20 Sankyo Maintenace Manual ICT3Q8-3A2761 [PDF]

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MAINTENANCE MANUAL Type Name :

ICT3Q8-3A0761

AMR-NP-05229-04

Spec. No. Notes : Application model Sankyo Model

No. of sheet Custody

Distribution

MCT1Q8-1R0761 ICT3Q8-3A0761 ICT3Q8-3A2761 MCT3Q8-3A0763

Sym.

Revision

Design R.Nishikawa May.31.2013 T.Watanabe May.31.2013 Det-che ICT3Q8-3A0761 Type Name

Appro.

Diebold P/N. 49-209537-000E 49-209540-000D 49-209542-000E 49-209544-000D

Page

Cha. No. Date By Reference Document

Appr.

AMR-NP-05229-01

NIDEC SANKYO CORPORATION No. S39Z-032-00-02E

No

AMR - NP -05229 –04

1

/ 65

Contents 1. Introduction ...........................................................................................................................................................3 1.1

Applicable models .........................................................................................................................................3

1.2

Applicable limit of this maintenance manual ................................................................................................3

2. Name of parts on Magnetic card reader.................................................................................................................3 3. Periodical Maintenance .........................................................................................................................................4 3.1

Maintenance by user......................................................................................................................................4

3.1.1

R/W Head cleaning................................................................................................................................4

3.1.2

LTI cover cleaning.................................................................................................................................4

3.2

Maintenance by Field service ........................................................................................................................4

4. Replacement steps of Maintenance parts...............................................................................................................6 4.1

R/W Amp. Board Ass'y Replacement ............................................................................................................7

4.1.1 Adjustment and check of Chip detect sensor..................................................................................................14 4.1.2 4.2

Adjustment and check of Skimmer sensor ..............................................................................................15

LTI PCB replacement ..................................................................................................................................24

4.2.1

To remove the front cover ...................................................................................................................24

4.2.2

To remove the diffusion cover.............................................................................................................25

4.2.3

To detach the Skimmer sensor cable from Bezel and remove the LTI PCB .......................................26

4.2.4

To detach the LTI cable from Bezel and remove the LTI PCB...........................................................28

4.2.5

To remove the LTI PCB ......................................................................................................................28

4.2.6

To insert the LTI cable of New PCB through the hole of the bezel ....................................................29

4.2.7

To insert the Skimmer sensor cable through the hole of the bezel ......................................................29

4.2.8

To put the LTI cable to the bezel.........................................................................................................29

4.2.9

To put the Skimmer sensor cable to the bezel .....................................................................................30

4.2.10

To attach the diffusion cover ...............................................................................................................30

4.2.11

To attach the front cover......................................................................................................................31

4.3

Motor Ass'y Replacement ............................................................................................................................33

4.4

R/W Head Guide Block Ass'y Replacement................................................................................................34

4.5

Guide Ass'y Replacement ............................................................................................................................37

4.6

Pre-Head Ass'y Replacement .......................................................................................................................38

4.7

Stripe-up Bracket .........................................................................................................................................39

4.8

Timing Belt & Roller Replacement .............................................................................................................40

4.9

Capture Roller #1 to #3 Replacement..........................................................................................................40

4.10

Circuit boards replacement ..........................................................................................................................42

4.10.1

Two extension cables are added to connecting with BEZEL Ass’y....................................................42

4.10.2

Change S44A456A01 and mounting plate ..........................................................................................44

4.11

BEZEL ASS’Y replacement ........................................................................................................................44

4.12

Gate lock replacement .................................................................................................................................46

No

AMR - NP -05229 –04

2

4.12.1

Change gate lock into hedgehog..........................................................................................................46

4.12.2

Change old hedgehog into new hedgehog ...........................................................................................47

4.13

Hedgehog replacement ................................................................................................................................47

5. SW1 Replacement (Micro Switch for card detector)...........................................................................................48 6. SW2 Replacement (Micro Switch for shutter) ...................................................................................................50 7. Shutter Solenoid Replacement (Including Bezel Ass'y Replacement) ................................................................52 8. Pad-Roller Gap Adjustment.................................................................................................................................54 9. IC contact block Ass'y Replacement ...................................................................................................................55 10.Trouble Shooting Flow Chart .............................................................................................................................57

No

3

AMR - NP -05229 –04

1. Introduction 1.1

Applicable models

Sankyo P/N Diebold P/N ICT3Q8-3A0761 49-209540-000D ICT3Q8-3A2761 49-209542-000E MCT3Q8-3A0763 49-209544-000D MCT1Q8-1R0761 49-209537-000E EAF: Enhanced anti-fishing 1.2

Description 3TK R/W / 8 Contacts / Chip Sensor /EAF / Skimmer sensor 3TK R/W Hi-Co / 8 Contacts / Chip Sensor /EAF / Skimmer sensor 3TK R/W / EAF/ Skimmer sensor TK2 Read only/ Skimmer sensor

Applicable limit of this maintenance manual This manual is designed only for those who maintain the listed products at a maintenance service center or equivalent location.

2. Parts of magnetic card reader R/W AMP Board DC Motor IC Contact Block

Pre-Head Fig.2-1

No

AMR - NP -05229 –04

4

3. Periodical Maintenance 3.1

Maintenance by user

3.1.1

R/W Head cleaning

(1) The cleaning card (Specification #68-76-02-51-8 DWG.No. EGCMC01881) specified by Sankyo must be used. (2) Cleaning should be done with a cleaning card when R/W errors often occur. (3) If R/W errors still occur after Head cleaning, clean the rollers. Working time : 1 minute Tool : EGCMC01881 (This card is provided separately. ) Cleaning frequency: approx. 6 month intervals (normal condition : Indoor use ) 3.1.2

LTI cover cleaning

(1) Cloth dampened with some alcohol liquid should be used for cleaning the LTI cover. (2) Cleaning should be done when the Skimmer sensor value with object decreases significantly. Working time :

1 minute

Tool :

alcohol liquid(ethanol etc.) , cloth (Felt, Swab)

Cleaning frequency: approx. 6 month intervals (normal condition : Indoor use )

3.2 Maintenance via Field service Rubber roller cleaning (1) A cloth dampened with some alcohol liquid should be used for cleaning the rollers when a cleaning card is not effective. (2) Cleaning should be done during periodical inspections. Note 1) If alcohol was used during the cleaning process, please wait until the alcohol dries off before resuming operation. Working time :

2 minutes

Tool :

alcohol liquid(ethanol etc.) , cloth (Felt, Swab)

Cleaning frequency: approx. 1 year intervals (normal condition : Indoor use )

No

AMR - NP -05229 –04

5

Cleaning point of rollers and LTI cover

#2 Roller #1 Roller #3 Roller

LTI cover

DC Motor

GATE

Fig.3.2-1

No

AMR - NP -05229 –04

6

4. Replacement steps of Maintenance parts (1) All maintenance parts are listed in the spare parts list and Exploded View drawing indicated below. Model No.

Spare parts List No.

Exploded view No.

Remarks

ICT3Q8-3A0761

AMP-NP-05229-02

T12A368A01

Maintenance only

ICT3Q8-3A2761

AMP-NP-05229-02

T12A368A01

-

MCT3Q8-3A0763

AMP-NP-05229-02

T12A368A03

Maintenance only

MCT1Q8-1R0761

AMP-NP-05229-02

T12A368A02

-

(2) Notes for maintenance There are two different kinds of values indicated in this manual; one is for adjustment and the other is for inspection. The adjustment value is more rigid than the inspection value. Please be sure to distinguish between the values.

No

7

AMR - NP -05229 –04

4.1 R/W Amp. Board Ass'y Replacement Working time : Tool :

20 minutes (includes inspection and adjustment) Screw Driver (M2.5), PC ( Tool that can send the commands ), Developer (Magnetic viewer), Gauge (M03A483A03), Speed Master Card (EGC201001)

Label on the main PCB

First 2 digits

PCB P/N

Type

15

S44A456A01

For 3Q8

27

S44A456A02

For 1Q8

The first 2 digits represent the type

PCB Rev Barcode label

No

8

AMR - NP -05229 –04

Remove screws, "I" shown in the Fig.4.1-1 from the board (Ref.No.112). Disconnect all connectors from the board. Replace the R/W Amp. Board Ass'y. Sankyo P/N.

Mylar Sheet

Board Ass’y + Case

ICT3Q8-3A0761 ICT3Q8-3A2761

Maintenance only M53A184A01

S44A456A01

MCT3Q8-3A0763 MCT1Q8-1R0761

Remarks Maintenance only

M33A918A01

S44A456A02

-

For the Pass counter: If it is possible to communicate with the old board, read the Pass counter for Life check and Head wear and save the data. The data is used after assembling. (1) Read the Pass counter command "CGA" Mylar Sheet

Screw(I)

Case

AMP Board Ass'y

Fig.4.1-1

(1) Assemble in the reverse order of the above disassembling. (2) Fasten screw, "I" at 35 cN.m (3.5Kgf.cm)

No

AMR - NP -05229 –04

About Back up RAM Error If Back up RAM Error (Error code B1) is detected, send Revive command "Cy0" twice. The first time, "N" response is returned. The 2nd time, check if "P" response is returned. Then follow procedure A~E. For details, see Back up RAM diagnosis (P.64)

A. Sensitivity of the detectors

(1) Send Sensor standard value setting Command "C>3".

(1) Send Sensor Level transmit Command "C>1". (2) Receive response. "P>100v1h v1l v2h v2l v3h v3l v4h v4l" Comparison of vi and each sensor is as follows. PD1:v1 PD2:v2 PD3:v3 PDI:v4 Convert to the Voltage Data 4.5V -> vih=34(H),vil=35(H) *Standard: Sensor Voltage >1.2V Note: 1) Adjustment and Check must be done without the presence of a card. 2) For detailed procedures if sensor check failed, please refer to Page 9. B. Card Speed Check (1) Send Enable Command "C:2". (2) Insert "Speed Master Card" (No. EGC201001). (3) Send card speed Command "C82". (4) Receive response at card forward. "P8202XXXX" XXXX = 0DEC+- 67hex (190mm/s +- 3%). If XXXX is out of 0DEC +- 67hex, replacement R/W Amp. Board Ass'y.

9

No

AMR - NP -05229 –04

C. Start sentinel Position Check and Adjustment (1) SS Position Check by magnetic pattern on card To write magnetic data on 3 tracks. To put the gage on the card that the data were written as Fig.4.1-2. To check that the 1st bit on Track 1 and 2 locates within Line A (6.94-7.94). To check that the 1st bit on Track 3 locates within Line B (6.44-8.44). Standard L = 7.44mm +- 0.5mm (Track 1 & Track 2) L = 7.44mm +- 1.0mm (Track 3) In case the 1st bit is not located within the above-mentioned position, the following re-adjustment should be done.

Fig.4.1-2 Note) In case of failure, please calculate the quantity for the shift guessing from the space of the gauge (0.5 mm).

10

No

AMR - NP -05229 –04

11

(2) SS Position Adjustment i) Send next Commands in sequence for initializing SS Position. "CB000" "CB100" In "CB0##" or "CB1$$", "##" and "$$" is the value for adjusting SS position. When "CB1xx" is executed, the value "$$" is compared the data which is sent by "CB0##" just before. If the value "$$" is same as "##", the value is written in F-ROM, and this value take effect for adjusting SS position. So, these commands must be a set and you must send these commands in this sequence above. If the value "$$" is not same as "##", the response is "NB104". If ICRW fails writing the data in F-ROM, the response is "NB115"(F-ROM Error). In this case, please execute "CB1$$" again. ii) Write magnetic data on a card. You should write the data to one track using "C71..", "C72..", "C73..". Must not use "C79" (All three tracks simultaneous write) iii) If SS Position of each Track is out of standard written above, adjustment is necessary. iv) Calculate reference value: x = (7.44 - L)/0.12 (Use any SS position that is out of standard value for calculating reference value)

Transfer hex code x>0

x -> ab

x cd . ab = 100h – cd

v) Send next Commands in sequence. "CBO ab" "CB1 ab" vi) Write magnetic data on a card. You should write the data to one track using "C71..", "C72..", and "C73..". Must not use "C79" (All three tracks simultaneous write) vii) If SS Position of each Track is out of standard written above, adjustment is necessary again. We recommend returning the step i) to avoid increasing error (If not succeeded, the different R/W amp board is required since the board might be damaged.)

No

AMR - NP -05229 –04

SS Position Adjustment Send Command "CB000" "PB000"

Must be a set and Must send in this sequence

Send Command "CB100"

"PB100"?

Negative Response "NB115"(F-ROM error)

Y Write magnetic data on a card (Three tracks) Check SS Position in each track

Finish Adjustment

N

SS Position is out of Standard?

Y Calculate reference value (using any SS Position which is out of standard value). ex. Reference value is 26 (1Ah)

Send Command "CB0xx" ex. "CB01A"

"PB000"

Must be a set and Must send in this sequence

Send Command "CB1xx" ex. "CB11A"

"PB100"?

Negative Response "NB115"(F-ROM error)

Y Write magnetic data on a card (Three tracks) Check SS Position in each track

Finish Adjustment

N

SS Position is out of Standard?

Y

12

No

AMR - NP -05229 –04

D. Set the Pass counter If there is the Pass counter of the old board, set it in the New board. Set the Pass counter command "CGBxxxxxxxx" (counter data length is 8 byte) "xxxxxxxx" is the counter of old board. If there is not the Pass counter of the old board, reset it in the New board. (1) Reset the Pass counter command "CGB00000000". (The pass counter is "00000000" when the board is provided) E. Set the Serial number Set the Serial number that is in the label of the model. (1) Set Serial number command "Ce0 ZYMMxxxx". "Ce1 ZYMMxxxx". The data that is transmitted by ASCII code is set with "Ce0". Subsequently the same data is set with "Ce1". (The serial number is "00000000" when the board is provided)

Serial number structure: The length of data = 8 bytes The meaning of each data is as follows. (in ASCII code) Z

Y

M

model

Year

Month

K

2

0

model

2012

May

M

X

X

X

X

0

3

Unit number

Ex.) S/N. J2050003

Model

5

0

0

#3 of May. production

Sankyo Model

Diebold P/N.

J

MCT1Q8-1R0761

49-209537-000E

D

ICT3Q8-3A0761

49-209540-000D

L

ICT3Q8-3A2761

49-209542-000E

H

MCT3Q8-3A0763

49-209544-000D

13

No

AMR - NP -05229 –04

4.1.1 Adjustment and check of Chip detect sensor Working time : Tool :

10 minutes (includes inspection and adjustment) Screw drivers(for adjusting trimmer) PC( Tool that can send the commands ) Oscilloscope.

(1) Supply power to the card reader. (2) Send the Initial command"C030" (3) Send chip detect sensor command "CQT".(Drive the sensor coil) (4) Adjust the VR3 until the sensor output becomes minimum value. The value after adjustment must be less than 0.17V. (5) Send chip detect sensor command "CQU".(Stop driving the sensor coil) (6) After adjustment, paint the VR3 for marking. Note. Adjustment must be done without the presence of a card. Test pin is TPS2 Ground pin is TSWG

(1) Send chip detect sensor command "CQT".(Drive the sensor coil) (2) Insert the IC card into card throat slowly. (3) Check whether the chip detect sensor output max voltage is more than 1.9V. (4) Without the IC card, check whether the chip detect sensor output voltage is less than 0.17V. (5) Send chip detect sensor command "CQU".(Stop driving the sensor coil) Note. Test pins are the same as the case of adjustment.

TSWG

TP92

VR3

Fig4.1-3. R/W Amp Board Ass’y (Inside)

14

No

4.1.2

15

AMR - NP -05229 –04

Adjustment and check of Skimmer sensor

This procedure is applicable for 49-209537, 542-000E or later Working time : Tool :

15 minutes (Including inspection and adjustment) PC( Tool that can send the commands ) Test tool (49-230926-000B) Insulation component.

4.1.2-1 How to handle the test tool A) Insert the tool on the side 1 with the splitter wall.

Slide 1

Fig2a. Measure the sensor resading values of side 1 B) Remove or insert the splitter wall from the tool.

Splitter wall Fig2b. Remove or insert the splitter wall C) Insert the tool on the side 2.

Slide 2

Fig2c. Measure the sensor reading values of side 2

No

AMR - NP -05229 –04

16

4.1.2-2 Adjustment and check of Skimmer sensor

KGS16: Sensor value (LED ON) of test tool (Side 2 +alpha). (See 4.2.4-1-C and fig6) Side 1: Sensor value (LED ON) under the condition of 4.2.4-1-A. < Check before operation and periodical calibration of the test tool> It is necessary to check the following test tool before operation and periodical calibration. See the ASD Diebold Test Tool Daily Inspection. 1) Master reader: JMM-365 2) Test tool: 49-230926-000B 3) Program tool: EAF-EB-00317

Perform the adjustment using the program tool that we provide. For more details, please refer to the following. In addition, please also refer to “Chart of Adjustment” section below. 1) Set the Ambient light to be less than 600Lux, Temperature: from 20 to 30 deg C. 2) Use the card reader without fascia. 3) Supply the power to the card reader. 4) Launch the Program tool (EAF-EB-00317). 5) Select the “2:Ajustment anti-skimmer”. (See Fig2d)

Fig2d

6) Enter the value of α.(See Fig2e, Fig6) 7) Set Test tool (Slide1) to the gate. (See Fig2f) 8) Next, set Test tool (Slide2) to the gate. (See Fig2g) 9) At the end, set Test tool (Slide1) to the gate. (See Fig2h)

Fig2e

Fig2f

Fig2g

Fig2h

No

AMR - NP -05229 –04

10) If it is displayed as shown in Fig2i, adjustment is complete. If it is displayed as shown in Fig2j, it is no good. Adjust from 7), again.

Fig2i

The adjustment value

Fig2j

1) Complete until 1-5 of adjustment procedure. 2) Enter the value of α and name of input Note. “input Note” is the file name of the result that is created after this check. (See Fig2k) e,g) Sankyo1 3) Set Test tool (Slide1) to the gate. (See Fig2m) 4) The results are displayed as shown in Fig2n.

Fig2k

Fig2m

Fig2n

17

No

AMR - NP -05229 –04

ASD adjustment Command 1.Offset adjustment CQy + Gain(1digit) + VR value(3digit) Gain:

1(H gain) 0(L gain)

VR value:001-255 Response: Gain(1digit) + OFF value(4digit) + ON value(4digit) 2.Offset adjustment save CQp + VR value(3digit) VR value:001-255 Response: non 3.Gain adjustment CQz + Gain(1digit) + VR value(3digit) Gain:

1(H gain) 0(L gain)

VR value:001-255 Response: Gain(1digit) + OFF value(4digit) + ON value(4digit) 4.Gain adjustment save CQp + VR value(3digit) VR value:001-255 Response: non

18

No

AMR - NP -05229 –04

19

1) Offset adjustment Chart1 (without the tool) (for example) Start CQy1001 ON value is v2

Yes

70 vih=34(H),vil=35(H) *Standard: Sensor Voltage >1.2V Note: Adjustment and Check must be done without the presence of any card. Procedures when sensor check fails 1) When Sensor Voltage = 0V Check the connections of the flat cables from Guide Ass'y and R/W Head Guide Block Ass'y. (Connector, B and C in the exploded view T12A368A01. ) 2) When 0 < Sensor Voltage < 1.2V The area around the photo sensors (PD1, PD2, PD3,PDi) might be dirty. Clean the portions around the sensors with the cleaning card (EGCMC01881) or clean the portion shown in the below dismounted R/W Head Guide Block Ass'y according to the article( Page 10 ).

PDi

PD3

PD2

PD1 R/W Head Guide Block Ass'y P/N. SBW247604 (ICT3Q8/MCT3Q8, LoCo) S31A644A08 (ICT3Q8, HiCo) R/W Head Guide Block Assy

Fig.4.4-2

Read Head Guide Block Ass'y P/N. S04A115A02 (MCT1Q8)

B. Track Skew Track Skew is checked in R/W Head Guide Block Ass'y testing at Sankyo and the checked R/W Head Guide Block Ass'y is provided. As long as it is mounted correctly, Track Skew is guaranteed. In order to verify mounting, Track 2 position shall be checked with the gauge. 1) Write magnetic data on Track 2 only. 2) Put the gage on the card that the data was written on as Fig. 4.4-3. 3) Check the written data located within line C. 4) In case failure, disassemble R/W Head Guide Block Ass'y and check whether there is a problem in mounting or not. If the test still fails, please change R/W Head Guide Block Ass'y.

TR.2 Read only models (MCT1Q8) After replacement of Read Head Guide Block Ass'y, please check ISO TR. 2 reading with a card.

No

AMR - NP -05229 –04

Fig.4.4-3 C. Start sentinel Position Check Please refer to P6. D. R/W operation (1) Check if R/W operation succeeds without any problem. If a problem occurs, please check Connector connection. If still unsuccessful, please take action according to the Trouble Shooting Chart. E. Reset the Pass counter Reset the Pass counter for Life check and Head wear. (1) Reset the Pass counter command "CGB00000000".

36

No

4.5

AMR - NP -05229 –04

Guide Ass'y Replacement Working time : Tool :

20 minutes (including inspection and adjustment) Screw Driver (M3) and PC (Tool that can send the commands) Developer (Magnetic viewer). Gauge ( M03A483A03)

(1) Remove the board (Ref.No.112) per the instructions of 4.1. (2) R/W Head guide block Ass'y (Ref.No.4) per the instructions of 4.2. (3) In case IC Contact Block is mounted, Remove the Bezel Ass'y(Ref.No105) (4) Remove screws shown in the Fig.4.5 from the Guide Ass'y upper side (Ref.No.108). (5) Replace Guide Ass'y.

Screws

Guide Ass'y P/N. SBW244902

Fig.4.5

(1) Assemble in the reverse order of the above Disassembling. (2) Fasten screws at 74 cN.m(7.5 Kgf.cm)

A. Sensitivity of the detectors (see P35 4.4, check points A) B. Track Skew (see P35 4.4, check points B ) C. Start sentinel Position Check (Please refer to P10) D. R/W operation Check if R/W operation succeeds without any problems. If a problem occurs, please check Connector connection. If still unsuccessful, please take the action according to Trouble Shooting Chart.

37

No

4.6

AMR - NP -05229 –04

38

Pre-Head Ass'y Replacement

Working time : Tool :

7 minutes (including inspection and adjustment) Screw Driver (M2), Card encoded on only track #2 (Sankyo P/N TMD-MS-043-02), PC (Tool that can send the commands), and Oscilloscope

(1) Remove screws shown in the Fig.4.6-1. (2) Replace Pre-Head Ass'y. Pre-Head Ass'y P/N.S31A035A02

Screw "a"

Screw

Leaf-Spring plate Leaf Spring: P/N. M02A139A01 Plate: P/N. MFA330001 Fig.4.6-1

(1) Assemble in the reverse order of the above Disassembling.

A. Head mounting (1) Adjust Pre-Head position to be set as indicated below and fix the screw, "a".

Fig.4.6-2 B. Amplifier output (1) Confirm if the Amplifier output of Pre-Head is more than 100mVo-p when the card is ejected. Amp. output *Standard (All Model) more than 100mVo-p (Check Point TP AMP :P) *Required tool: card encoded on only track #2

No

4.7

AMR - NP -05229 –04

39

Stripe-up Bracket Working time : Tool :

3minutes Screw Driver (M3)

1. Remove Screw-C and disassemble Cover 2. Rotate Cover to fit "R" shaped part to Solenoid side and mount it with Screw-C. 3. Mount Stripe-up Bracket.

Stripe-up Bracket

Screw-C

R-shape

Cover P/N.S28A646A03 Fig.4.7-1

P/N S01A478A01

Screw

No

4.8

AMR - NP -05229 –04

40

Timing Belt & Roller Replacement Working time: Tool:

10 minutes (including inspection and adjustment) Screw Driver (M3), Scale and Tension gauge ( In case of no tension gage, please refer to the note below. ), E-Clip Tool (E5), CE-Clip Tool (CE6)

1) Remove the R/W Amp.Board Ass'y per the instruction of 4.1(p.7). 2) Lose "Screw" and decrease the tension of Belt 3) Remove Timing Belt "7". 4) Remove the screw "g" fixing capture roller "2". 5) Remove the retaining rings "I" and "k" fixing shaft. 6) Pull out Pulley Ass'y to the direction shown with the arrow in the figure. 7) Remove Timing Belt “6” and Roller“2” and Roller“5” 8) Replace Belt or Roller, and then assemble in the reverse order of the above disassembling. Note 1) Pay attention to the insert locking pin in Roller "5". 2) Fit the tooth form of Timing Belt "6" and Timing Pulley when assembling. 3) There is the possibility of deformation of Retaining Ring "I" and "k" during remova. If deformed, the part(s) should be replaced by new ones. CE-Clip

i E-Clip k

g

h

pin

2

g

k

i

P/N.KYG214502 PIN

5

6 2

5

P/N.S28A731A01 Capture Roller

7 P/N.KYG212912 4.9

11

screw Fig.4.8-1

Capture Roller #1 to #3 Replacement

(1) Remove screw “g” and fixing capture roller “2”. (2) Remove the retaining rings “i” and “k” and Poli-Slider "h" fixing shaft. (3) Pull out Pulley Ass’y to the direction shown with the arrow in the figure (Fig.4-9-1). (4) Remove #1Roller“2” to #3Roller“2”. (5) Replace Capture Roller, and then assemble in the reverse order of the above disassembling.

Note (1) There is the possibility of deformation of Retaining E-Ring “i” during removal. If deformed, the part(s) should be replaced by new ones. (2) Please tighten screw "g" with 54N･cm(5.5kgf･cm) when you exchange capture roller "2" . (P/N.S28A731A01 #1Roller to #3Roller)

No

AMR - NP -05229 –04

i Screw Screw tightening torque：54N・cm

g

41

E-Ring h

Poli-Slider k

2

CE-Ring

#3 Roller

P/N.S28A731A01 Capture Roller #1 to #3

g

2

Pull out Pulley Ass’y

2

#2 Roller

#1 Roller

Fig.4.9-1

1) Loosen Screw and add pressure between 400 and 450 gf to the position of the Tension Pulley shown in Fig. 4.9-2. 2) Attach Screw under the conditions that the above-mentioned pressure added. Note) In case of no tension gage for adding pressure, mark the fixing position before replacement and fix Screw to fit the position to the mark after replacement. 3.9-4.4N (400-450gf)

Fig4.9-2

No

AMR - NP -05229 –04

42

4.10 Circuit boards replacement Has the consolidated circuit board?

No.

Yes.

Mounted Anti fishing unit?

Yes.

Yes.

Gatelock.

Hedgehog.

No.

Change to New S44A456A01.

Change to S44A456A01 and change mounting plate.

Two extension cables are added to connect with BEZEL ASS’Y. ( S39A914A01 , S39A915A01) Change to S44A456A01.

An extension cable is added to connect with BEZEL ASS’Y. ( S39A914A01 ) 4.10.1

Two extension cables are added to connect with BEZEL Ass’y Working time : Tool :

15 minutes (including inspection and adjustment) Screw Driver (M2) , Scale and PC ( Tool that can send the commands )

(1) Disconnect the connector from the External PCB. (2) Remove screws, "I" shown in the Fig.4.1-1 from the board (Ref.No.112) (3) Cut a tube. (4) Connect the extension cables. (S39A914A01,S39A915A01) (5) Bind BEZEL ASS’Y and cables with tubes. (Without chip detect and led) (6) Connect all cables. (7) R/W operation Check if R/W operation has been done without any problem. If a problem occurs, please check Connector connection. If still unsuccessful, please take the action according to the Trouble Shooting Chart.

(1) (1)

(3)

No

AMR - NP -05229 –04

Extension cables.( S39A914A01 LTI)

Extension cables.( S39A915A01 Gatelock)

(5)

(5)

Gatelock’s cables. LTI board’s cables.

LTI board’s cables.

Red, Brown.

Yellow, Purple, Orange.

43

No

4.10.2

AMR - NP -05229 –04

44

Change S44A456A01 and mounting plate (Refer to page “4-2”.)

New mounting plate (M47A921A01)

AMP Board ASS’Y + Case

4.11 BEZEL ASS’Y replacement Has the consolidated circuit board?

No.

Yes.

Mounted Anti fishing unit?

Mounted Anti fishing unit?

Yes.

Yes.

Gatelock.

Hedgehog.

No.

Yes.

Yes.

Gatelock.

Hedgehog.

Change S28A643A09

Change S28A643A04.

(with Skimmer sensor and Chip Detect).

(with Skimmer sensor and Chip Detect).

No.

Change Gatelock into Hedgehog. (S45A981A01) Change S28A643A05 Change S28A643A09. (with Skimmer sensor and Chip Detect). Change S28A643A08 (with Skimmer sensor , without Chip Detect).

(with Skimmer sensor , without Chip Detect).

No

Working time : Tool :

AMR - NP -05229 –04

45

10 minutes (includes inspection and adjustment) Screw Driver (M3) , Scale and PC ( Tool that can send the commands )

(1) Disconnect the FPC cable from the sensor PCB. (2) Disconnect the connector from the External PCB and AMP Board ASS’Y (3) Remove screws “f”. (4) Replace the BEZELAss'y.( S28A643A09, S28A643A08 , S28A643A04 S28A643A05 ) (5) R/W operation Check if R/W operation occurs without any problem. If problem occurs, please check Connector connection. If still unsuccessful, please take the action according Trouble Shooting Chart.

(1) S28A643A04 or S28A643A05

(2)

(2)

(2)

(1) S28A643A08 or S28A643A09

Screw(f)*3

No

4.12 Gatelock replacement

4.12.1

AMR - NP -05229 –04

Has the consolidated circuit board?

No.

Yes.

Change Gatelock into hedgehog.

Change old Hedgehog into new hedgehog.

Change gate lock into hedgehog.

Working time : Tool :

10 minutes (including inspection and adjustment) Scale and PC ( Tool that can send the commands )

(1) Disconnect the gate lock’s connector from the External PCB. (2) Bind BEZEL ASS’Y and gate lock’s cables with tube. (3) Add Hedgehog to card reader.(Refer to page 55) (4) Connect hedgehog’s cables. (5) Bind BEZEL ASS’Y and Hedgehog’s cables with tubes. (6) R/W operation Check if R/W operation occurs without any problem. If problem occurs, please check Connector connection. If still unsuccessful, please take action according to the Trouble Shooting Chart. (2)

(5)

4.12.2

Change old Hedgehog into new hedgehog

46

No

Working time : Tool :

AMR - NP -05229 –04

47

10minutes (including inspection and adjustment) Screw Driver (M2) , Scale and PC ( Tool that can send the commands )

(1) Cut tubes. (2) Remove screws, "I" shown in the Fig.4.1-1 from the board (Ref.No.112) (3) Disconnect the Hedgehog’s connector from the AMP board. (4) Change old Hedgehog into new hedgehog. (5) Connect Hedgehog’s cables (6) Bind BEZEL ASS’Y and Hedgehog’s cables with tube. (7) R/W operation Check if R/W operation has been done without any problem. If problem happens, please check Connector connection. If still NG, please take the action with Trouble Shooting Chart according to the content of the error.

(1) & (6)

4.13 Hedgehog replacement Has consolidated circuit board?

No.

Yes.

Change a new Hedgehog.(Refer to 4.12.2)

Change a new Hedgehog.(Refer to 4.12.2)

No

AMR - NP -05229 –04

5. SW1 Replacement (Micro Switch for card detector) Working time : Tool :

3minutes Screw Driver(M 2) and ST-SW card (No. EGCMC0119) and Soldering iron

1. Disassemble Bezel Ass'y 2. Remove Screw D and Screw P 3. Remove lead wires along the ditch 4. Remove the soldered 2 parts for the wires by a soldering iron. (Lead wires/ red and brown ) 5. Replace Micro Switch and solder the lead wires as shown in Fig. 5.1, 5.2. (Thermal Shrink Tube has to be inserted. ) 6. Assemble in the reverse order of the above 1., 2. and 3. ( 3. -> 2. -> 1.) Screw D Plate Ass'y

Screw P

Detect lever Micro Switch P/N. E11A255A01 Plate

Detail Fig.5.1

Brown wire

102 Connector Ass'y

Micro Switch P/N. E11A255A01

Tube Red wire

b Fig.5.2

48

No

AMR - NP -05229 –04

49

< Adjustment> (1) Insert the ST-SW card (No. EGCMC0119) into card throat slowly. When the position B of ST-SW card contacts micro switch actuator (see Fig.5.1), a click sound will come from the switch. This sound shows the SW1 detected the card (SW1 ON). At this position, fasten the adjusting screws for SW1. (2) Next, draw out the ST-SW card a little bit. A click sound will come from the SW1 again when position A of the ST-SW card comes by the micro switch actuator. This sound indicates the switch turned OFF. (3) Confirm if the SW1 works correctly at each ST-SW card position.

ST-SW Card DWG No.EGCMC0119

Adjusting Screw for SW1

SW1 Lever

Position A (52.7mm) Position B (53.5mm)

Fig.5.3

No

AMR - NP -05229 –04

50

6. SW2 Replacement (Micro Switch for shutter) Working time : Tool :

3 minutes Screw Driver(M2) and Shaft(1.5mm Diameter) and Soldering iron

1. Disassemble Bezel Ass'y 2. Remove Screw D and Screw P 3. Remove lead wires along the ditch 4. Remove the soldered 2 parts for the wires with a soldering iron. (Lead wires/ green and blue) 5. Replace Micro Switch and solder the lead wires as shown in Fig. 6.2. (Thermal Shrink Tube has to be inserted. ) 6. Assemble in the reverse order of the above 1., 2. and 3. ( 3. -> 2. -> 1.) Screw P Micro Switch P/N. E11A255A01

Screw D

Plate

Fig.6.1 Green wire Micro Switch P/N E11A255A01

102 Connector Ass'y

Tube

b

Blue wire

Fig.6.2 Micro Switch detail

No

AMR - NP -05229 –04

51

1) Insert the shaft of 1.5mm diameter into the bezel hole A through plate hole P. 2) Loosen Screw B. 3) Set micro switch (SW2) ON (OFF -> ON) and fix it with Screw B. 4) Checkpoint: After setting SW2 OFF (ON -> OFF) by moving the solenoid plunger, the shutter should fully close the card entry gate of the bezel. In addition, after returning the solenoid plunger, SW2 should be set ON

Bezel Hole "A"

Micro Switch

Shaft

Screw B

Plate Hole "P" Detail Fig6.3

No

AMR - NP -05229 –04

52

7. Shutter Solenoid Replacement (Including Bezel Ass'y Replacement) Working time : Tool :

5 minutes Screw Driver (M3) and Shaft(2mm diameter)

Refer to the exploded view (T00A527A01) and the next page for replacement. Remove Screws "L" (3 screws) for disassembling Bezel Ass'y. (Refer to Fig.7-1) < Shutter Solenoid Replacement (SBE413301(old TYPE) -> Lead wire TYPE:S28A328A01)> 1. Disassemble Bezel Ass'y 2. Remove Screw M 3. Remove Lead wires (Orange and Yellow) from connector of old solenoid 4. Insert Lead wires (White) in the connector of new solenoid (Refer to Fig.7-2 at the next page ) 5. Replace Solenoid and lead wires 6. Assemble in the reverse order of the above 1., 2. ( 2. -> 1.)

1) Remove Screw L and disassemble the shutter gate assembly. 2) Loosen Screw M and, when the solenoid is fully plunged, adjust the solenoid so that Plate hole P coincides with Bezel hole B. (Insert the shaft of 2mm diameter into the bezel hole B through plate hole P.) After this adjustment is done, fix the solenoid with Screw M. 3) Checkpoint: When the solenoid is plunged, the shutter shall be fully open. Note. If you change the whole Bezel Ass'y , it is necessary to adjust the "chip detect sensor" and "skimmer sensor". (See 4.1 R/W Amp. Board Ass'y Replacement) Screw L

Screw M Shutter Solenoid Ass'y P/N. SBE413301(old) P/N. S28A328A01(new)

Screw L

fully plunged Bezel Ass'y

Connector Ass'y Fig.7-1

Sankyo P/Ns of Bezel Ass'y S28A643A09(for ICT) S28S643A08(for MCT) With effect from the consolidation of the circuit board. S28A643A04(for ICT) S28A643A05(for MCT)

No

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53

Connector Ass'y NEW Solenoid Lead Wire

SW1 and SW2 From Soleniod Yellow

White (twe)

Orange

Yellow & Orange Removes

Both are acceptable White Wire Insert

Fig7-2

Bezel Hole "B"

Plate Hole "P" Fig7-3

No

AMR - NP -05229 –04

54

8. Pad-Roller Gap Adjustment Working time : Tool :

8 minutes Screw Driver(M3),Thickness Gauge(0.1mm) ,0.25mm Card(Sankyo P/N EGC203501)

(1) Loosen the attachment screws, "e", then fasten screws, "e" at the position where Gap A and Gap C looks equal to each other. (2) Adjust Gap A and C with nut "b" to be at 0.0mm- 0.1mm. (3) Confirm if a card (of thickness = 0.25mm) can transport back and forth. How to check the gap (Min. over 0 mm / Max. less than 0.1 mm) Max. less than 0.1 mm: 0.1 mm thickness gauge cannot be inserted GAP A and GAP C. Min. over 0 mm: Pad Roller M can rotate smoothly when rotated by hand.

Gap C

Gap A

Nut(b)

Screws(e) Fig.8-1 PAD Roller "M"

Fig.8-2

No

9.

AMR - NP -05229 –04

55

IC contact block Ass'y Replacement Working time : Tool :

10minutes (including inspection and adjustment) Screw Driver (M3,M4) and Adjustment card and PC( Tool that can send the commands )

Stay; (1) Remove the R/W Amp.Board (see 4.1) Tamper Protect Type (P/N.SBM945601) (2) Dismount lock machine unit(hedgehog) by removing screw 1 Applicable Model ICTxQx (3) Dismount Stay (Tamper Protect) by removing screw 2. Non Tamper Protect Type (P/N MBE454001) (4) Remove screws 3 from IC Contact Block Ass'y. Applicable Model MCTxQx (5) Replace IC Contact Block Ass'y. Screw1

Hedgehog (P/N.S45A981A01)

emboss IC Contact Block Ass'y P/N. SBM947802 Screw3

Screw2

Screw2 Stay (Tamper Protect)

Fig.9-1

(1) Assemble in the reverse order of the above Disassembling. (2) Attach the Block at the very right side of positioning. (3) Connect Cables to connector of PCB.

No

AMR - NP -05229 –04

56

(1) Preparation for IC contact position adjustment card Stick the sheet with the holes that those fit in the minimum specification of EMV IC contact position as shown in the drawing on IC card. The sheet shall be stacked on the card to fit in the edge of the card. ( less than +/- 0.1 from the edge of the card )

Sheet Sankyo P/N:BVS224801

Stick (adhesive)

IC Card

FFF Fig.9-2 (2) (3) (4) (5) (6)

Send Enable Command "C:0". Insert "Adjustment card " (Fig.7-2). Send IC set Command "C@0" . Send ICC Power on Command "CI0" Receive response. Positive response "PI0 " *** OK Negative response "NI0 " *** NG (9) Readjustment (7) Send IC release Command "C@2" . (8) Send Eject Command "C30". (9) Readjustment i) Shift the Block about 0.2mm to the left then attach the Block. ii) Follow the instruction (2) - (8) again. O.K.**** finish (Set PCB to fasten screws.) N.G.**** exchange the Block and readjustment Note Normally, the position of IC Contact Block decides the default position (Assembly position). However, in case degradation of the lighting sensors occurs, the ICC feed position moves and readjustment is required.

No

AMR - NP -05229 –04

10. Trouble Shooting Flow Chart START

Encoded card Standard card

(Recover Rate: **%: For Reference only)

Card Insertion

No 1. Shutter open?

Go to Bezel Ass'y diagnosis

Yes No 2. Card captured?

Go to card Transport diagnosis

Yes No 3. Data read?

Go to data Read diagnosis

Yes No 4. Data written?

Go to data Write diagnosis

Yes No 5. Card ejected?

Go to card Transport diagnosis

Yes

6.IC contact ?

No

IC contact block Ass'y Diagnosis

Yes No Skimmer sensor is OK?

Go to Skimmer sensor diagnosis

Yes LTI function is OK? Yes END

No

Go to Bezel Ass'y diagnosis

57

No

Bezel Ass'y Diagnosis

Recovered

SW1 signal (point A)

No

AMR - NP -05229 –04

42%

SW1 needs adjustment

Check ON/OFF

58

fail

or replacement (see p.48)

Yes Recovered

Pre-Head signal (point Gp Check ON/OFF

65%

No

Pre-Head needs fail adjustment or Replacement (see P.50)

Yes Recovered Solenoid section signal (point D) Check ON/OFF

42%

No

Sol. needs adjustment or replacement (see p.52)

fail

SW2 needs adjustment or replacement (see p.50)

fail

LTI PCB replacement (See P.24)

fail

Yes Recovered SW2 signal (point C) Check ON/OFF

No

44%

Yes Recovered LTI function is OK?

No

Yes

Chip detect sensor adjustment (See p14) Skimmer sensor adjustment (See p15) END EAF: Enhanced anti-fishing

Bezel Ass'y Replacement (see p.52)

No

AMR - NP -05229 –04

59

Transport Diagnosis

Recovered

Sensor ON/OFF Check Points: F1 for PD1 F2 for PD2 F3 for PD3 Fi for Pdi

No

Yes Motor ON Check Point E Yes

Slipping Roller #1- #4 Yes END

Sensor adjustment (see p.9) Guide Ass'y Replacement (see p.37) Recovered

No

No

R/W Amp. Board Ass'y Replacement (see p.7) and/or R/W Head Guide Block Ass'y

94%

Motor Replacement and adjustment (see p.33) Recovered

No

94%

No

R/W Amp. Board Ass'y Replacement (see p.7)

85%

Cleaning roller (see p.4)

No

Roller Gap adjustment (see p.54)

No

AMR - NP -05229 –04

Read Diagnosis Recovered

Amplifier Output Point: G1 for TR#1 G2 for TR#2 G3 for TR#3 Internal specification within TR#1 and #3 :510mV0-p +-43% TR#2 : 560mV0-p +-43% at Standard Card all"1" (P/N:TMD-MS-043)

Amplifier output level Check OK ?

Card Speed Check 190mm/s +- 3% (see p.9) Yes END

R/W Amp. Board Ass'y Replacement (see p.7) And or R/W Head Guide Block Ass'y Replacement (see p.37)

No

Yes No

67%

60

No

AMR - NP -05229 –04

61

Write Diagnosis Recovered Write Current Check Point: H1: for TR#1 H2: for TR#2 H3: for TR#3

85%

R/W Amp. Board Ass'y Replacement (See p.7)

No

Yes Recovered Read after Write Amplifier Output Lever Check More than G1 for TR#1: 120mVo-p G2 for TR#2: 120mVo-p G3 for TR#3: 120mVo-p

95%

R/W Head Guide Block Ass'y Replacement (See p.37)

No

Yes Recovered Card Speed 190mm/s ± 3%

No

48%

R/W Amp. Board Ass'y Replacement (See p.7)

Yes Recovered SS Position 7.44 ± 0.5mm Yes

END

No

SS Adjustment (See p.10)

90%

No

R/W Amp Board Ass'y Replacement (See p.7)

No

AMR - NP -05229 –04

62

IC contact block Ass'y Diagnosis Recovered

97%

R/W Amp Board Ass'y replacement (See p.7)

No Solenoid

No

IC contact block Ass'y

Section signal(Point H)

replacement

Check ON/OFF

(See p.55)

Yes Recovered

IC contact position Check (See p.56)

Yes

End

No

Yes 78%

Yes

IC contact block Ass'y

No

Sensor ON/OFF Check

adjustment

Point:

(See p.55)

Fi for PDi No Go to card Transport Diagnosis

No

AMR - NP -05229 –04

63

Skimmer sensor diagnosis

Download the applicable

Yes

"Received command was undefined" is received? (Error code"00")

F/W for skimmer sensor No R/W Amp. Board

R/W Amp. Board is broken

replacement

Correct the skimmer sensor cable connection No Yes

Cable connection is OK? Yes Skimmer sensor read Command

No

response is positive?

"LED wire broken"

Yes No

is returned?

No

"Command to the hardware that does not exist" was received? (Error code"03")

Yes

Yes

LTI cover is

Following value is OK?

No

1.KGS#16-Xtalk=(480+α)+/-30mV

LTI cover cleaning (See p.4)

2.LED OFF value is about 50mV

Yes No

Test jig is clean

Yes

and not scratched?

Photo sensor is broken

No No Sensor adjustment is OK?

Check the Test jig

Bezel Ass'y Replacement

(See p.15 Check before operation and periodical calibration)

(See P.52)

Yes END

Skimmer sensor Adjustment (See p.15)

No

AMR - NP -05229 –04

64

Back up RAM diagnosis

Back up RAM Error? No

(Error code "B1) Yes Send Revive command "Cy0"twice.

Send Initial command "C000".

Back up RAM Error? (Error code "B1) No Follows Procedure A~E. A. Sensor adjustment B. Card speed check C.SS adjustment D. Set the pass counter E. Set the Serial number (See P.7 About Back up RAM error)

END

Yes

R/W Amp Board Ass'y replacement (see p.7)

No

Appendix: Outside view of R/W Amp. Board Model No. ICT3Q8-3A2761 ÎS44A456A01 Other Model

AMR - NP -05229 –04

65

*For reference Parts List No.

Inside View of R/W Amp. Board

S44A456A01 for ICT3Q8-3A0761 ICT3Q8-3A2761 MCT3Q8-3A0763 S44A456A02 for MCT1Q8-1A0761 Note: ICT3Q8-3A0761 and MCT3Q8-3A0763 are only maintenance.

Point D(2pin) Point C(4pin) Point A(6pin)

R/W Amp Board

J301 ① ① GND

Point H (19pin)

IC301 Point E (FWD) Point E (BWD)

GND Point GP Point G3 Point G2 Point G1

①

Point Fi Point F1 Point F3 Point F2

TPS TPF2F TPAMP

Point H(12pin)

J6

Point H(8pin) Point H(3pin)

①