable, round, 0.32 diameter, sanp-in 29-014447-000A 29-014447- 14
000A
31 Pulley, timing belt, M03.0P,14-groove 49-202752-000A 49-202752- 3
000A
32 Face, push plate, rear-load 49-200599-000C 49-200599- 1
000C
33 Molding, push plate 49-007828-000E 49-007828- 1
000E
34 Shaft, push plate assembly 49-202753-000A 49-202753- 1
000A
35 Ring, retainer, type E, M5 19-038411-000A 29-016284- 1
000A
36 Platen, presenter, 860mm, transport 49-200598-000A 49-200598- 1
000A
37 Deflector, divert 49-202783-000A 49-202783- 1
000B
38 Belt, timing 3mm, 274-tooth 29-008375-00AF 29-008375- 1
00AF
39 Brushes, anti-static (Transport Rev 10 and above have 49-204047-000B 49-204047- 2
brushes, Rev 9 or below do not) 000B
40 Belt, timing, M3, 529-tooth 29-008375-00AG 29-008375- 1
00AG
41 Rail, non-sensor, 860 mm transport 49-200611-000C 49-200611- 1
000C
42 Rail, with sensor, 860 mm transport 49-200610-000C 49-200610- 1
000C
43 Rail, outer, 860 mm transport 49-200608-000B 49-200608- 2
000B
44 Pulley, timing belt, 14-tooth/20-tooth, double 49-202762-000A 49-202762- 1
000A
45 Ring, retaining, external, M3-2 19-035288-000A 29-016276- 1
000A
[1]
Part of harness assembly
Figure 4-21 Transport Module, Short, Rear-load 620mm (49-211436-000A)

Table 4-3 Transport Module Parts, Short, Rear-load 620 mm (49-211436-000A)
Part Number
RoHS Non- RoHS
Figure 4-21
1 Clamp, cable, round, snap-in, 0.9 29-014446-000A 29-014446- 2
000A
2 Presenter, sensor cable harness (lead-through 49-200638-000D 49-207982- 1
indicator indicated) 000D
3 Screw, self tapping, pan head, M3-6, philps, Nytorq 29-014333-000C 29-016368- 3
000C
4 Actuator, gate, 620 mm transport 49-202792-000D 49-202792- 1
000E
000E
6 Belt, timing 274-tooth 29-008375-00AF 29-008375- 1
00AF
000A
8 Ring, retaining, external, M3.2 19-035288-000A 29-016276- 1
000A
000B
10 Standoff, self clinching, M3 x 10, roundhead 29-009281-000A 29-009281- 2
000A
11 Gate 49-200605-000B 49-200605- 1
000E
12 Bushing, gate bar, large 49-207969-000A 49-207969- 2
000A
000A
14 Shaft, presenter, pinch roller 49-202777-000A 49-202777- 2
000A
000A
16 Grease, Rheolube 362HB 16-003082-000A 16-003082- A/R
000A
17 Fascia 49-200604-000F 49-200604- 1
000H
18 Fastener, pnl, push-in, roundhead, nylon 29-012227-000E 29-012227- 6
000E
19 Screw, machine, pan head, M4-8.0, philips, Nylock 29-014331-000C 29-016337- 2
000C
20 Standoff, self clinching, M03.0-0.50 29-009105-000D 29-009105- 2
000D
21 Screw, machine, panhead, M03.0-0.50-006.0 29-014330-000A 29-016399- 3
000B
22 Bushing, idler 49-201087-000A 49-201087- 1
000A
23 Cabling guide 49-202761-000B 49-202761- 1
000B
24 Shaft, exit drive 49-200615-000C 49-200615- 1
000C
25 Belt, flat, 0.250, semi-stretch 29-008482-000H 29-008482- 3
000H
26 Brush, anti-static (Transport Rev 10 and above have 49-204047-000B 49-204047- 2
27 Rail, sensor, 620 mm transport 49-202796-000A 49-202796- 1
000A
28 Rail, non-sensor, 620 mm transport, center 49-202797-000A 49-202797- 1
000A
29 Rail, transport, outer, 620 mm transport 49-202793-000A 49-202793- 2
000A
30 Screw, machine, SEMS, pan head/square dome 29-013932-000B 29-016398- 1
000B
31 Nut, SEM, hex/conical M3-.50 29-009778-000A 29-016303- 2
000A
32 Pin, dump, open 39-009224-000C 39-009224- 1
000C
000C
34 Bearing, ball, radial M6 bore 49-201066-000A 49-201066- 3
000A
35 Belt, timing, 375-tooth 29-008375-000Q 29-008375- 1
000Q
36 Divert deflector 49-202783-000A 49-202783- 1
000B
37 Pulley, timing belt, 14-tooth, M03.0P 49-202752-000A 49-202752- 3
000A
000C
000E
000A
41 Retainer, type E, M5 19-038411-000A 29-016284- 1
000A
42 Platen, presenter, 620 mm transport 49-202798-000A 49-202798- 1
000A
43 Clamp, cable, round, snap-in, 0.32 29-014447-000A 29-014447- 12
000A
000A
Figure 4-22 Transport Module, Short, Rear-load 620mm, Open (49-211436-000B)

Table 4-4 Transport Module Parts, Short, Rear-load 620 mm, Open (49-211436-000B)
Part Number
RoHS Non- RoHS
Figure 4-22
1 Bracket, sensor, 620 mm transport, Open 49-202794-000C 49-202794- 1
000C
2 Screw, self tapping, pan head, M3-6, philps, 29-014333-000C 29-016368- 3
Nytorq 000C
3 Actuator, gate, 620 mm transport, Open N/A 49-220610- 1
000A
000E
5 Divert deflector N/A 49-202783- 1
000B
6 Pulley, timing belt, 14-groove, M03.0P 49-202752-000A 49-202752- 3
000A
7 Belt, timing 274-tooth 29-008375-00AF 29-008375- 1
00AF
8 Brush, anti-static 49-204047-000B 49-204047- 2
000B
9 Rail, non-sensor, 620 mm transport, center 49-202797-000A 49-202797- 1
000A
10 Rail, sensor, 620 mm transport 49-202796-000A 49-202796- 1
000A
11 Rail, transport, outer, 620 mm transport 49-202793-000A 49-202793- 2
000A
12 Ring, retaining, external, M3.2 19-035288-000A 29-016276- 1
000A
000A
000B
15 Standoff, self clinching, M03.0-0.50 29-009105-000D 29-009105- 2
000D
000A
17 Spring, helical, extension 19-033359-000A 29-016411- 2
000A
18 Fastener, pnl, push-in, roundhead, nylon 29-012227-000E 29-012227- 6
000E
19 Fascia N/A 49-200604- 1
000H
20 Presenter, sensor cable harness (lead-through 49-200638-000D 49-207982- 1
indicator indicated) 000D
21 Gate N/A 49-200605- 1
000E
000A
000A
24 Screw, machine, panhead, M03.0-0.50-006.0, 29-014330-000A 29-016399- 3
philips, Nylock 000B
25 Bushing, idler 49-201087-000A 49-201087- 1
000A
26 Screw, machine, pan head, M4-8.0, philips, 29-014331-000C 29-016337- 2
Nylock 000C
27 Standoff, self clinching, M3 x 10, roundhead, 29-009281-000A 29-009281- 2
blind 000A
28 Cabling guide 49-202761-000B 49-202761- 1
000B
29 Clamp, cable, round, snap-in, 0.9 diameter, 29-014446-000A 29-014446- 2
snap-in, with release 000A
30 Nut, SEM, hex/conical M3-.50 29-009778-000A 29-016303- 2
000A
31 Screw, machine, SEMS, pan head/square dome 29-013932-000B 29-016398- 1
000B
32 Pin, dump, open 39-009224-000C 39-009224- 1
000C
000C
34 Belt, flat, 0.250, semi-stretch 29-008482-000H 29-008482- 3
000H
000C
000A
37 Clamp, cable, round, snap-in, 0.32 diameter, 29-014447-000A 29-014447- 12
snap-in, with release 000A
000Q
000E
40 Shaft, push plate 49-202753-000A 49-202753- 1
000A
000C
42 Platen, presenter, 620 mm transport N/A 49-202798- 1
000A
43 Retainer, type E, M5 19-038411-000A 29-016284- 1
000A
Not Grease, Rheolube 362HB 16-003082-000A 16-003082- A/R
Shown 000A
Figure 4-23 Transport Module, Long, Front-load 720mm (49-211435-000A)

Table 4-5 Transport Module, Long, Front-Load 720 mm (49-211435-000A) Parts
RoHS Non- RoHS
Compliant Compliant
Figure 4-23
000A
2 Actuator, gate, 720 mm transport 49-202766-000E 49-202766- 1
000E
000E
4 Presenter, sensor cable harness (lead-through 49-200638-000C 49-207982- 1
indicator indicated) 000C
5 Screw self tapping, panhead, philips, nytorq, M3-6 29-014333-000C 29-016368- 3
000C
6 Platen, presenter, 720 mm, transport 49-202769-000A 49-202769- 1
000D
7 Rail, outer, transport, 720 mm transport 49-202772-000B 49-202772- 2
000B
8 Screw, machine, pan head, M3-.05-6.0, philips, 29-014330-000A 29-016399- 3
nylock 000B
9 Bushing, idler 49-201087-000A 49-201087- 1
000A
000A
000D
000A
000A
000A
000A
16 Fascia 49-200604-000F 49-200604- 1
000H
17 Fastener, pnl, push-in, roundhead 29-012227-000E 29-012227- 6
000E
18 Screw, mach, pan hd, M4-0.7, philips. nylock 29-014331-000C 29-016337- 2
000C
19 Gate, security 49-200605-000B 49-200605- 1
000E
20 Washer, flat M4, reg 19-033445-000A 19-056810- 2
000A
21 Standoff,self clinching, M3 x 10 29-009281-000A 29-009281- 2
000A
22 Screw, self tapping, pan head, M3-14, 29-014333-000B 29-016368- 1
000B
000B
24 Clamp, cable, round 0.09 snap-in 29-014446-000A 29-014446- 5
000A
25 Cabling guide 49-202761-000B 49-202761- 1
000B
26 Pin, dump, open 39-009224-000C 39-009224- 1
000C
27 Screw, machine, SEMs, pan head, square dome, 29-013932-000B 29-016398- 1
philips, M3-8 000B
28 Nut, SEMs, heical/conical, M3 29-009778-000A 29-016303- 1
000A
000C
30 Belt, flat, 0.250, semi-stretch 29-008482-000G 29-008482- 3
000G
31 Pulley, timing belt, M3.0P, 20-tooth 49-201100-000A 49-201100- 1
000A
000C
33 Bearing, ball, radial, M6 bore 29-014431-000A 29-014431- 3
000A
34 E-ring, retainer, M5 19-038411-000A 29-016284- 1
000A
35 Face, push plate, front-load 49-202773-000A 49-202773- 1
000A
36 Molding, push plate, front-load 49-007828-000E 49-007828- 1
000E
000A
000A
39 Belt, timing, 445-tooth 29-008375-00AH 29-008375- 1
00AH
40 Rail, non-sensor, 720 mm transport 49-202770-000C 49-202770- 1
000C
41 Rail, sensor, 720 mm transport 49-202771-000C 49-202771- 1
000C
Not Brush, antistatic (Transport Rev 11 and above have 49-204047-000B 49-204047- 2
Shown brushes, Rev 10 or below do not) 000B
Figure 4-24 Transport Module, Short Front-load 625mm (49-211437-000A)

Table 4-6 Transport Module, Short, Front-Load 625 mm (49-211437-000A) Parts
RoHS Non- RoHS
Compliant Compliant
Figure 4-24
1 Bracket, sensor, 625 mm transport 49- 207961-000B 49- 207961- 1
000B
2 Screw, selftapping, panhead M3-14, Phil nylock 29-014333-000B 29-016368- 2
000C
3 Actuator, gate, 625 mm transport 49-207957-000B 49-207957- 1
000C
000E
5 Presenter, sensor cable harness, 625 mm (lead- 49-200638-000F 49-207982- 1
through indicator and gate switch included) 000F
000Q
7 Rail, outer, 625 mm transport 49-207960-000A 49-207960- 2
000A
8 Bushing, idler, ID 5.4, OD 10.3 49-201087-000A 49-201087- 1
000A
9 Screw, machine, pan head, M03.0-0.50-006.0, philips, 29-014330-000A 29-016399- 5
nylock 000B
000A
000A
000A
000A
14 Fascia 49-200604-000F 49-200604- 1
000H
15 Fastener, panel, push-in, roundhead, nylon 29-012227-000E 29-012227- 6
000E
000C
000D
000A
19 Gate 49-200605-000B 49-200605- 1
000E
20 Cabling guide 49-207963-000C 49-207963- 1
000C
21 Pin, dump, open 39-009224-000C 39-009224- 1
000C
22 Screw, SEMs, pan head square domel, M3-5 29-013932-000B 29-016398- 1
000B
23 Nut, SEMs, M3 29-009778-000A 29-016303- 1
000A
24 Shaft, transport exit drive assembly 49-200615-000C 49-200615- 1
000C
25 Pulley, timing belt, M3.0P, 18-tooth 49-201100-000A 49-201100- 1
000A
000C
27 Belt, flat, 0.250, semi-stretch 29-008482-000K 29-008482- 3
000K
28 Standoff, self clinching, M3 x 10 29-009281-000A 29-009281- 2
000A
29 Nut, lock, M3-50 19-038374-000A 29-016283- 2
000A
000B
31 Brush, anti-static (Transport Rev 7 and above have 49-204047-000B 49-204047- 2
32 Rail, non-sensor, 625 mm transport (new) 49-207959-000B 49-207959- 1
000B
000A
000A
000A
000E
000A
38 Pulley, timing belt, 14-tooth, M03.0P 49-202752-000A 49-202752- 2
000A
39 Platen, presenter, 625 mm transport 49-207956-000D 49-207956- 1
000D
40 Rail, sensor, 625 mm transport 49-207958-000B 49-207958- 1
000B
41 Clamp, cable 29-014446-000A 29-014446- 5
000A
Figure 4-25 Transport Module, Short, Front-load 625mm, Open (49-211437-000C)

Table 4-7 Transport Module, Short, Front-Load 625 mm, Open (49-211437-000C) Parts
Part Number
RoHS Non- RoHS
Figure 4-25
1 Clamp, cable 29-014446-000A 29-014446- 5
000A
2 Bracket, sensor, 625 mm transport, Open 49-220636-000A 49-220636- 1
000A
3 Actuator, gate, 625 mm transport, Open 49-220634-000A 49-220634- 1
000A
000E
5 Presenter, sensor cable harness, 625 mm (lead- 49-200638-000F 49-207982- 1
through indicator and gate switch included) 000F
000C
7 Gate N/A 49-200605- 1
000E
8 Spring, helical, extension 19-033359-000A 29-016411- 2
000A
000A
10 Bushing, idler, ID 5.4, OD 10.3 49-201087-000A 49-201087- 1
000A
11 Screw, machine, pan head, M03.0-0.50-006.0, 29-014330-000A 29-016399- 5
philips, nylock 000B
000Q
13 Rail, outer, 625 mm transport 49-207960-000A 49-207960- 2
000A
14 Brush, anti-static 49-204047-000B 49-204047- 2
000B
000A
000A
17 Fascia N/A 49-200604- 1
000H
18 Screw, self-tapping, panhead, M03.0-0.50-006.0, 29-014333-000C 29-016368- 2
philips, Nytrq 000C
000D
000A
000A
22 Rail, sensor, 625 mm transport 49-207958-000B 49-207958- 1
000B
23 Rail, non-sensor, 625 mm transport 49-207959-000B 49-207959- 1
000B
24 Cabling guide, short transport , AFD 49-207963-000C 49-207963- 1
000C
25 Standoff, self clinching, M3.0-0.50 29-009281-000A 29-009281- 2
000A
26 Nut, lock, M3-50 19-038374-000A 29-016283- 2
000A
000B
28 Platen, presenter, 625 mm transport 49-207956-000D 49-207956- 1
000D
000A
000A
31 Pin, dump, open 39-009224-000C 39-009224- 1
000C
32 Screw, SEMs, pan head square domel, M3-5 29-013932-000B 29-016398- 1
000B
33 Nut, SEMs, hex/conical, M3.0-0.50 29-009778-000A 29-016303- 1
000A
34 Shaft, exit 49-200615-000C 49-200615- 1
000C
35 Belt, flat, 0.250, semi-stretch 29-008482-000K 29-008482- 3
000K
36 Pulley, timing belt, M3.0P, 20-groove 49-201100-000A 49-201100- 1
000A
37 Shaft, transport drive assembly 49-200630-000C 49-200630- 1
000C
000B
39 Molding, push plate, modified N/A 49-214755- 1
000A
Not Grease, Rheolube 362HB 16-003082-000A 16-003082- A/R
Shown 000A
Not Fastener, panel, push-in, roundhead, nylon 29-012227-000E 29-012227- 6
Shown 000E
Section 5
Stacker Module Repair
The procedures in this section assume that the stacker has been removed from the dispenser.
5.1 Divert Door
5.1.1 Removal
1. Rotate the cam fully counterclockwise so that the gate actuator is at the rear.
2. Slide the divert door until it touches the stacker end platen, then lift it up and out of the stacker
module (Figure 5-1).
5.1.2 Replacement
1. Transfer static brushes from the old divert platen to the new divert platen.
NOTE
The static brushes (49-204047-000A) that are attached to the divert door (49-200596-000A),
have been removed from stacker modules that are at Revision 7 or above.
2. Be sure to rotate the cam counterclockwise until the cam pin is in the divert door yoke.
3. To replace the divert door, reverse the removal procedure.
Figure 5-1 Removing the Divert Door
1 Stacker end platen

2 Divert door
3 Static brushes
4 Divert door yoke
5 Cam pin
5.2 Stacker Transport Shaft
Removal
1. Lift the non-geared side of the top transport module drive shaft out of the recess in the frame and
lower it to remove the tension on vertical timing belts (Figure 5-2).
Figure 5-2 Transport Module Top Drive Shaft

1 Non-geared side of top transport module drive shaft assembly
2. Remove the three vertical timing belts from the top transport module drive shaft assembly.
3. Remove the transport drive shaft pulley (Figure 5-3).
Figure 5-3 Transport Drive Shaft Removal and Installation

1 Left-hand shaft bearing (engages notch in frame) bearing is pressed onto shaft
2 Stacker transport drive shaft
3 Timing belt gear pulley - M3 pitch, 20-groove, snap-on
4 41-tooth timing belt
5 Right-hand shaft bearing (engages hole in frame) bearing is pressed onto shaft
4. Remove the stacker transport drive shaft (Figure 5-3).
Replacement
To replace the stacker transport shaft reverse the removal procedure (Figure 5-3). Make sure the shaft
goes through the 41-tooth timing belt.
5.3 Paddle Wheel Shaft and Paddle Wheels
5.3.1 Removal
1. Remove the 67-tooth paddle wheel shaft timing belt (Figure 5-4 ).
2. Remove the e-ring that secures the paddle wheel shaft on the end opposite the geared pulley.
3. Remove the paddle wheel shaft from the cam side of the stacker. Rotate the shaft to remove it
from the frame.
4. Pull the paddle wheels to remove them from the shaft.
NOTE
There is a groove in the shaft for each paddle wheel. A corresponding ridge inside the
paddle wheel hub engages the shaft to keep it in place.
Paddle Wheel Shaft

If you are replacing the paddle wheel shaft, perform the following steps:
1. Lift the latch and slide the 30-tooth gear/pulley off of the shaft.
2. Remove the bearing.
3. Remove the e-ring.
5.3.2 Replacement
To replace the paddle wheels and the paddle wheel shaft, reverse the removal procedure.
Figure 5-4 Removing the Paddle Wheel Shaft Timing Belt
1 Bearing 5 30-tooth gear/pulley

2 E-ring 6 67-tooth timing belt
3 Paddle wheel 7 Groove on shaft
4 Paddle wheel shaft
5.4 Combination Gear
5.4.1 Removal
1. Release the latch and remove the 20-tooth pulley from the transport drive shaft.
2. Remove the paddle wheel shaft 67-tooth timing belt (Figure 5-4).
3. Release the latch and remove the paddle wheel shaft 30-tooth gear/pulley.
4. Remove the 41-tooth combination gear timing belt.
5. Remove the e-ring that secures the combination gear (Figure 5-5).
6. Remove the combination gear from the shaft.
5.4.2 Replacement
To replace the combination gear, reverse the removal procedure.
Figure 5-5 Removing the Combination Gear
1 E-ring retainer
2 Combination gear
5.5 Brushless DC Motor
5.5.1 Removal
1. Remove the 67-tooth paddle wheel shaft timing belt (Figure 5-4).
2. Remove the brushless DC motor cable from the cable clamp and cut all cable ties that secure the
motor cable (Figure 5-6).
3. Remove the 15-tooth brushless DC motor pulley.
4. Loosen, but do not remove the two screws (M3-6) that secure the motor.
5. Support the weight of the motor, then remove the motor mounting screws. Note the orientation of
the motor cable connector for replacement.
6. Lower the motor until the end of the motor shaft clears the frame.
7. Tilt and angle the motor and remove it, shaft-first, through the cutout in the bottom of the frame.
5.5.2 Replacement
To replace the brushless DC motor, reverse the removal procedure. During replacement, note the
following:
• Take care to not damage wires and cables.

• Be sure to orient the motor cable before installing the motor.
• Be sure to route the motor cable through the frame cut out (Figure 5-6).
Figure 5-6 Removing the Brushless DC Motor
1 Cable tie 4 Motor cable

2 Screw 5 Motor
3 Pulley 6 Cable clamp
5.6 Cam Motor
5.6.1 Removal
1. Remove the 140-tooth cam timing belt (Figure 5-8).
2. Remove the 20-tooth cam motor pulley.
3. Remove the cable connector at the motor. Note the orientation of the motor for replacement.
4. Remove the push-in fasteners that secure the motor.
5. Note the position of the note stop in the guide rails.
Figure 5-7 Note Stop Position
1 Note Stop 4 Position 8 (reference)

2 Note Stop Track 5 Position 4 (U.S. currency) hidden
3 Rail on Frame Floor 6 Note Stop Locking Tab (set at Position 1)
6. Support the cam motor and move the note stop to position 1 (Figure 5-7).
NOTE
Push on the note stop from the BOTTOM ONLY. Pushing the note stop near the top may
cause damage to the note stop.
7. Rotate the cam motor so its connector clears the note stop.
8. Lower the cam motor and remove it, shaft first, through the cut out in the bottom of the frame.
5.6.2 Replacement
To replace the cam motor, reverse the removal procedure. After replacement is complete, move the note
stop back to the position noted in Step 5.
Figure 5-8 Removing the Cam Motor (motor rotated for removal)
1 Cam motor cable connector 4 140 tooth cam timing belt

2 Cam motor push-in fasteners 5 Cam motor rotated for removal
3 20-tooth cam motor pulley
5.7 Push Plate Motor
5.7.1 Removal
1. Remove the 20-tooth push plate motor pulley (Figure 5-9).

2. Note the position of the note stop in the guide rails.
3. Cut ties that secure the push plate motor cable.
4. Support the weight of the motor and remove the push-in fasteners.
5. Rotate the motor toward the frame cut out, then remove the cable connector at the motor.
6. Support the motor, then move the note stop to position 8 (Figure 5-7)
7. Lower the motor behind the note stop and remove it, shaft-first, through the frame cut out.
5.7.2 Replacement
To replace the push plate motor, reverse the removal procedure.
Figure 5-9 Removing the Push Plate Motor

1 Push-in fastener 3 Motor cable connector
2 20 tooth push plate motor pulley 4 Push plate motor rotated for removal
5.8 Cam
5.8.1 Check
Remove the cam from the AFD (Section 5.8.2), and check if the inner side surface of the cam has
scratches (Figure 5-10). Scratches indicate interference between the cam and the stacker. An inhibited
cam cannot put the divert partition in the proper position. If there are signs of scratching on the cam,
Diebold recommends that you replace the cam.
Figure 5-10 Cam Scratch Check

1 Scratches on the inner surface of the cam
2 Bad cam with scratches
3 Good cam without scratches
5.8.2 Removal
1. Remove the 140-tooth cam timing belt.

2. Rotate the cam counterclockwise so that the partition drive link notch is at the 5 o'clock position
(Figure 5-11).
3. Remove the cam pin.
4. Remove the cam.
If you are replacing the cam rollers, perform the following step to remove the old rollers:
5. Pull the roller with pliers to remove it from the pin. Note the orientation of the roller.
5.8.3 Replacement
To replace the cam, reverse the removal procedure. Note the following points during the replacement:
• When replacing a cam roller, be sure that the latches engage the groove on the pin. Apply 20W
oil (local purchase) to the rollers after assembly.
• Make sure that the arrow on the gate actuator aligns with the notch in the frame (gate closed
position) (Figure 5-11).
• Insert the pin into the cam and make sure it passes through the hole in the sensor mounting
bracket.
• Verify that the gate actuator cam roller and the transport cam roller are in the cam groove and the
cam vain is in the sensor.
• Position the cam with the partition drive link notch at 5 o'clock.
• After assembly, rotate the cam to verify that the tray raises before the gate actuator moves to the
gate open position.
Figure 5-11 Positioning the Cam for Removal
1 Partition drive link notch at 5 o'clock position 5 Alignment notch in frame

2 Cam 6 Arrow on gate actuator
3 Cam pin (11 mm hex head) 7 Cam roller
5.9 Cable Harness
5.9.1 Removal
1. Remove the cam (Section 5.8).

2. Remove the two mounting screws (M3-6) that secure the cam sensor, then remove the cam
sensor from the sensor mounting bracket (Figure 5-12). Note the sensor wire routing.
3. Cut ties and remove the cable from the cable clamps.
4. Remove the two mounting screws that secure the cassette present switch, then remove the
switch.
5. Remove the stacker rail with the sensor from the end plate, then remove the cable from the rail
hook and the sensor from the rail. Note how the cable routes through the hook.
6. Remove the vertical rail from the end plate, then remove the cable from the rail hook (Figure 5-
13). Note how the cable routes through the hook.
7. Note the routing of the sensor emitter wires, then remove them from the stacker chassis.
Figure 5-12 Removing the Cam Sensor
1 Cam sensor with mounting screws

2 Cassette present switch mounting screws
3 Cassette present switch
Figure 5-13 Removing the Harness from the Stacker Rail and the Vertical Rail
1 Stacker rail with sensor 3 Hook on vertical rail
2 Sensor 4 Cable in vertical rail hook
5.9.2 Replacement
1. Be sure to observe the keying of the emitter when installing it.

2. To replace the cable harness, reverse the removal process.
3. Cam sensor problems may be attributed to incorrect cable routing. Make sure the cable is routed
as shown in Figure 5-14.
Figure 5-14 Cam Sensor Cable Routing

1 Correct cam sensor cable routing
2 Incorrect cam sensor cable routing
5.10 Partition Follower
5.10.1 Removal
1. Position the cam to the 5 o'clock position so that the partition follower can pass through the notch.
2. Look down inside of the hollow opening of the hub on the cam follower to see the release latch
(Figure 5-15). Use a small flat blade screwdriver (or other similar tool) to disengage the release
latch while pulling out on the partition follower/cam follower assembly.
3. Remove the partition drive link and the partition follower from the stacker.
4. Remove the push-in fastener from the partition follower (Figure 5-15).
5. Remove the cam follower.
6. Remove the roller.
5.10.2 Replacement
1. Make sure that the alignment tab on the partition drive link aligns with the partition follower
(Figure 5-15).
2. To replace the partition follower, reverse the removal procedure.
Figure 5-15 Removing the Cam Follower and the Partition Drive Link
1 Alignment tab on partition drive link
2 Partition drive link
3 Release latch
4 Old partition drive link (49-201061-000A)
5 New partition drive link (49-201061-000B)
6 Cam notch at 5 o'clock position
7 Partition follower
8 Roller
9 Cam follower
10 Push-in fastener
5.11 Gate Actuator
5.11.1 Removal
1. Remove the cam (Section 5.8).

2. Remove the partition follower assembly (Section 5.10).
3. Remove the screws that secure the sensor mounting bracket, then move the bracket to facilitate
removing the gate actuator (Figure 5-16).
4. Remove the remaining gate actuator mounting screws, nylon washers and metal washers.
5. Slide the gate actuator forward and down so that the spacer roller is in the keyway of the slot.
6. If you are replacing the gate actuator, unscrew the gate actuator pin and remove it. Retain the pin
for use on the new gate actuator.
5.11.2 Replacement
To replace the gate actuator, reverse the removal procedure.
Figure 5-16 Removing the Gate Actuator

1 Spacer roller 6 Roller
2 Nylon washer 7 Gate actuator pin (riveted not screwed)
3 Gate actuator mounting screw M3-8 8 Gate actuator
4 Sensor bracket mounting screws (M3-8) 9 Metal washer
5 Sensor mounting bracket
5.12 End Plate Bump, Vertical Rails, and Tray Rails
5.12.1 Removal
To remove the end bump plate, the vertical rails, and the tray rails, release the snap latch feature of each
part and rotate the part out of the chassis (Figure 5-17).
5.12.2 Replacement
To replace the end bump plate, the vertical rails, and the tray rails, align the locating tab and insert the
part making sure that it snaps into the chassis and fits flush.
Figure 5-17 Stacker Bump, Vertical Rails, and Tray Rails

1 Bump (left) 4 Tray rail (right)
2 Stacker rail with sensor 5 Bump (right)
3 Tray rail (left) 6 Vertical rails
5.13 Latch Pin
5.13.1 Removal
1. Rotate the latch pin 90° either direction (Figure 5-18).

2. Remove the latch from the platen.
5.13.2 Replacement
1. Insert the latch pin into the platen cut out with the small tabs oriented vertically.
2. Hold the latch pin firmly and rotate the latch pin 90° in either direction.
3. Verify that the pin can move vertically in the platen cut out.
Figure 5-18 Stacker Latch Pin

1 Small tab
2 Latch pin
3 Large tab
5.14 Stacking Tray Tab Check
Two tabs (see Figure 5-19) on the stacking tray may rub on the transport. This problem prevents the tray
from rising to its highest possible position. Consequently, some notes can be left on the tray after the
push plate pushes and presents notes to customers.
To check the interference between the two tabs and the transport, use the cam to manually lower the
stacking tray. Examine the tabs for rub marks. The presence of rub marks indicates interference between
the tabs and the transport.
To prevent the tabs from rubbing on the transport, turn the tabs inward approximately 5 degrees so that
each tab is about 85 degrees against the tray (see Figure 5-19). Perform the following steps to reform the
tabs.
CAUTION
Electrostatic discharge (ESD) sensitive components. Use proper ESD handling and storing
procedures when removing the dispenser CCA. Failure to comply may result in permanent
damage to the CCA and operational problems with the dispenser.
1. Loosen, but do not remove, the two screws that secure the CCA cover to the stacker module
(Figure 3-1).
2. Slide the CCA cover so that the keyholes align with the screw heads.
3. Remove the CCA cover.
4. Rotate the cam manually so the stacking tray is in the lowest position.
5. Use pincers/pliers to turn the tabs inward approximately 5 degrees, making each tab about 85
degrees against the tray (Figure 5-19).
Figure 5-19 Rework of Stacking Tray Tabs
1 Transport
2 Turn each tab inward approximately 5 degrees to make an 85-degree angle against the tray
3 Stacking tray
5.15 Stack/Divert Platen Check
1. Manually raise and lower the stacker tray using the cam.
2. Verify that there is no interference between the tray and the stacker divert platen. Verify the tray
completely rises and does not rub on the stacker divert platen. Observe from the side of the AFD
to check if there is any interference.
3. If there is interference, reach in from the back of the stacker and reform the stack divert platen
away from the tray for a 1 mm to 3 mm (0.03 inch to 0.118 inch, 1/32 to 1/8 inch) clearance
(Figure 5-20).
NOTE
To check for the 1 mm to 3 mm (0.03 inch to 0.118 inch, 1/32 to 1/8 inch) clearance in
Figure 5-20, the transport must be removed from the stacker.
Figure 5-20 Stack Divert Platen and Tray Check
1 Stack divert platen

2 Stacking tray
3 Reform the stack divert platen 1 mm to 3 mm (0.03 inch to 0.118 inch, 1/32 inch to 1/8 inch)
clearance
4 Reform stack divert platen in this direction
5.16 Bumper and Washer
The bumper (Figure 5-21) reduces excessive noise, by acting as a cushion between the stacker tray and
the stacker frame. The bumper is subject to shearing due to the impact from the stacker tray. The washer
adds support and extends the life of the bumper.
5.16.1 Removal
Grasp and slide the stacker tray bumper out of the slot (Figure 5-21) to remove it from the stacker tray.
Figure 5-21 Bumper Removal
1 Bumper
2 Remove bumper in this direction
5.16.2 Replacement
Perform the following steps to install the new washer on the bumper.
1. If the bumper is damaged discard it and use a new bumper.

2. Install the washer over the bumper (Figure 5-22).
3. Slide the bumper back into the stacker tray slot with the washer below the sheet metal (Figure 5-
23).
Figure 5-22 New Washer on Bumper
1 Old bumper
2 New bumper with washer
3 Washer
Figure 5-23 Bumper and New Washer Installed

1 Bumper
2 Sheet metal
3 Washer
5.17 Stacker Module Illustrated Parts List
NOTE
NOTE
Table 5-1 Stacker Module Parts

RoHS Non- RoHS
Compliant Compliant
Figure 5-24, View A
Stacker, AFD 49-200596-000A 49-211433-
000A
1 Ring, retaining, type E, M05 19-038411-000A 29-016284- 5
000A
000A
3 Pulley,timing belt, M03.0, snap-on, 20-tooth 49-200262-000B 49-200262- 1
000B
4 Washer, flat, 0.191 ID, 0.311 OD N/A 19-060581- 1
000A
5 Bumper, PVC, round, press-in N/A 19-044711- 2
000A
6 Divert door (new, for stackers Rev 7 and above) 49-200672-000B 49-200672- 1
000D
7 Brushes, anti-static (Stacker Rev 6 or prior, relocated 49-204047-000A 49-204047- 5
to transport for Rev 7 and later) 000A
8 Pulley,timing belt, M03.0P, 20-groove, extension 49-201068-000A 49-201068- 1
000A
9 Shaft, paddle wheel 49-200634-000A 49-200634- 1
000A
10 Paddle wheel 49-201058-000A 49-201058- 3
000B
11 Gear/pulley, combo helic gear, 30-tooth/45-tooth 49-200637-000A 49-200637- 1
000A
12 Belt, timing, 67-tooth 29-008375-000E 29-008375- 1
000E
13 Pulley, timing belt, M03.0P, 15-groove 49-201076-000A 49-201076- 1
000A
14 Gear/pulley, combination, 22-groove/33-tooth, M03.0, 49-200635-000A 49-200635- 1
000A
15 Belt, timing, 41-tooth 49-018410-000B 49-018410- 1
000B
16 Fastener, push-in 29-012227-000F 29-012227- 6
000F
17 Screw, machine, pan head, M3-8, philips, nylock 29-014330-000A 29-016399- 2
000A
18 Motor, DC brushless 49-202751-000A 49-211438- 1
000A
19 Motor, stepper (cam motor) 49-200502-000A 49-207984- 1
000A
20 Motor, stepper (push plate motor) 49-200502-000A 49-207984- 1
000A
21 Cable, stepper motor, 385mm (Not Shown) 49-202781-000A 49-207979- 2
000A
Figure 5-24, View B
1 Bump, endplate, right 49-200673-000A 49-200673- 1
000A
2 Bump, endplate, left 49-200674-000A 49-200674- 2
000A
3 Rail, stacker with sensor 49-200675-000A 49-200675- 1
000A
[1]
4 Sensor (emitter) 19-021538-000A 29-016410- N/A
000A
5 Rail, tray 49-200670-000A 49-200670- 2
000A
6 Rail, tray 49-200629-000A 49-200629- 2
000A
7 Pin, snap latch, square 49-023555-000A 49-023555- 1
000A
8 Drive link, partition 49-201061-000A 49-201061- 1
000C
9 Spacer, gate actuator bar 49-200678-000A 49-200678- 3
000A
[2]
10 Flip gear, 30-tooth, 720 mm transport 49-202778-000A 49-202778- 1
000A
[2]
11 Standoff, self-clinching, M4-20 29-009595-000A 29-009595- 1
000A
12 Actuator, gate 49-200652-000E 49-200652- 1
000F
13 Washer, flat, 0.218 ID, 0.430 OD, 0.031 thick 19-045910-000A 19-045910- 7
000A
14 Washer, metal, flat, 3.2 ID, 10.0 OD 19-046621-000A 19-056827- 3
000A
15 Screw, machine, pan head, M3-8, philips, nylock 29-014330-000A 29-016399- 10
000A
[1]
16 Detector (cam sensor dual) 49-200653-000A 49-200653- N/A
000A
17 Cam 49-201057-000B 49-201057- 1
000B
18 Pin, cam 49-200661-000B 49-200661- 1
000B
19 Belt, timing, 140 tooth 29-008375-00AD 29-008375- 1
00AD
20 Screw, self tapping, flathead, M3-0.50, philips, nytorq 29-014335-000B 29-016400- 2
000A
21 Plate, sensor mounting 49-200676-000C 49-200676- 1
000C
22 Roller, cam 29-008780-000A 29-008780- 2
000A
23 Pin, gate actuator 49-200660-000B 49-200660- 1
000C
24 Fastener, pnl, push-in, round head nylon 29-012227-000B 29-012227- 1
000B
25 Follower, cam 49-202784-000A 49-202784- 1
000A
26 Roller 49-202785-000A 49-202785- 1
000A
27 Follower, partition 49-201060-000A 49-201060- 1
000A
28 Shaft, stacker transport drive (non-grooved roller) 49-202789-000B 49-202789- 1
000B
29 Screw, self tapping, pan head, M3-14, philips, nytorq 29-014333-000B 29-016368- 3
000C
[1]
30 Switch, cassette present (divert cassette) 49-202780-000A 49-202780- N/A
000A
31 Rail, vertical 49-200626-000A 49-200626- 2
000A
N/A Harness, cable, stacker assembly 49-200639-000A 49-207983- 1
000A
[1]
Part of stacker sensor cable harness (49-207983-000A)
[2]
Not part of the stacker module.
Figure 5-24 Stacker Module Parts
View A
View B
Section 6
Picker Module Repair
The procedures in this section assume that the picker module has been removed from the dispenser.
6.1 Feed Wheel Replacement Considerations
1. Check the date when the following items were replaced. Confirm the last replacement using the
call history or a label on each feed channel inside of the dispenser.
o Feed wheel (Section 6.2)
o Stripper wheel (Section 6.4)
o Take-away wheel (Section 6.6)
o Fender (Section 6.4)
2. If the feed wheel was replaced more than 90 days ago, it is recommended that the items listed
above be replaced.
a. If there is already a label inside of the feed channel, add todays's date on the next line.
b. If there is not label inside of the feed channel, add the label (89-031083-000A) and write
today's date.
3. If the feed wheel was replaced less than 90 days ago, it is recommended that the following be
performed:
. Examine the stripper wheel:
Look for wear past the visual indictor (inner ring).
Look for paper stuck between the stripper wheel and the stripper fender.
Check that the rotation of the stripper wheel clutch is free and in the correct
direction.
a. Examine the take-away wheel:
Check for excessive wear or greatly reduced diameter.
Check for free rotation in both directions.
4. Examine the cassettes for proper operation.
. Check the stripper floor extension operation and adjustment according to the procedure
in the Advanced Function Dispenser Media Supply Cassette On-site Repair Manual (TM-
000027-000G). Recommended adjustment for stripper floor extension is 12 to 14 ounces.
a. Check the take-away floor extension operation and adjustment according to the
procedure in the Advanced Function Dispenser Media Supply Cassette On-site Repair
Manual (TM-000027-000G). Recommended adjustment for take-away floor extension: 48
to 51 ounces.
5. Check the cassette tambour door operation. Replace the cassette if needed. Refer to Tambour
Door Actuator Spring (BU-IB1274-000A).
6. Check the cassette low mechanism for proper operation according to the Advanced Function
Dispenser Media Supply Cassette On-site Repair Manual (TM-000027-000G).
7. Check the condition of the three press-in rubber bumpers on the stacker module. Replace the
bumpers as required (Section 5.16).
6.2 Feed Wheel Assembly
6.2.1 New Style Pivot Blocks and Shafts
A new version of the picker module will be introduced in the Asian market after April 2010. These pickers
will have changes to the fork, stepper motor, fender and coupling that impact some aspects of module
repair. These picker modules are referenced as 1.5.
Most repair procedures are unchanged. However, where impacted, procedures for both AFD 1.0 and AFD
1.5 picker modules are provided.
The stripper wheel shaft and pivot block have been changed in pickers manufactured after February
2005. The pickers containing the new stripper wheel pivot block can be identified by the revision level of
the picker (Table 6-1).
Table 6-1 Pickers with New Pivot Block

Picker Revision
Level Description Part Number
RoHs Non- RoHS
compliant Compliant
9 AFD picker with aggressive feed wheel 49-20000-000A 49-211432-000A
2 AFD picker with non-aggressive feed wheel 49-20000-000B 49-211432-000B
2 AFD 1.0 AFD picker with aggressive feed N/A 49-211433-000A
wheel
2 AFD 1.5 AFD picker with aggressive feed N/A 49-225262-000A
wheel
Picker assemblies with the new pivot blocks may be intermixed with picker assemblies with old pivot
blocks in the same AFD. The new pivot blocks cannot be used in older picker assemblies.
6.2.1.1 Removal
1. Use a small flat blade screw driver to pry the stripper wheel (Figure 6-1) and shaft assembly out
of the fork block.
2. Slide the bottom half of the pivot toward the fork block and slide it out of the floor brace.
3. Remove the stripper wheel.
4. To remove the shaft, lift the shaft retaining clip at the pivot block and slide the shaft out of the
pivot block (Figure 6-2).
Figure 6-1 Removing the Stripper Wheel and Shaft
1 Fender
2 Stripper wheel
3 Stripper shaft
4 Pivot block
5 Floor brace
Figure 6-2 Removing Shaft From Pivot Block
1 Pivot block
2 Retaining clip
3 Stripper Shaft
4 Pivot block
5 Take-away shaft
6.2.1.2 New Style Pivot Blocks and Shafts Replacement
To replace the pivot block or shaft, reverse the removal procedure.
NOTE
• Pivot blocks and shafts are not interchangeable. You must use the stripper shaft with the
stripper pivot block, and the take-away shaft with the take-away pivot block.
• The pivot blocks are designed in such a fashion that they can not be installed in the wrong
location in the floor brace.
6.2.2 Old Style Pivot Blocks and Shaft Removal
1. Use a small flat blade screwdriver (or similar object) to disengage the take-away wheel and shaft
from the fork block (Figure 6-3).
2. On the stripper wheel fender, push downward and toward the back to disengage the stripper
wheel and shaft from the fork block, then roll the stripper wheel shaft assembly out of the fork
block.
3. Rotate the feed wheel shaft so that the motor coupling tooth points toward the end plate (Figure
6-4).
CAUTION
4. If the motor coupling tooth is not facing the front platen, removal or replacement of the
feed wheel shaft assembly will be very difficult and may cause unnecessary damage to the
positioning sensor on the keyboard CCA , the fork block, and the take-away spring.
5. Move the feed wheel shaft away from the motor to disengage the motor coupling.
6. Push against the frame finger so that the bearing moves in the direction away from the shaft
coupling, then remove the feed wheel shaft from the bearing.
NOTE
Be careful not to damage the positioning sensor mounted on the keyboard assembly CCA
when removing the feed wheel shaft assembly.
Figure 6-3 Moving the Take-away and Stripper Wheel and Shaft Assemblies from the Fork Block
1 Take-away wheel and shaft

2 Fork block
3 Stripper wheel and shaft
Figure 6-4 Positioning the Motor Coupling Tooth

1 End plate 3 Feed wheel assembly
2 Coupling tooth 4 Frame finger with bearing
6.2.3 Old Style Pivot Blocks and Shaft Replacement
1. Apply grease (Diebold part number 16-000047-000A) to the coupling end of the feed wheel shaft
and to the tooth notch in the coupling (Figure 6-4).
2. Reverse the removal procedure Step 5 through Step 3.
CAUTION
3. The take-away spring (Figure 6-5) is delicate and not a service item. Do not damage the
take-away spring when replacing the feed wheel assembly. Failure to comply may result in
permanent damage to the module.
4. Figure 6-5 Take-Away Spring (part removed for clarity)
5.
1 Roller - (part of spring assembly)
2 Take-Away Spring Assembly
6. Check the alignment of the feed wheel assembly as follows:

a. Rotate the feed wheel assembly so that the drive section is toward the end plate and the
feedwheel shaft tooth is visible (Figure 6-6).
b. Insert the alignment block (part number 49-023715-000B) into the fork block. Move the
feed wheel assembly to make room if necessary.
c. The center feed wheel must rest against the finger on the alignment block with no gap or
overlap (Figure 6-7).
7. If necessary, adjust the alignment of the feed wheel assembly as follows:
a. With the alignment block installed in the fork block, remove the set screws from the motor
coupling, apply Loctite to the set screws, and re-insert the set screws, but do not tighten
them.
b. Slide the motor coupling on the motor shaft until the center feed wheel is properly
aligned, then tighten the set screws.
c. Remove the alignment block.
8. Install the stripper wheel and shaft assembly into the fork block. Make sure that the wheel moves
freely.
9. Install the take-away wheel and shaft assembly into the fork block. Make sure that the wheel
moves freely.
Figure 6-6 Alignment Block Installed in Fork Block
1 Fork block 4 Motor coupling tooth

2 Alignment block installed in fork block 5 Notch in feed wheel shaft
3 Set screw in motor coupling
Figure 6-7 Correct Feed Wheel Shaft Alignment
1 Incorrect: alignment block overlaps wheel, move motor coupling toward wheel
2 Incorrect: alignment block does not contact wheel, move motor coupling away from wheel
3 Correct: alignment block touches wheel (no gap)
4 Alignment block
6.3 Motor
6.3.1 Removal
NOTE
The AFD 1.5 picker module uses a stepper motor with a round shaft and a matching coupling
(Figure 6-8).
1. If not already done, disconnect the motor cable.

2. Remove the two screws that secure the motor (M4-8), then remove the motor from the chassis
(Figure 6-8). Note the orientation of the motor and its connector for replacement.
3. Loosen the set screws and remove the coupling from the motor shaft.
4. Remove the feed wheel assembly (Section 6.2).
Figure 6-8 Removing the Picker Module Motor
1 Motor coupling 5 Round shaft

2 Motor coupling tooth 6 Picker motor
3 Set screw nearest tooth 7 Motor connector
4 Flat of shaft 8 Motor mounting screws
6.3.2 Replacement
1. Install the coupling onto the motor shaft. Observe the following:
o Completely remove the set screws from the coupling and apply Loctite, then reinstall the
set screws.
o Position the coupling on the motor shaft so that the set screw closest to the coupling
tooth is on the flat of the shaft (Figure 6-8).
Position the coupling on the motor shaft so that the set screw closest to the coupling
tooth is on the AFD 1.5 round shaft (Figure 6-8).
o Leave the set screws loose so that the coupling can be adjusted after the feed wheel
assembly is installed.
2. Install the motor. Make sure that the connector is in the correct position.
3. Install the feed wheel assembly.
4. Perform the feed wheel adjustment (Section 6.2.3) and position the coupling before the Locktite
sets.
6.4 Stripper Wheel and Fender
6.4.1 Removal
1. Use a small flat blade screwdriver (or similar object) to disengage the take-away wheel and shaft
from the fork block (Figure 6-3).
2. On the stripper wheel fender, push downward and toward the back to disengage the stripper
wheel and shaft from the fork block, then roll the stripper wheel shaft assembly out of the fork
block.
3. Pull the fender and wheel off the shaft (Figure 6-9). Note the flat on the shaft.
4. Remove the wheel from the fender. Note the orientation of the wheel for replacement.
Removing New Stripper Wheel Shaft

To remove the shaft, lift the shaft retaining clip at the pivot block and slide the shaft out of the pivot block
(Figure 6-1).
Removing Old Stripper Wheel Shaft
1. Remove the screw (6-32 x 0.25 in.) that secures the shaft and pivot block.
2. Remove the shaft and pivot block assembly from the floor brace. Remove the star lock washer
and standoff from the pivot block.
NOTE
Note that there is a lock washer between the pivot block and the floor brace.
3. Remove the shaft from the pivot block.

4. Remove the nylon washer and e-ring.
Figure 6-9 Removing the Stripper Wheel and Old Shaft

1 Fender 6 Threaded standoff
2 Stripper wheel 7 Pivot block
3 Stripper shaft 8 Nylon washer
4 Screw (6-32 x 0.25) 9 E-ring
5 Star lock washer 10 Floor brace
6.4.2 Replacement
Replacing New Stripper Wheel Shaft

To replace the shaft, lift the shaft retaining clip at the pivot block and slide the shaft into the pivot block
(Figure 6-1).
Replacing Old Stripper Wheel Shaft
1. Install the nylon washer and e-ring.

2. Insert the shaft in the pivot block.
3. Insert the standoff through the pivot block (hole side through the slot) and place the lock washer
on the pivot block.
4. Position the pivot block into the floor brace and install the mounting screw. Make sure that the
star lock washer does not fall out.
Replacing Stripper Wheel and Fender
NOTE
The wide fender on the stripper wheel has been updated on both the AFD 1.0 and the AFD 1.5
picker modules to a new part (49-225396-000A) that reduces the collection of paper dust (Figure 6-
9).
1. Insert the wheel into the fender. Make sure that the wheel is oriented correctly.
2. Orient the slot in the wheel with the shaft, then slide the wheel and fender onto the shaft. The end
of the shaft must be flush with the wheel hub when properly installed.
3. Install the stripper wheel and shaft assembly into the fork block.
4. Install the take-away wheel and shaft assembly into the fork block.
6.5 Take-away Spring Assembly - Check
There is no replacement procedure for the take-away spring assembly. You can check the spring force by
measuring it. If this check fails, replace the picker module.
1. Feed a single thickness strip of a test note (25 mm [1 inch] wide) into one of the back (leading)
take-away spring rollers so that the strip is past the back take-away spring roller, but out of the
front take-away spring roller (Figure 6-10).
NOTE
o The test note cannot be on the drive segment of the feed wheel.
o The following check requires a spring scale.
2. With the spring scale attached to the top of the test note, hold the feed wheel shaft to prevent it
from turning, then pull the test note strip from the dispenser and note the value on the spring
scale. The spring scale must indicate a force between 283 g and 680 g (10 oz. and 24 oz.).
3. Do the same check on the other back take-away spring roller.
4. Slide the two outside dispenser transport belts off their pulleys to access the rollers of the take-
away spring assembly.
Figure 6-10 Take-away Spring Drive Force Test

1 283 g to 538 g (10 oz. to 19 oz.) of force required to 7 Stripper shaft
remove test note strip
2 283 g to 680 g (10 oz. to 24 oz.) of force required to 8 Take-away spring too low
remove test note strip
3 Back (leading) take-away spring roller 9 Position feed wheels on non-drive
segment for test
4 Take-away spring too high 10 Test note strip
5 Floor brace 11 Spring scale
6 Correct take-away spring position 12 Front (exit) take-away spring roller
5. Feed the test note strip into one of the front (exit) take-away spring rollers, so the strip is past the
front take-away spring roller, but out of the back take-away spring roller and not on the drive
segment of the feed wheel.
NOTE
o The test note cannot be on the drive segment of the feed wheel.
o The following check requires a spring scale.
6. With the spring scale attached to the top of the test note, hold the feed wheel shaft to prevent it
from turning, then pull the test note strip from the dispenser and note the value on the spring
scale. The spring scale must indicate a force between 283 g and 538 g (10 oz. and 19 oz.).
7. Perform the same check on the other front take-away spring roller.
8. Place the dispenser transport belts back on their pulleys.
9. If any of the above drive forces are out of specification, replace the picker module (Section 3.4).
10. Check that the four take-away spring rollers turn freely. If they do not turn freely, replace the
picker module (Section 3.4).
11. Rotate the feed shaft assembly so that the take-away spring rollers are off the drive segments of
the feed wheels.
12. With the feed wheels in this position check that the end of the take-away spring does not protrude
past the top of the floor brace (Figure 6-10).
13. If the end of the take-away spring is higher than the top of the floor brace, carefully bend the take-
away spring by hand to the correct position.
14. Rotate the feed shaft assembly so that the take-away spring rollers are on the drive segments of
the feed wheels.
15. With the feed wheels in this position gently push the stripper wheel against the center feed wheel
and check that the end of the take-away spring is not in front of or touching the stripper shaft.
16. If the end of the take-away spring is touching or in front of the stripper shaft, carefully bend the
take-away spring by hand to the correct position.
6.6 Take-away Wheel
The take-away wheel shaft and pivot block have been changed in pickers manufactured after February
2005. The pickers containing the new take-away wheel pivot block can be identified by the revision level
of the picker (Table 6-1).
Table 6-2 Pickers with New Pivot Block

Picker Revision RoHS Non-compliant RoHS Compliant Part
Level Description Part Number Number
9 AFD picker with aggressive feed 49-20000-000A 49-211432-000A
wheel
2 AFD 1.0 picker with non- 49-20000-000B 49-211432-000B
aggressive feed wheel
2 AFD 1.5 picker with aggressive N/A 49-225262-000A
feedwheel
Picker assemblies with the new pivot blocks may be intermixed with picker assemblies with old pivot
blocks in the same AFD. The new pivot blocks cannot be used in older picker assemblies.
The existing take-away wheel, and stripper fender have not changed, and are used with the new pivot
block. There is no prox adjustment in the new picker assemblies.
NOTE
The take-away wheel (49-016971-000F) snaps on but does not appear to be as secure on the shaft
as previous take-away wheels. Once the wheel is in the fork block, the fork block holds the wheel
securely.
6.6.1 New Style Pivot Blocks and Shafts Removal
1. Use a small flat blade screw driver to pry the take-away wheel (Figure 6-11) and shaft assembly
out of the fork block.
2. Slide the bottom half of the pivot toward the fork block and slide it out of the floor brace.
3. Remove the take-away wheel.
4. To remove the shaft, lift the shaft retaining clip at the pivot block and slide the shaft out of the
pivot block (Figure 6-12).
Figure 6-11 Removing the Take-away Wheel and Shaft
1 Take-away shaft
2 Take-away wheel
3 Pivot block
4 Floor brace
Figure 6-12 Removing Shaft From Pivot Block

1 Pivot block
2 Retaining clip
3 Stripper Shaft
4 Pivot block
5 Take-away shaft
6.6.2 New Style Pivot Blocks and Shafts Replacement
To replace the pivot block or shaft, reverse the removal procedure.
NOTE
• Pivot blocks and shafts are not interchangeable. You must use the take-away shaft with
the take-away pivot block.
• The pivot blocks are designed in such a fashion that they can not be installed in the wrong
location in the floor brace.
6.6.3 Old Style Pivot Blocks and Shafts Removal
1. Use a small flat blade screw driver (or other similar object) to pry the take-away wheel and shaft
assembly out of the fork block.
2. Pull the wheel off of the shaft (Figure 6-13).
If you are replacing the shaft, perform Step 3 and Step 4.
3. Remove the screw (6-32 x 0.25 in.) that secures the pivot block assembly.
NOTE
Note that there is a lock washer between the pivot block and the floor brace.
4. Remove the shaft and pivot block assembly from the floor brace. Remove the star lock washer
and standoff from the pivot block. Note the orientation of the pivot block for replacement.
5. Remove the shaft from the pivot block.
6. Remove the e-ring.
6.6.4 Old Style Pivot Blocks and Shafts Replacement
1. Make sure that the pivot block is correctly oriented.

2. To replace the take-away wheel and shaft assembly, reverse the removal steps that apply.
Figure 6-13 Removing the Take-away Wheel and Old Shaft

1 Take-away shaft 5 E-ring
2 Take-away wheel 6 Standoff
3 Screw (6-32 x 0.25) 7 Pivot block
4 Star lock washer
6.7 Vertical Platen Rail
6.7.1 Removal
1. Release the locking tabs (Figure 6-14).

2. Remove the rail.
6.7.2 Replacement
1. Make sure that the locking tabs are properly seated and latched.
2. Make sure that the lower finger is inside of the end plate, then press the rail into place.
Figure 6-14 Removing the Vertical Platen Rail

1 Rail finger
2 Vertical platen rail
3 Locking tabs
6.8 Latch Pin
6.8.1 Removal
1. Rotate the latch pin so the small tabs are vertical (Figure 6-15).
2. Remove the latch pin from the keyboard assembly.
Figure 6-15 Picker Latch Pin Removal
1 Latch pin
2 Small tab
3 Large tab
6.8.2 Replacement
NOTE
There is a new white latch pin (49-023555-000C) used with the 18-button keyboard. Old and new
latch pins are not interchangeable.
1. Orient the latch pin to the keyboard assembly cut out with the small tabs oriented horizontally
(Figure 6-16).
2. Firmly push the latch pin into the keyboard assembly.
NOTE
Do not install the pin with a rotation, just push the pin directly in place.
3. Verify that the pin can move in the keyboard assembly cut out.
Figure 6-16 Latch Pin Replacement
1 Latch pin (Note: Do not install the pin with a rotation, just push the pin directly in place.)
2 Small tab
3 Large tab
6.8.3 Cassette Opening Pin Inspection and Replacement
Figure 6-17 Cassette Opening Pin (parts removed for clarity)

1 Cassette opening pin
2 Screws apply LOCTITE SUPERBONDER #414
6.8.3.1 Removal
1. Inspect the canister opening pin for wear and deformity (Figure 6-17).
2. Remove the two mounting screws and remove the opening pin.
6.8.3.2 Replacement
1. Apply Loctite Superbonder #414 to the mounting screws (Figure 6-17).
CAUTION
2. Do not use Loctite #242 with the plastic cassette opening pin. Loctite #242 adhesive is for
anodized machined aluminum opening pins only. Loctite Superbonder #414 should be
used with all cassette opening pins (plastic or aluminum).
3. Note the proper orientation of the cassette opening pin and install the pin.
6.9 Troubleshooting A Picker With A Bad Keyboard
If you are troubleshooting an AFD problem where all picker modules report the following symptoms, it
most likely indicates that one or more of the picker modules have a bad keyboard pulling down the +12
volts on the AFD CCA, causing all picker keyboards to fail.
• Double detect end-of-life

• All cassettes are not recognized (AFD does not beep when cassettes inserted)
• In the appropriate diagnostics there are check marks next to all picker channels
Perform the following steps to locate the picker module(s) that may have bad keyboards.
1. Confirm proper button coding on the cassette to use in this procedure.
2. Perform an orderly shut down of the system according to the appropriate terminal manual.
3. Turn off power to the module.
4. Disconnect the USB cable from the dispenser CCA so that no commands are sent to the
dispenser.
5. Disconnect all keyboards from the dispenser CCA, except keyboard 1.
6. Power on the module and wait until D12 (2Hz), D14 (2Hz) and D15 (5Hz) are blinking normally,
approximately 15 seconds.
7. Install a good cassette in channel 1.
a. If a beep is heard, keyboard 1 is good. Continue checking the remaining keyboards.
b. If a beep is not heard, keyboard 1 is bad. Remove power and disconnect keyboard 1
from the dispenser CCA. Continue checking the remaining keyboards.
8. Remove the cassette and turn off power to the module.
9. Connect keyboard 2 to the dispenser CCA.
10. Power on the module and wait until D12 (2Hz), D14 (2Hz) and D15 (5Hz) are blinking normally,
approximately 15 seconds.
11. Install a good cassette in channel 2.
a. If a beep is heard, keyboard 2 is good, continue checking the remaining keyboards.
b. If a beep is not heard, keyboard 2 is bad. Remove power and disconnect keyboard 2
from the dispenser CCA. Continue checking the remaining keyboards.
12. Continue checking the remaining picker module keyboards, one at a time using the steps listed
above.
13. Replace all picker modules that have bad keyboards.
14. Perform an orderly start up of the terminal according to the appropriate terminal manual. Bring the
terminal into customer service. Test the operation of the dispenser.
6.10 Picker Module Illustrated Parts List
NOTE
NOTE
Table 6-3 AFD 1.0 Picker Module Parts

RoHS Non-Compliant RoHS Compliant
Figure 6-18
Picker, AFD (with 49-200000-000A 49-211432-000A
aggressive feed wheel)
Picker, AFD (with non- 49-200000-000B 49-211432-000B
aggressive feed wheel)
1 Old style pivot block and shaft
2 Screw, machine, flat head, 29-007968-015B 29-016298-000A 5
6-32 x 0.25
3 Wheel, take-away, 49-016971-000D 49-016971-000F 1
overmold
[3]
4 Shaft, take-away wheel 29-007646-000B N/A 1
[3]
5 Pivot block, take-away 39-011717-000A N/A 1
[3]
6 Ring, retaining 19-015934-000A N/A 2
[3]
7 Washer, flat, 0.128 ID, 29-006978-000C 29-006978-000C 1
0.245 OD
[3]
8 Standoff, self clinching, 29-007268-000C N/A 1
round head, 6-32 x 0.562
9 Wheel, wide stripper, 49-016968-000F 49-016968-000F 1
overmold
10 Fender, wide 49-016962-000D 49-225396-000A 1
[3]
11 Shaft, stripper wheel 29-007308-000A N/A 1
[3]
12 Pivot block assembly, 19-020669-000B N/A 1
stripper
[3]
13 Standoff, self clinching, 29-007268-000A N/A 1
round head, 6-32 x 0.437
[3]
14 Washer, external lock, #6 01-027028-0150 19-056801-000A 2
15 New style pivot fork block and shaft
16 Pivot block with clutch, 49-204054-000A 49-204054-000A
stripper
17 Shaft, stripper wheel 49-204051-000A 49-204051-000A 1
18 Wheel, wide stripper, 49-016968-000F 49-016968-000F 1
overmold
19 Shaft, take-away wheel, 49-204050-000A 49-204050-000A 1
new
20 Pivot block, without clutch 49-204049-000A 49-204049-000A 1
take-away, wheel
21 Bearing, ball, radial M6 49-201066-000A 49-201066-000A 1
bore
22 Coupling, motor 29-007592-000D 49-214767-000A 1
23 Motor, stepper 49-200502-000A 49-207984-000A 1
24 Screw, self tapping, pan 29-014336-000A 249-225394-000A 2
head, M4-0.7, philips,
nytorq
25 Feedshaft assembly, 49-204018-000A 49-204018-000A 1
overmold
25 Feedshaft assembly, 49-204018-000C 49-204018-000C 1
overmold, non-aggressive
26 Cassette opening pin 49-202706-000B 49-202706-000E 1
27 Rail, platen 49-200019-000A 49-200019-000A 2
28 Pin, snap latch square 49-023555-000B 49-023555-000C 1
N/A Adhesive, Locktite 16-000008-000A 16-000008-000A A/R
Superbonder #414
N/A Grease, silicon with lithium 16-000047-000A 16-000047-000A A/R
soap
[1]
Not Cable, keyboard 49-200009-000A, 49- 49-211110-000A, 49- 1
shown 200009-000B, 49-200009- 211110-000B, 49-211110-
[1]
000C, 49-200009-000D 000C, 49-211110-000D
[1]
Not Cable, motor 49-202781-000A, 49- 49-207979-000A, 49- 1
shown 202781-000B 207979-000B
[1]
Not AFD feedwheel preventive 49-204020-000A 49-204020-000A

shown maintenance kit
(aggressive)
Feedshaft assembly, 49-204018-000A 49-204018-000A
overmold
Fender, wide 49-016962-000D 49-225396-000A
Wheel, wide stripper, 49-016968-000F 49-016968-000F
overmold
Wheel, take-away, 49-016971-000D 49-016971-000F
overmold
Not AFD feedwheel preventive 49-204020-000B 49-204020-000B
Shown maintenance kit (non-
aggressive)
Feedshaft assembly, 49-204018-000C 49-204018-000C
overmold
Fender, wide 49-016962-000D 49-225396-000A
Wheel, wide stripper, 49-016968-000F 49-016968-000F
overmold
Wheel, take-away, 49-016971-000D 49-016971-000F
overmold
Not Adhesive, Locktite 242 16-000016-000A 16-000016-000A A/R
Shown
Tool, alignment block 49-023715-000B N/A
[1]
Refer to Figure 3-12 and Table 3-1.
[2]
Kit contains one feedwheel, one stripper wheel, one fender, and one take away wheel.
[3]
Parts included in old style pivot block and shaft.
Figure 6-18 AFD 1.0 Picker Module Parts

Table 6-4 AFD 1.5 Picker Module Parts
Part Number
RoHS Non- RoHS
Figure 6-19
Picker, AFD (with aggressive feed wheel) N/A 49-225262-
000A
1 Rail, platen 49-200019-000A 49-200019- 2
000A
2 Pin, snap latch, square 49-023555-000B 49-023555- 1
000C
3 Feedshaft, overmold 49-204018-000A 49-204018- 1
000A
4 Pivot block with clutch, stripper 49-204054-000A 49-204054- 1
000A
5 Shaft, stripper wheel 49-204051-000A 49-204051- 1
000A
6 Fender, wide N/A 49-225396- 1
000A
7 Wheel, wide stripper, overmold 49-016968-000F 49-016968- 1
000F
8 Bearing, ball, radial, M 06.00, bore, 15,00 OD, N/A 49-201066- 1
flg, dshld 000A
9 Wheel, take away, overmold N/A 49-016971- 1
000F
10 Shaft, takeaway wheel N/A 49-204050-
000A
11 Pivot block, take-away, wheel 49-204049-000A 49-204049- 1
000A
12 Spring, helical, extension N/A 49-225264- 1
000A
13 Coupling, motor (AFD 1.5) N/A 29-007592- 1
000F
14 Motor, stepper (AFD 1.5) N/A 49-207984-
000C
15 Screw, self-tapping, pan head, M4-0.7, N/A 49-225394- 2
Philips, nytorq 000A
16 Pin, can opening 49-202706-000E 49-202706- 1
000E
Not AFD feedwheel preventive maintenance kit 49-204020-000A 49-204020-
shown (aggressive) 000A
Feedshaft assembly, overmold 49-204018-000A 49-204018-
000A
Fender, wide 49-016962-000D 49-225396-
000A
Wheel, wide stripper, overmold 49-016968-000F 49-016968-
000F
Wheel, take-away, overmold 49-016971-000D 49-016971-
000F
Figure 6-19 AFD 1.5 Picker Module Parts

Section 7
CCA
When you replace the advanced function dispenser control CCA, then you must set the AFD
communication (Section 2.5). When you replace the advanced function dispenser control CCA the AFD
sensors must be manually recalibrated. Refer to Section 2.6 to recalibrate the sensors.
7.1 Control CCA
7.1.1 Removal
To remove the CCA, refer to Section 3.1
7.1.2 Replacement
To replace the CCA, refer to Section 3.1
7.2 Control CCA Connectors, Switches, Fuses, and LEDs
This section identifies the connectors, switches, fuses, and LEDs on the control CCA. The pin and signal
relationship for each connector is listed in a separate table, refer to Figure 7-1 and Table 7-1 through
Table 7-9.
Figure 7-1 CCA Connectors

1 J1 - stacker brushless DC motor 13 Stepper motor 2
2 F1 (and associated LED) - brushless DC motor 14 Stepper motor 3
3 Feed channel 3 15 Stepper motor 4
4 J2 - stacker sensor harness 16 Stepper motor 5
5 J3 - transport sensor harness 17 Stepper motor 6
6 Status LEDs 18 J13 - stacker cam motor
7 Feed channel 4 19 J10 - stacker push plate motor
8 Feed channel 5 20 F2 (and associated LED) - stepper motors
9 Feed channel 6 21 Feed channel 2
10 S1 - remain in boot load 22 Feed channel 1
11 S2 - reset 23 J5 - USB
12 Stepper motor 1 24 J4 (and associated LED) - power
Table 7-1 Connector J1, Stacker Brushless DC Motor
Pin Signal Name Pin Signal Name
1 RTN 6 + 5 VDC
2 BLDC C sense 7 Connector key
3 BLDC B sense 8 BLDC C
4 BLDC A sense 9 BLDC B
5 Connector key 10 BLDC A
Table 7-2 Connector J2, Stacker Sensor Harness
1 Cam 2 in 5 Divert present in
2 Cam 1 in 6 RTN
3 Cam power 7 Note LED anode
4 RTN 8 Note LEDS cathode
Table 7-3 Connector J3, Transport Sensor Harness
1 + 5 VDC 7 Gate in
2 Note emitter 8 RTN
3 Exit LED anode 9 Lead through red
4 Exit LED cathode 10 Lead through green
5 + 5 VDC 11 Lead through yellow
6 Exit emitter 12 + 14 VDC
Table 7-4 Connector J4, Power
1 + 48 VDC 3 RTN
2 + 48 VDC 4 RTN
Table 7-5 Connector J5, USB
1 NC 3 USB DP
2 USB DM 4 RTN
Table 7-6 Connector J10, Push Plate Motor
1 ST PH A 4 ST PH D
2 ST push plate AB 5 ST push plate CD
3 ST PH B 6 ST PH C
Table 7-7 Connector J13, Cam Motor
1 ST PH A 4 ST PH D
2 ST cam AB 5 ST cam CD
3 ST PH B 6 ST PH C
Table 7-8 Feed Channel Stepper Motor (all channels)
1 ST PH A 4 ST PH D
[1] [1]
2 ST x AB 5 ST x CD
3 ST PH B 6 ST PH C
[1]
Where x indicates the number of the channel (1, 2, 3, 4, 5, 6)
Table 7-9 Feed Channel Keyboard (all channels)

[1]
1 NC 14 KYBD x DRVR 5
[1]
2 NC 15 PROX x
3 NC 16 KYBD DRVR 4
4 NC 17 RTN
5 NC 18 KYBD DRVR 3
6 NC 19 + 12 VDC
[1]
7 KYBD x RCVR 0 20 KYBD DRVR 2
[1] [1]
8 KYBD x RCVR 1 21 KYBD x RCVR 3
[1]
9 VANE x PWR 22 KYBD DRVR 1
[1]
10 KYBD DRVR 7 23 KYBD x RCVR 2
[1]
11 VANE x IN 24 KYBD DRVR 0
[1]
12 KYBD DRVR 6 25 Keyboard ID x
13 RTN 26 (pin removed)
[1]
Where x indicates the number of the feed channel (1, 2, 3, 4, 5, 6)
7.3 Control CCA LEDs
This section describes the LEDs on the control CCA.
Table 7-10 Control CCA Status LEDs

LED Description
D1 (yellow) Status of F1 (brushless DC motor fuse) - OFF = fuse OK, ON = fuse bad
D11 (red) ARM status (refer to Table 7-11)
D12 (green) ARM status (refer to Table 7-11)
D13 (yellow) ARM status (refer to Table 7-11)
D14 (green) Happy LED (system working properly) - blinking = 5 VDC present and code is running
[2]
[2]
D15 (red) Flashing LED indicates normal communication between dispenser co-processors.
D16 (red) Divert/retract cassette present - ON = cassette present, OFF = cassette absent
D18 (red) Gate - ON = gate closed, OFF = gate open
D19 (red) Cam upper sensor - ON = cam not blocking upper sensor, OFF = cam blocking upper
[1]
sensor
D20 (red) Cam lower sensor - ON = cam not blocking lower sensor, OFF = cam blocking lower
[1]
sensor
D21 (red) Exit - ON = transport exit sensor blocked, OFF = transport exit sensor not blocked
D22 (red) Stacker - ON = stacker sensor blocked, OFF = stacker sensor not blocked
D23 (yellow) Stepper fuse - ON = fuse is bad, OFF = fuse is good
D91 (green) Power ON indicator - ON = +48V is present, OFF = +48V is absent
[1]
The cam sensor has two channels, upper and lower.
[2]
Not available on control CCA 49-208102-000B.
Table 7-11 Control CCA ARM Processor LED Sequences

LED LED LED
(D11) (D12) (D13)
[1] [2] [3]
Action When LED Sequence and notes
Boot loader startup application
Detected boot loader load At startup X One flash, then boot loader happy
request flag set only lights flash
Detected stay in boot At startup X Two flashes, then boot loader happy
loader switch only lights flash
Detected application load At startup X Four flashes, then boot loader happy
request flag set only lights flash
Boot loader check did not At startup X Five flashes, then boot loader happy
match stored value only lights flash
Application checksum did At startup X Six flashes, then boot loader happy
not match stored value only lights flash
Co-processor checksum At startup X Seven flashes, then boot loader
did not match stored value only happy lights flash
Boot loader main application
Boot loader happy Startup and X X Both lights flash together at 2 Hz
runtime
USB chip failure At startup X X Both lights stay on steady
only immediately at startup
ARM system failure Startup and X Light stays on steady at time of failure
runtime
Green and yellow lights retain their
states
Flash erase Runtime X Toggles for each block erased (slow,
1-2 Hz)
Flash erase verify Runtime X Toggles for each block erase verified
(fast, 5-10 Hz)
Flash verification complete X One flash only
or flash erase complete
Flash parameter block Runtime X X Alternate for each parameter block
writes write (will be slightly faster than the
flash block write)
Flash block writes Runtime X X Alternate for each block write (steady
red LED indicates checksum failure)
Flash verification or write X Two flashes
complete
Flash verification complete X Three flashes
or parameter block update
complete
ARM application
ARM happy Runtime X Flashes at 2 Hz
EEPROM error Runtime X Toggle every 128 characters cleared
(about 1-2 Hz)
EEPROM writes Runtime X Toggle every 32 characters written
(about 5-7 Hz)
Note counting calibration Runtime X Yellow ON during calibration, remains
and exit sensor calibration ON if calibration fails
Proximity sensor Runtime X Yellow ON during calibration, (The
calibration proximity sensor will report an end of
life status if fail happens)
[1]
Red
[2]
Green
[3]
Yellow
7.4 Illustrated Parts List
For CCA parts, refer to Section 3.5.
Section 8
Cabling
This section contains illustrations that show how cable harnesses are routed through the transport
modules, and the stacker module and how cables are routed between modules.
Figure 8-1 Rear-load 860 mm Transport Module Cabling
Figure 8-2 Rear-load 620 mm Transport Module Cabling

Figure 8-3 Front-load Transport Module Cabling
1 Tie strap (11-007615-000A)

2 Front-load cable harness wires
3 Place tie strap 110 mm (4.74 inches, 4-3/4 inches) from clip
Figure 8-4 Stacker Module Cabling
For picker module cabling refer to the following figures:
• Figure 3-9 for motor cabling for picker modules 1 and 2.

• Figure 3-10 for keyboard cabling for picker modules 3, 4, and 5.
• Figure 3-11 for motor cabling for picker modules 3, 4, and 5.
Section 9
Preventive Maintenance
Perform the steps in the following checklist to maintain the transport.
Table 9-1 Transport Checklist

Checked
/ OK Corrected Replaced Incomplete
1. Check that all pulleys are securely mounted on their
respective shafts.
2. Check for cracked bearings or bearings missing balls.
Ensure that all bearings are mounted flush to the
frame. Inner and outer races should be flush with each
other and should operate smoothly. Replace bearings
in pairs as required.
3. Check all timing belts for frayed edges or flat or worn
teeth. Belts should not skip teeth on their respective
pulleys. Replace the belts as required.
4. Ensure that the gate actuator operates smoothly
without binding. Replace as required.
5. Check the gate for smooth operation. It must operate
freely without binding. Lubricate contact parts as
shown in Figure Figure 9-1 with Rheolube grease.
Replace as required.
6. Inspect the push plate face for distortion. Replace as
required.
7. Check the transport for tight mounting.
8. Clean the exit sensor with a soft brush and ensure that
it is securely mounted in the rail. Ensure that the cable
routing is correct and that the cable is secure and not
damaged. Checked the blocked and unblocked
conditions of the sensor.
9. Ensure that all shaft retaining rings are secure on their
respective shafts.
10. Check that all rails are secured properly.
11. Clean the platen surface and the transport rails using a
soft cloth dampened with a mild soap and water
solution, if access permits.
12. Lubricate the transport at the following locations
(Figure Figure 9-1).
13. Run diagnostics to verify proper operation of the
transport.
Figure 9-1 Transport Module Lubrication Points (rear-load 860 mm shown)
9.2 Stacker Module
Perform the steps in the following checklist to maintain the stacker module.
Table 9-2 Stacker Checklist
Checked
1. Check that all pulleys are securely mounted to their
respective shafts.
2. Check for cracked bearings or bearings missing balls.
Ensure that all bearings are mounted flush to the
frame. Inner and outer races should be flush with each
other and should operate smoothly. Replace bearings
in pairs as required.
3. Check all timing belts for frayed edges or flat or worn
teeth. Belts should not skip teeth on their respective
pulleys. Replace the belts as required.
4. Check the vertical timing belts and ensure that they are
not damaged or worn and that they track correctly on
the shafts. Clean belts with a soft cloth dampened with
water. Replace as required. Verify that the vertical
belts lower shaft floats freely in its slots and the springs
provide the correct force.
5. Manually operate the cam assembly to ensure that it
does not bind, that the stacking tray moves up and
down freely, and the gate actuator moves freely.
Replace as required.
6. Clean the top rail (transport) sensor with a soft brush
and ensure that it is securely mounted in the rail.
Ensure that the cable routing is correct and secure,
and that the cable is undamaged. Check the blocked
and unblocked conditions of the sensor. Replace the
cable harness as required.
7. Rotate the cam completely clockwise until the access
hole in the cam is over the cam sensor. Use
compressed air to clean the cam sensor.
8. Ensure that all shaft retaining rings are secure on their
respective shafts.
9. Check the paddle wheels and ensure that they are not
worn or frayed and that they are properly seated on the
shaft. Check for the following and replace as required.
Paddle wheels should be 37.6 mm ±3.6 mm (1.48 inch
±0.150 inch) long and 3.00 mm ±0.50 mm (0.118 inch
±0.020 inch) wide along their full length.
10. Check all cable routing to the CCA and ensure that no
cables are pinched or rubbing against moving parts.
11. Run diagnostics to verify proper operation of the
stacker.
12. Lubricate as necessary (cam rollers, partition actuator,
etc.)
13. Check note stop setting.
14. Check that stacking tray does not hit divert wall during
raising and lowering.
15. Check that stacking tray rails do not hit end plate
during raising and lowering.
16. Check that all rails are secured properly
17. Check the stacker tray bumpers and replace as
necessary.
18. Check the divert door motion and clearance with the
divert platen. Replace if necessary.
9.3 Picker Module
Perform the steps in the following checklist to maintain the picker module.
Table 9-3 Picker Checklist

Checked
1. Vacuum or thoroughly dust the module to remove paper
dust.
2. Perform the following steps on each feed module:
a. Replace feed shaft assemblies if it was last replaced
more than 90 days ago. Ensure that the take-away
spring is not bent while installing the feed shaft. Verify
that the take-away spring has the proper drive force.
b. Replace stripper wheel and fender.
3. Run diagnostics after completing the preventive
maintenance checklists.
4. Check that vertical rails are seated properly.
Section 10
Parts Lists
For intermodule, module level, and CCA repair parts, refer to Section 3.5.
For transport repair parts, refer to Section 4.13.
For stacker repair parts, refer to Section 5.17.
For picker repair parts, refer to Section 6.10.
Appendix A
Related Documentation
The following table lists related documentation:
Table A-1 Related Documentation

Title Part Number
Advanced Function Dispenser Media Supply Cassette On-site Repair Manual TM-000027-001G
Advanced Function Dispenser Divert/Retract Cassette On-site Repair Manual TM-000052-001D
Advanced Function Dispenser Operating Guide TP-820714-001C

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Advanced Function Dispenser

On-site Repair Manual

CONFIDENTIAL - Trade Secret Material

The main components of the AFD are:

Figure 1-1 Advanced Function Dispenser Components

1.1 Transport Module

Figure 1-2 Transport Modules

1.2 Stacker Module

1.3 Picker Module

Figure 1-4 Picker Module

Feed Shaft Assembly

Stripper Wheel and Fender Assembly

Figure 1-5 Picker Module Major Components

1 Motor coupling 6 Take-away wheel shaft

Take-away Wheel Assembly

Stepper Drive Motor

Figure 1-6 Picker Stepper Motor

1.4 Circuit Card Assembly (CCA)

2.1 AFD Communication

2.2 Service Considerations

• Replace the processor hard disk drive

• Replace the AFD control CCA

2.3 How to Determine Advanced Function Dispenser Communication Status

Component Status Action

2.4 Updating the Advanced Function Dispenser Communication

To update the AFD communication perform the following steps:

1. Select Advanced Function Dispenser from the appropriate diagnostics.

2.5 Setting the Advanced Function Dispenser Communication

To set the AFD communication perform the following steps:

1. Access the AFD by opening the terminal chest door.

2.6 Sensor Recalibration

Sensors are calibrated using the appropriate diagnostics.

3.1 Control Circuit Card Assembly (CCA)

1. To replace the dispenser CCA, reverse the removal procedure.

Figure 3-1 Removing the CCA Cover

Figure 3-2 Removing the Dispenser CCA

1 Control CCA mounting screws (2)

3.2 Transport Module

1. Remove the divert cassette, if present.

Figure 3-4 Removing the Transport Module

1 Connector not properly seated

3.3 Stacker Module

1. To replace the stacker module, reverse the removal procedure.

Figure 3-6 Transport Module Top Drive Shaft

Figure 3-7 Stacker Module Latch Springs

1 Latch spring (2), push inward to release

3.4 Picker Module

3.4.1.1 Picker Module One and Two

1. Remove the control CCA (Section 3.1).

3.4.1.2 Picker Modules Three, Four, Five and Six

3.5 Dispenser Module-level Parts List

Figure 3-12 Dispenser Module-level Parts

Table 3-1 Rear-load Module-level Parts (860 mm and 620 mm)

Not Fuse, F2, CCA (5A, 125V, 19-040586- 19-040586- 1 1 1

Table 3-2 Front-load Module-Level Parts (720 mm and 625 mm)

Not Fuse, F2, CCA (5A, 125V, 19-040586- 19-040586- 1 1 1

4.1 Fascia Plate

Figure 4-1 Lubrication

1 Diebold lubricant (16-003082-000A)

2. To replace the fascia plate, reverse the removal procedure.

Figure 4-2 Removing the Lead-through Indicator and Exit Sensor

Figure 4-3 Removing the Fascia Plate

1 Fascia plate mounting screws at sides of transport module (M4-0.7)

1. Remove the fascia plate (Section 4.1.1).