Dixie Narco 90 Series User manual

803,902,620.01
DIXIE-NARCO
SERVICE MANUAL
SERIES 90
TWO/FOUR PRICE
VENDERS
(With Vend/Cam-Hold/By-Pass Switches)
Beginning Serial# 0001-6000CO
April 1997

INDEX
General Information......................................................................................................................Page 3
Installation / Set-Up / General Maintenance ............................................................Pages 4 through 11
Electrical Parts & Functions ...................................................................................Pages 12 through 19
Product Shimming ......................................................................................................................Page 20
Adjustments: Cams/Rear Spacers...........................................................................Pages 21 through 24
Sequence of Operation................................................................................................................Page 25
Troubleshooting ............................................................................................................ Pages 26 and 27
Refrigeration
Parts & Functions..............................................................................................Pages 28 through 31
Refrigeration Cycle...............................................................................................................Page 32
Refrigeration Troubleshooting..........................................................................Pages 33 through 37
Product Hot - Compressor will not run........................................................................Page 33
Product Hot - Compressor starts but will not keep running ........................................Page 34
Product Hot - Miscellaneous........................................................................................Page 34
Product Cold But Not Cold Enough - Compressor runs but won't cool product.........Page 35
Product Too Cold or Frozen - Compressor runs too long or continuously.................Page 36
Noisy Refrigeration Unit .............................................................................................Page 36
Excessive Condensate..................................................................................................Page 37
Electrical Schematics.................................................................................................... Pages 38 and 39
DIXIE-NARCO, INC.
P.O. Drawer 719
Williston, SC 29853
Phone: [phone]
Phone: [phone]
Fax: [phone]
Page 2 of 39

GENERAL INFORMATION
VENDER SAFETY PRECAUTIONS
Please read this manual in its entirety. This service information is intended to be
used by a qualified service technician, who is familiar with proper and safe
procedures to be followed when repairing, replacing or adjusting any Dixie-Narco
vender components. All repairs should be performed by a qualified service
technician who is equipped with the proper tools. Use only genuine Dixie-Narco
Factory replacement components.
Repairs and/or servicing attempted by untrained persons can result in hazards
developing due to improper assembly or adjustments while performing such
repairs. Persons not having the proper background may subject themselves to the
risk of injury or electrical shock which can be serious or even fatal.
PRODUCT IDENTIFICATION
The age of Dixie-Narco products is determined by the date code incorporated in the serial number.
The vender serial number takes the form xxxx-yyyyzz. The first 4 digits (xxxx) identify the specific vender.
The next 4 digits (yyyy) identify the manufacturing run that the vender was built in. The last two alpha
characters (zz) identify the quarter and the year the vender was built. The first alpha character identifies the
quarter:
A = 1st quarter
B = 2nd quarter
C = 3rd quarter
D = 4th quarter
The second alpha-character identifies the year:
O = 1990 U = 1996
P = 1991 V - 1997
Q = 1992 W = 1998
R = 1993 X - 1999
S = 1994 Y = 2000
T = 1995
General Information Page 3 of 39

INSTALLATION / SET-UP /
GENERAL MAINTENANCE
SERIES 90 CAN & BOTTLE VENDER
RECEIVING INSPECTION
Upon receipt, inspect the vender for shipping damage. If there is any damage, have the driver note the
damage on the Bill of Lading and notify Dixie-Narco. Although the terms of the vender sale require that the
consignee originate shipping damage claims, Dixie-Narco will gladly help if you must file a claim.
UNPACKING THE VENDERS
Remove the stretch wrap and top cover from the vender. If flavor cards were shipped with your vender they
will be in an envelope affixed to the back of a vender in the shipment or in the cash box.
Remove the shipping boards from the bottom of the vender. The shipping boards are attached by the
leveling legs. Remove the shipping boards by unscrewing the leveling legs. This will avoid unnecessary
damage to the leveling legs or the base. A 1½ inch "socket type" wrench should be used on the bottom of
the leveling legs. Be sure to replace the legs after removing the shipping boards.
NOTE
DO NOT STORE THE VENDER OUTSIDE WITH THE STRETCH WRAP ON.
THIS COULD CAUSE THE STRETCH WRAP TO BOND TO THE VENDER'S SURFACE,
WHICH COULD DAMAGE THE FINISH.
To open the vender, locate the door lock keys which are secured inside the coin return cup. After unlocking
the door, rotate the "T"-handle counter-clockwise until the door can be opened. Once inside, check the coin
box on the door for any additional parts, pricing labels, or information concerning factory equipped
accessories. Check the "T"-handle for proper alignment and locking functions. Check the lamps for proper
installation.
WARNING! Ensure that power is disconnected from the vender or that the power
interrupt switch (if provided) is not defeated before inspectin
g
or replacin
g
the lamps. Failure to compl
y
with these instructions ma
y
sub
j
ect the user to
the risk of injury or electrical shock, which can be serious or fatal.
Installation/Set-Up/General Maintenance Page 4 of 39

ELECTRIC POWER NEEDED
Refer to the vender serial number plate to determine the proper voltage and frequency the machine requires
(domestically this requirement is 115 Volts, 60 Hertz). Domestic venders will operate properly at +/- 10% of
the specified voltage. For domestic models this is between 103 volts and 127 volts. Single phase,
alternating current is required. The vender must be plugged in its own properly rated circuit with its own
circuit protection (fuse/circuit breaker).
DO NOT USE AN EXTENSION CORD.
GROUND THE VENDER
The vender is equipped with a three wire power supply cord and MUST be plugged in a properly grounded
outlet.
If the outlet will not accept the power cord plug, contact an electrician to install a proper AC outlet.
DO NOT REMOVE THE GROUND PIN OR IN ANY WAY BYPASS THE GROUNDING OF
THE VENDER
COIN CHANGERS AND OTHER ACCESSORIES
WARNING!
Failure to compl
y
with these instructions ma
y
sub
j
ect the user to the
risk of injury or electrical shock, which can be serious or fatal.
The Series 90 vender must have a 115 Volt 2/4 Price Coin Changer installed. Some styles can have a bill
acceptor installed. If the coin changer and other accessories are not factory installed refer to the instructions
received from the manufacturer of the coin changer and other accessories for proper set-up and installation.
INSTALLING A COIN CHANGER
Open the main door. Hang the coin changer on its mounting plate and secure it by tightening the three
securing screws in the vender. Set the vend prices according to the manufacturer's instructions. Plug the
coin changer in the 8-pin Jones socket in the vender. Manually load all the coin changer tubes with at least
ten coins each and "prime" the coin changer by making one correct change transaction.
BILL ACCEPTORS
Note: If a bill acceptor is not factory installed a bill acceptor interface harness may be required. Contact
the bill acceptor manufacturer or Dixie-Narco for interfacing information.
Installation/Set-Up/General Maintenance Page 5 of 39

PLACING THE VENDER ON LOCATION
DO NOT TRANSPORT THE VENDER TO OR FROM THE
LOCATION WHEN IT IS LOADED WITH PRODUCT; DAMAGE TO
THE VENDER MAY RESULT.
CAUTION!
The vender must be located on a solid, flat, and level surface. The vender must be positioned close enough
to an electrical outlet that an extension cord is not required. If securing the vender to the floor or wall is
required, call the Dixie-Narco Factory Service Department or your Dixie-Narco Representative for
suggestions.
LEVEL THE VENDER
Level the vender. When the vender is level the door can be opened to any position and it will not move by
itself. Open the door to several different positions before deciding the vender is level. A carpenter's level
will help verify that the machine is level.
Make sure that all of the leveling legs are in contact with the floor. If you cannot level the vender, select
another location. Do not place any objects under the machine.
SPACE THE VENDER
The vender must be properl
y
located and leveled to minimize the risk
of injury or death from tippin
g
in the event of user misuse or
vandalism.
DANGER!
Do not block the rear of the vender. Keep the vender 4 inches (10 cm) from the wall to insure adequate
airflow to the condenser and compressor. At the front of the vender, make sure that nothing obstructs the air
intake at the bottom of the main door. At the rear of the vender, make sure nothing obstructs the air exhaust
at the bottom of the cabinet.
INITIAL LOADING
Oscillators must be in the extreme left or right position to insure proper loading. When loading wide
columns, the first row of cans should be loaded on the bottom bar of the oscillator. The second row of cans
must be loaded on the top bar of the oscillator. Rotors must be in the "cup" position to receive the first cans.
When loading narrow columns lay the rows in the column until the column is full.
Do not fill the columns to the top of the cabinet. Allow about 3 inches (7.6 cm) at the top of the column
because the can stack will move up and down in the column during the vend cycle. Correct loading will
prevent service calls and insure proper vending.
After loading a vender for the first time, test vend each selection with money until the first can is delivered.
This will ensure that the vender is loaded and working properly.
NOTE: TO INSURE PROPER AIR FLOW THROUGH THE EVAPORATOR, DO NOT PLACE
CANS (OR OTHER FOREIGN OBJECTS) IN THE BOTTOM OF THE TANK.
Installation/Set-Up/General Maintenance Page 6 of 39

INSTALLING FLAVOR CARDS
The flavor cards may be inserted one of two ways: 1) in the select buttons, or 2) in the flavor card carrier.
1.) Swing the coin changer mounting plate away from the outer door, exposing the back of the
select buttons. The flavor cards are inserted in the back of the select buttons from either side.
Ensure the flavor cards are placed in the select buttons that correspond to the column in
which the product is loaded.
2.) Swing the coin changer mounting plate away from the outer door, exposing the back of the
select panel. Remove the flavor card carrier. Ensure the flavor cards are placed in the select
button flavor card carrier position that corresponds to the column in which the product is
loaded. Install the flavor card carrier back into position.
Installation/Set-Up/General Maintenance Page 7 of 39

CLEANING THE VENDER
WHAT TO CLEAN
DO NOT USE A WATER JET OR NOZZLE TO CLEAN THE VENDER.
SIGN FACE
The polycarbonate sign face requires proper cleaning to prolong the service life of this item. It is
recommended that you periodically clean the sign face as follows:
1. Rinse the sign with a soft cloth or sponge soaked in warm water.
2. If necessary, use a mild soap to loosen any dirt or grime. To prevent damage, DO NOT SCRUB
or use a brush or squeegee, as some signs have a clear ultraviolet resistant coating to prevent
yellowing.
3. Repeat the above steps as necessary, then dry using a soft cloth to prevent spotting.
CABINET
1. Wash the cabinet with a good detergent or soap mixed in warm water.
2. Wax the vender often with a good grade of automobile wax.
3. Any corrosion inside the vender should be removed with fine steel wool and the area should be
painted with aluminum paint.
4. Repair any scratches on painted surfaces to prevent corrosion.
REFRIGERATION CONDENSER
THE COMPRESSOR ELECTRICAL CIRCUIT IS ALWAYS LIVE
WHEN THE PLUG IS CONNECTED TO AN ELECTRICAL
OUTLET.
WARNING!
1. Check the condenser periodically for dirt or lint build up.
2. Remove the build up with a brush or vacuum, or blow the dirt out of the condenser with
compressed air and approved safety nozzle.
3. Ensure nothing obstructs air intake at the bottom of the main door.
4. Ensure nothing obstructs air exhaust at the rear of the cabinet.
COIN ACCEPTOR
Follow the Coin Acceptor Manufacturer's instructions.
Installation/Set-Up/General Maintenance Page 8 of 39

LUBRICATING THE VENDER
The vender refrigeration system does not require any field lubrication. The hermetic refrigeration system
and fan motors are manufactured with lifetime lubrication.
TIME COMPONENT LUBRICANT EXAMPLE
Every 6 Months
(or as needed)
Main Door
1. Lock Bolt & Nut Retainer
2. Hinge Pivot Points
Inner Door
1. Hinge Pivot Points
Mechanics Friend
Mechanics Friend
Every Year
(or as needed)
Inner Door
1. Door Gasket Petroleum Jelly
Installation/Set-Up/General Maintenance Page 9 of 39

TEMPERATURE CONTROL ADJUSTMENTS
Adjustment #1 - Temperature Adjustment
Turn the adjustment clockwise for colder product and counter-clockwise for warmer product. This
will change the cut-out temperature only, the cut-in temperature remains constant.
Adjustment #2 - Altitude Adjustment
WARNING
DISCONNECT POWER TO THE VENDING MACHINE BEFORE PROCEEDING
WITH THIS ADJUSTMENT.
The control is factory set for an altitude of 152 M (500 ft.). For higher altitudes, adjust the inside range
screws to prevent freeze-up of the product. Adjust the inside range screws as follows.
ALTITUDE CUTLER-HAMMER 9531N272
Meters Feet Turn both screws counter clockwise
610 2,000 1/8 Turn
1219 4,000 1/4 Turn
1829 6,000 1/2 Turn
2438 8,000 5/8 Turn
Installation/Set-Up/General Maintenance Page 10 of 39

CHECK IT OUT
WHAT TO DO WHAT SHOULD HAPPEN
Plug the power cord in. The compressor, condenser fan, and evaporator fan
run, "Use Correct Change" window lights and "Sold
Out" lamps light. The fluorescent tubes light.
Load at least six beverages in each column. Sold out lights go off.
Close the vender door, put in correct change, and
push a select button.
Product is dispensed and delivered.
If a dollar bill validator is used: Load the changer
with at least 10 quarters, 10 dimes, and 10
nickels. Prime the coin changer, insert $1 bill in
the validator.
Correct change is paid back.
Push a select button. Product is dispensed and delivered.
Once the vender is placed on location, load the
changer money tubes. Fully load the vender with
product and allow it to run overnight.
Return to the vender the next day and vend a product
from each column. A cold product is dispensed from
each column and correct change is returned. The first
product vended has a temperature of 00 C (320F) to
10 C (340F).
Installation/Set-Up/General Maintenance Page 11 of 39

ELECTRICAL PARTS AND FUNCTIONS
CORRECT CHANGE LAMP
O
R
Correct Change Lamp
804,700,540.21
(125 VAC)
Correct Change Lamp
904,700,180.31
(English)
The Correct Change Lamp is mounted in the Coin Insert Casting.
The Correct Change Lamp is controlled by the Coin Changer and is "OFF" when coins are in the tubes of
the coin changer.
SELECT SWITCH
OR
The Select Switch is located in the Select Panel behind the press button and is secured with two (2) screws.
Select Switch
804,100,710.21
804,100,510.01
The Normally Closed contact of the Select Switch is in the Select Panel Circuit.
The Normally Open contact of the Select Switch is in the Sold-Out Lamp and Vend Motor Coil Circuits.
When a Select Button is pressed, the Normally Open contact closes and completes the Sold-Out Lamp
Circuit and the Vend Motor Coil Circuit.
Electrical Parts & Functions Page 12 of 39

SOLD OUT SWITCHES (2 in a cluster)
The Sold-Out Switch Cluster is located on the Front Mechanism Plate under the Vend Motor Cover.
The Sold-Out Switches are the "snap-in" type. To install, place the switch in position over the opening,
push in and at the same time slide to the right.
Sold-Out Switch Cluster
804,100,910.01
SOLD-OUT SWITCH CLUSTER
A) Front Sold Out Switch (one per column)
•The Common terminal of the front Sold-Out Switch receives power from the Vend Motor
Switch Circuit.
•The Normally Closed contact of the front Sold-Out Switch is in the Coin Changer Inhibit
Circuit. This Normally Closed contact (kept closed by can or bottle) is in parallel with all the
other Normally Closed contacts of the Front Sold-Out Switches and when all are open, the Coin
Changer will not accept coins.
•The Normally Open contact of the front Sold Out Switch is in the Sold-Out Lamp Circuit. The
Normally open contact illuminates the Sold-Out Lamp when a column is empty of product.
B) Vend Sold Out Switch (one for each vending circuit)
•The Normally Closed contact of the Vend Sold Out Switch is in the Vend Motor Circuit. This
Normally Closed contact (held closed by can or bottle) stays closed in the Vend Motor Circuit so
the Vend Motor Circuit can be completed.
•The Normally Open contact of the Vend Sold Out Switch has no function.
Electrical Parts & Functions Page 13 of 39

SOLD OUT LAMPS
Sold-Out Lamp
804,700,510.01
The Sold-Out Lamps (one for each vending circuit) are secured to the back or to the Select Buttons in the
Selector Panel.
The Sold-Out Lamp is turned on by the closing of the Normally Open contact of the Vend Sold-Out Switch.
COIN CHANGER
There are Coin Changers available which contain either two or four circuits to
enable the vender to operate with two or four different priced items.
Inside the Coin Changer are circuits called Price Lines. The Price Lines are in the
Vend Motor Circuits and complete the Vend Motor Circuits so that a selection can
be made.
The Price Lines are connected to the vender through the Changer Socket which is a
part of the Vender Wiring Harness.
Four Price Coin Changer
Price Line # Changer Socket Pin #
1 3
2 4
3 7
4 8
Two Price Coin Changer
Price Line # Changer Socket Pin #
1 3
2 4
Coin Changer
Electrical Parts & Functions Page 14 of 39

VEND MOTOR
For Wide Column
For Narrow Column
The Vend Motor (one for each vending stack) is mounted on a bracket on the Front Mechanism Plate.
The Vend Motor is in the Vend Motor Coil Circuit. The Vend Motor runs when a select button is pushed.
The Normally Open contact of the Select Switch closes and completes the Vend Motor Coil Circuit.
The Vend Motor continues to run through the Normally Open contact (closed by the Vending Cam) of the
Vend Motor Switch. The Vend Motor stops when the Vend Motor Switch arm drops off the high side of the
Vend Motor Cam, and the Normally Open contact of the Vend Motor Switch opens.
Electrical Parts & Functions Page 15 of 39

CLUSTER (TRIPLE) SWITCH
The Vend Motor, Cam-Hold, and the By-Pass Switches are secured together to make the Cluster (Triple)
Switch. The Cluster (Triple) Switch, one per Vend Motor, is located on the Vend Motor Assembly and
secured by two screws.
A) Vend Motor Switch
•The Normally Open contact of the Vend Motor Switch is in the Vend Motor Coil Circuit.
This contact closes to keep the Vend Motor operating until the arm of the Vend Motor
Switch drops off the high side of the Vending Cam at the end of the Vend Cycle.
•The Normally Closed contact of the Vend Motor Switch is in series with all the other
Normally Closed contacts of the Vend Motor Switches to send power to the next Vend
Motor Switch to its right and on to the Coin Changer Inhibit Circuit.
B) Cam-Hold Switch
•The Normally Open contact of the Cam-Hold Switch is in the Coin Changer Inhibit Circuit
and is in series with the other Normally Open contacts of the Cam-Hold Switches. This
contact opens and cancels credit when the arm of the Cam-Hold Switch drops off the high
side of the Vending Cam.
•The Normally Closed contact of the Cam-Hold Switch is in the Vend Motor Coil Circuit.
This contact supplies power to run the Vend Motor while both the Vend Motor Switch and
the Cam-Hold Switch arms are in the notch of the Vend Cam.
C) By-Pass Switch
•The Normally Open contact of the By-Pass Switch forms a circuit around Vend Motor
Switch to keep the Coin Changer Inhibit Circuit closed if the Vend Motor stops while the
arm of the Vend Motor Switch is on high cam. This ensures that all other vending circuits
are operative.
•The Normally Closed contact of the By-Pass Switch is in the Counter circuit. Shortly after
the beginning of the vending cycle, the arm of the By-Pass Switch drops off the high side
of the Vending Cam. At this time the Normally Closed contact closes, sending current to
the Counter.
Electrical Parts & Functions Page 16 of 39

VEND RELAY
The Vend Relay is not used in Two/Four Price venders.
The Vend Relay Function is an integral part of the Coin Changer itself.
SEQUENCE RELAY (Not on all Venders)
The Sequence Relay, if used, is located on a bracket adjacent to the Vend Relay Socket on the main door
and is secured with two screws.
When a credit is set up by the Coin Changer and Select Switch #1 is pressed, the Normally Open contact of
Select Switch #1 completes the Sequence Relay Coil Circuit.
Electrical Parts & Functions Page 17 of 39

VEND MOTOR WIDE COLUMN
Mounted on the Vender with the Cluster (Triple) Switch on the left side (See Fig. 3). The Linkage and
Drive Arm assembly is used to connect the Vend Motor to the Oscillator. (See Fig. 4)
Fig. 3
Cluster (Triple) Switch
804,100,700.01 - 2/4 Price
Vend Motor - Wide Column - 2/4 Price
491,170,100.13 - 1¼" Deeper
497,170,100.13 - T-Models
Not Available At Print - E-Models
e Pin 900,901,940.01
OLD STYLE
A Drive Pin 900,901,940.41
B. Drive Arm, Zinc 801,200,950.91
C. Washer 900,700,600.01
D. Linkage Arm, Zinc 801,201,030.01
E. Nyliner (Top) 901,803,160.01
F. Sems Screw 900,301,640.01
G. Nyliner (Bottom) 901,804,770.01
NEW PLASTIC STYLE
B. Drive Arm (Plastic) 801,806,160.21
D. Linkage Arm (Plastic) 801,806,170.01
F. Sems Phil Pan Screw 900,303,090.01
E-MODELS
B. Drive Arm (Zinc) 801,200,950.91
D. Linkage Arm (Zinc) 801,201,590.21
F. Truss Screw 900,303,180.01
Fig. 4
Nyliner (Rear Stack)
801,803,170.01
Oscillator Assembly
491,070,900.03 - 1¼" Deeper
497,071,000.03 - T-Models
609,070,400.03 - E-Models Cans
609,070,500.03 - E-Models Bottles
Electrical Parts & Functions Page 18 of 39

Nyliner (front stack)
901,804,230.01
Electrical Parts & Functions Page 19 of 39

Sold-Out Spring
901,700,740.01
Sold-Out Paddle
Wide and Narrow
432,070,190.23 - Standard
432,070,270.03 - Large Product Special Use Only
609,070,190.03 - E-Model Special Use Only
Sold-Out Switch Assy. Snap In
804,100,680.51 - 2/4 Price
(Insulator & Switch are one piece)
VEND MOTOR NARROW COLUMN
Mounted on the Vender with the Cluster (Triple) Switches on the underside (See Fig. 1). The shaft of the
Vend Motor slides into a slot in the Vend Rotor (See Fig. 2).
Fig. 1
Cluster (Triple) Switch - 2/4 Price
804,100,700.01
Vend Motor - Narrow Column (2/4 Price)
491,170,200.03 - 1¼" Deeper
497,170,200.03 - T-Models
Not Available At Print - E-Models
Fig. 2
Vend Rotor
801,201,211.61 - 1¼" Deeper
801,201,230.01 - T-Model, Narrow
801,201,220.01 - T-Model, Wide
801,201,560.31 - E-Model
Electrical Parts & Functions Page 20 of 39