Suzohapp Bill to Bill 300XE User manual

Rev. 2.4 - 1 - © 2014 Suzo-Happ Group
Serviceability Manual
The information contained here-in is the property of Suzo-Happ Group and is not to be disclosed or used
without the prior written permission of Suzo-Happ Group. This copyright extends to all the media in which
this information may be preserved including electronic, printout or visual display.
Under no circumstances any part of this publication may be copied, transmitted, transcribed or distributed
in any form or by any means, or stored in a database or retrieval system, or translated into any language
(natural or computer) without the prior written permission of Suzo-Happ Group.
Suzo-Happ Group reserves the right to change the product specifications at any time. Also, Suzo-Happ
Group disclaims any liability for any direct or indirect losses arising out of use or reliance on this
information. This information is for guidance only.

Rev. 2.4 - 2 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
Disclaimer
- Unplug power from unit before performing any of the procedures described in this manual
(with the exception of using the validator head cleaning card)
- Ensure all work is performed with an anti-static grounding hand strap to ensure no damage is
done to the electronic components inside
- Do not scratch any of the lenses in the unit
- Do not apply excessive force when cleaning the lenses
- Do not apply any liquids directly on unit, apply onto micro-fiber cloth instead
- All operations must be performed by a trained and qualified operator
- Any disassembly not performed according to this manual voids manufacturer’s warranty
- The unit displayed in this manual may vary from the unit being serviced due to different available
configurations. The main modules, however, are the same
- A side note pertaining to the particular module or operation
- A warning, steps that must be taken to avoid injury to the operator and/or damage to the
unit
Revision History
Aug. 30, 2011
Rev. 0
M. Bruhanov
Original Release
Jan. 31, 2014
Rev. 1
M. Bruhanov
Added DIP SW8 Description –Ch. 4.1
Feb. 13, 2014
Rev. 2
M. Bruhanov
Added A, B and C group reference, ownership
changes
Feb. 13, 2014
Rev. 2.1
M. Bruhanov
Corrected BPD Maintenance Chart
Apr. 03, 2014
Rev. 2.2
M. Bruhanov
Clarification of groups A, B and C / Piston position
adjustment
May 29, 2014
Rev. 2.3
M. Bruhanov
Troubleshooting 4.1. 5); 5, paragraph 1, change
chapter 6 to 7; 6 paragraph 1 change chapter 6 to 7
Nov 10, 2014
Rev. 2.4
R. DSouza
Updated sections 9.1 and 9.4

Rev. 2.4 - 3 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
Table of Contents:
1. SCOPE 5
2. INTRODUCTION 6
3. DEFINITIONS 7
3.1. Definitions of Dust and Debris 7
4. LEVEL 1 MAINTENANCE 8
4.1. Bill Validator (MFLV-9013, MFLV-2110) 9
4.1.1. Upper Compartment 11
4.1.2. Lower Compartment 11
4.1.3. Bezel Maintenance 12
4.2. Chassis (BBC-0110) 14
4.3. Recycling Cassettes (BBR-011X) 17
4.4. Path Switch (BBS-0110) 19
4.5. Dispenser (BBD-XXXX) 23
5. LEVEL 2 MAINTENANCE 26
5.1. Bill Validator (MFLV-9013, MFLV-2110) 28
5.2. Chassis (BBC-0110) 30
5.3. Recycling Cassettes (BBR-011X) 32
5.4. Path Switch (BBS-0110) 34
5.5. Dispenser (BBD-0X10) 36
5.6. Cashbox (FLSCXXXXX) 40
5.7. Box Control Unit 44
6. LEVEL 3 MAINTENANCE 47
6.1. Bill Validator (MFLV-9013, MFLV-2110) 50

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Bill-to-Bill™ 300XE
6.2. Chassis (BBC-0110) 53
6.3. Path Switch (BBS-0110) 54
6.4. Recycling Cassettes (BBR-011X) 55
6.5. Dispenser (BBD-XXXX) 58
6.6. Cashbox (FLSCXXXXX) 60
6.7. Box Control Unit 60
6.8. B2B Power Interface (BBP-571X) 60
6.9. Final Money Test 60
7. MAINTENANCE CHART 61
8. SPARE PARTS LIST 62
9. CONTACT INFORMATION 63
9.1. Technical Support 63
9.2. Training 63
9.3. Service Centers 63
9.4. Customer Service 64
APPENDICES 65
9.5. Sense-A-Click™ Module identification 65
9.6. Bill-to-Bill™ 300XE Field Report 67

Rev. 2.4 - 5 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
1. Scope
This document strictly pertains to the service and maintenance of the Bill-to-Bill™ 300XE
(MBB-5XXX) units. If in doubt whether this manual is applicable to your device, or any steps require
clarification, please contact a certified technician before beginning the service process.
Any hardware qualification involves the same three criteria. These criteria are as follows:
a) Reliability –This includes such parameters as Mean Cycle Before Jam (MCBJ)
and Mean Cycle Before Failure (MCBF)
b) Availability –The percent of the uptime the unit will experience in the field as well as downtime
during maintenance
c) Serviceability –This defines the ease with which a component, device or system can be
maintained and/or repaired. Also, the discussion of steps one may take in order to detect a
potential issue early, before it significantly influences the performance of the component, device or
system.

Rev. 2.4 - 6 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
2. Introduction
The Bill-to-Bill™ 300XE unit is a high-tech device that relies on its many sensors and mechanical
components in order to excel in its field of fare collection and bill exchange. It is designed to withstand
a multitude of environments ranging from northern to tropical and desert climates. It can operate in a
wide range of humidity levels and dusty air conditions. However, in order to ensure that the Bill-to-
Bill™ 300XE unit continues to function properly, it must be cleaned and preventative maintenance
must be performed regularly as outlined in this manual.
This document contains the recommended steps that should be taken to keep the Bill-to-Bill™ 300XE
unit running properly. It also includes a breakdown of all the required tools and detailed diagrams of
the procedures.

Rev. 2.4 - 7 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
3. Definitions
3.1. Definitions of Dust and Debris
Mild –Mild dust is being held loosely on the surface and can be removed simply by using either a
can of compressed air or by cleaning it lightly using a lint-free microfiber cloth
Moderate –The moderate level includes dust and debris that has been mixed with oily residue and
requires additional effort in order to remove it from the surface (this can be seen mainly
on rollers which place the dirt under pressure causing it to compact on its surface)
Extreme –Extreme dirt and debris cannot be removed without damaging the part. It has fused with
the part or is located in an area that cannot be reached and therefore the part must be
replaced in order for the Bill-to-Bill™ 300XE unit to function well.

Rev. 2.4 - 8 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
4. Level 1 Maintenance
This is the most basic level and it is designed to remove mild dust and debris along the various bill
paths in the Bill-to-Bill™ unit. It includes light cleaning of the sensors and rollers inside the bill
validator, chassis, recycling cassettes and dispenser. For recommended frequency of the
performance of this service level please refer to the Maintenance Chart in section 7.
Level
Location
Responsibility
Service Time (per unit)
1
On-Site
Operator
7-10min
The tools required for this level are:
1) Can of compressed air (found in local office supply stores, a compressed gas dust remover)
2) Alcohol-free LCD cleaner (found in local office supply stores)
3) Anti-static microfiber cloth
4) A set of cotton swabs
5) A pair of gloves
6) Cleaning card for bank note acceptor
Recommended replacement parts for this level
Part Number
Name
Quantity
Notes
OPT-CLEAN-KIT-1
Level 1 Kit
1
Level 1 cleaning kit
(Cleans up to 10 units)
5110049-01
Cam
1
Dispenser Housing Cam
(1)
(2)
(3)
(4)
(5)
(6)

Rev. 2.4 - 9 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
4.1. Bill Validator (MFLV-9013, MFLV-2110)
Two methods exist for cleaning the bill validator. The first is using a special bill validator cleaning card
and the second is by manually cleaning the sensors and internal surfaces of the bill validator.
Method 1:
A set of cleaning cards may be used to perform level 1 cleaning without the need of dismantling the
unit. The cleaning card acceptance mode can be activated either via switch No. 8 on the back of the
unit, or via the host interface. For more information on how to enable maintenance mode via the host
machine, please refer to the host machine manual. To enable the cleaning mode via switch No. 8 you
may follow these steps:
1) Unplug the power form the unit
2) Remove the validating head from the housing
3) Slide switch No. 8 to the OFF position as follows:
4) Replace the validating head and power cord
5) The unit is now in maintenance mode and will not accept the cleaning cards once enabled
6) Follow the instructions on the cleaning card to clean the unit
7) Once the cleaning was completed you may follow steps 1 to 5 in reverse order by bringing switch
No. 8 into the ON position.
Method 2:
When manually cleaning the bill validating head, the following steps must be followed:
First, remove the Bill Validator from the Bill-to-Bill™ 300XE unit by depressing the latch under the Bill
Validator Head and puling it out.
After the bill validator has been removed, open the lower and upper compartments.

Rev. 2.4 - 10 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
When trying to open the upper compartment, the motion is being restricted by a latch on the right side
of the validator head (in a position where the front is facing the operator). The latch should be
pressed inwards to allow the upper compartment to open up fully for easy access to the sensors.
1.
2.

Rev. 2.4 - 11 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
4.1.1. Upper Compartment
The upper compartment consists of a set of 3 o-ring rollers (bottom), bill aligning mechanism
(bottom), 3 plastic rollers (top) and 4 sets of sensors (2 on the bottom and 2 on top).
First, clean all the sensors (light guides) using a cotton-swab. Using the can of compressed air, spray
all rollers, aligning mechanism and other areas where dust has noticeably accumulated. Ensure the
can is pointing outwards when sprayed to prevent dust from entering deeper into the bill validator.
The rest of the surfaces should be wiped using the microfiber cloth and LCD cleaner.
Do not spray LCD cleaner directly on the unit. Spray on the micro-fiber cloth only.
Do not over saturate the micro-fiber cloth with LCD cleaner, apply sparingly.
Bottom section of Upper compartment: Top section of Upper compartment:
Extra care should be taken as to not dislodge the sensors out of their place by applying
excessive force!
4.1.2. Lower Compartment
The lower compartment consists of a set of 6 o-ring rollers (bottom), 6 plastic rollers (top) and 2
Sense-A-Click™ modules (one on the top and the second is on the bottom). The Sense-A-Click
sensors and other hard to reach sensors should be cleaned using a cotton swab. All rollers and
sensors then have to be cleaned using a can of compressed air following by cleaning the rest of the
surface using a microfiber cloth and LCD cleaner.
Bottom section of Lower compartment: Top section of Lower compartment:

Rev. 2.4 - 12 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
4.1.3. Bezel Maintenance
Both the bill validating head and the dispenser bezels attached to the door should be now
inspected for any damage caused by a vandalism attempt. If any such excessive damage is found
(such as dent or scratches in the bill entrance or perimeter areas) please contact our technical
support department.
Additionally, spray the compressed air can around the bill entrance (for the bill validating head
bezel) and exit (for the dispenser bezel) areas to remove dust particles and debris. This will
ensure it will not be transferred into the unit during future transactions.

Rev. 2.4 - 13 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
Spray the can of compressed air in all the cavities on the two bezels and ensure the dust is
sprayed outwards away from the unit as shown below:
Validating Head Bezel:
Dispenser Bezel:

Rev. 2.4 - 14 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
4.2. Chassis (BBC-0110)
First, remove the chassis out of the Bill-to-Bill™ unit by pressing the two blue buttons inwards and
pulling the handlebar out.
Next, remove the recycling cassettes and dispenser by pressing the release button of each module
and pull it away from the chassis. Set the module aside.

Rev. 2.4 - 15 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
Open the chassis to reveal the bill path by pressing down the two latch buttons at the top face

Rev. 2.4 - 16 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
Each half of the chassis consists of 6 sets of bill position sensors distributed along the bill path. The
sensors on one half can be distinguished by their clear rectangular appearance, and the sensors on
the other half are clear circular lenses embedded in the body. These 12 sets of sensors have to be
cleaned using a new cotton swab.

Rev. 2.4 - 17 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
Then, using a can of compressed air, spray the bill path (sensors and rollers) on the two halves of the
chassis.
Extra care should be taken when cleaning the area under the belts since this area is prone
to dust accumulation.
4.3. Recycling Cassettes (BBR-011X)
After the recycling cassettes have been removed from the chassis in previous step, turn the module
around in order to get the door to face you.

Rev. 2.4 - 18 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
This reveals two sets of sensors, one at the edge of the cover, and the other at the edge of the
recycling cassette. The sensors on the cassettes can be cleaned using a cotton swab without
opening the cover. However, do not use the compressed air can in this case.

Rev. 2.4 - 19 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
4.4. Path Switch (BBS-0110)
While the chassis is in the “open” position, remove the path switch from the chassis by disconnecting
the two bearings holding it in place and turning them until the bearing snap piece is pointing away
from the chassis.
In some cases, the switch lock might interfere in the removal of the switch and has to be
depressed as the switch is taken out of the chassis.

Rev. 2.4 - 20 - © 2014 Suzo-Happ Group
Bill-to-Bill™ 300XE
After the switch has been removed, using a can of compressed air, spray each slit thoroughly. Also
spray all other surfaces including the gears end and the stepping end (index disk) of the switch. This
will prevent the dust from wearing the surface of the teeth on the gears and that of the index disk.
Finally, find the location sensor on the index disk and clean it using a new cotton swab.
Do no clean the gears using cleaners or the micro-fiber cloth. This will remove the lubricant
and will dramatically shorten the lifespan of the path switch.
It is paramount to install the switch properly back into the chassis to avoid serious damage to the
switch and Bill-to-Bill™ 300XE unit.