PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 1 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 REVISION HISTORY Revision Revision Date Prepared by (E-Signature) Approved by (E-Signature) Description of Change A 24-APR-2014 SENTHILRAJAN.S JOS SENDEN Initial release B 04-JUN-2014 SENTHILRAJAN.S JOS SENDEN C 21-AUG-2014 SENTHILRAJAN.S JOS SENDEN Mandatory List Added, Cleaning method updated, Shutter Adjustment Spec corrected from 2.1mm to 2.0mm, Packing & Best practices Details added. Added Sankyo Part number for width switch adjustment card & Packing Specification Added. D 08-SEP-2014 SENTHILRAJAN.S JOS SENDEN Added Plastic Box packing details. E 27-NOV-2014 SENTHILRAJAN.S JOS SENDEN Handling Instructions Added (Ref section 8.0) F 16-APR-2014 SENTHILRAJAN.S JOS SENDEN Motor testing connection diagram added in section 5.4.3.9. G 01-DEC-2015 SENTHILRAJAN.S JOS SENDEN H 19-JUN-2016 SENTHILRAJAN.S JOS SENDEN I 25-SEP-2016 SENTHILRAJAN. S JOS SENDEN Added torque settings for bezel in section 5.4.2.1. Removed S06A093A01 – IC Contact Position Card in Sec 5.4.4.3, and from Test card list in Sec 3.0. Document Ref# format changed from NCR-RO-STD-XXXX TO GRO-PRDXXXX. Compatible Card reader P/N’s list added for the New Motor P/N 9980914467(Sankyo P/N S35A210A10). Ref Sec 5.4.3.5. The below mentioned line removed from this procedure. Ref Sec 5.4.3.5 (For the Non compatible models PCB need to be changed to make it compactible). J 05-FEB-2018 SENTHILRAJAN. S JOS SENDEN SA BLOCK ICB PIN ASSY 9980914613 REPLACEMENT PROCEDURE ADDED IN SECTION 5.4.4.2. 009-0028982 CONTACT BLOCK - ROHS COMPLIANT (NEMO) DETAILS ADDED IN SECTION 5.4.6. TEST PROCEDURE ADDED FOR MEI & SW1, SW2 3RD CONNECTOR IN SECTION 6.9 & 6.10. (IPT-0772) Special Comments: NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 2 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 TABLE OF CONTENTS 1.0 GENERAL INFORMATION: ................................................................................................................................ 3 2.0 HARDWARE & SOFTWARE MANUALS: .............................................................................................................. 3 3.0 TOOLS, FIXTURES, JIGS & TEST EQUIPMENTS:................................................................................................ 4 4.0 MANDATORY CHANGING PARTS: ..................................................................................................................... 6 5.0 REPAIR PROCESS: ........................................................................................................................................... 7 5.4.1 DISASSEMBLY: .............................................................................................................................................. 12 5.4.2 BEZEL ASSEMBLY (Throat / Shutter):............................................................................................................ 15 5.4.3 MAIN TRANSPORT: ........................................................................................................................................ 20 5.4.4 SMART CARD BLOCK: ..................................................................................................................................... 39 5.4.6 UPGRADES: ................................................................................................................................................... 57 6.0 TESTING: ....................................................................................................................................................... 59 7.0 PACKING: ...................................................................................................................................................... 74 8.0 SPECIAL INSTRUCTIONS: ............................................................................................................................. 83 NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 1.0 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 3 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 GENERAL INFORMATION: The purpose of this document is to provide a minimum set of standards for Motorized Card Readers. The information is presented in a sequence that is expected to provide the most consistent results. Although organizations may have different techniques for accomplishing the work, the basic sequence outlined in the document is a recommendation which should be taken up going forward. 2.0 HARDWARE: 2.1 2.2 HARDWARE: • NCR 56XX & 66XX ATM or equivalent • All I-MCRW, U-MCRW and NU-MCRW SOFTWARE: • Windows XP • Aptra XFS NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 3.0 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 4 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 TOOLS, FIXTURES, JIGS & TEST EQUIPMENT’S: REPAIR TOOLS : Screwdriver Phillips: 0, 1 & 2. Screwdriver Slotted: 3 mm. Tweezers 649SA (antimagnetic). Cutter. Nippers. Pliers. Universal AVO Meter. Spanner 8mm and 5.5 mm. Allen Key 1.5 mm. LUBRICANTS: P/N 009-0009020 LUBRICATION P/N 009-0004618 GREASE-85GM SYNTHETIC OIL/LITH NLG1 WHITE Grease MOLYKOTE BR2 Plus. Grease dispenser, nozzle Ø 0.8 mm. Automatic transmission Fluid (Castrol Syntec 5W30). Compressed air. Isopropyl alcohol. TEST & ADJUSTMENT TOOLS: APTRA Test Rig. APTRA USB key or Keydisk. DC Power Supply +24V / 5A or NCR 009-0010001, connector I-MCRW, U-MCRW and NU-MCRW Card Readers. TEST CARDS: 009-0017008 ISO test card - (Tool P/N : GRO-TOL0011) 009-0016436 HICO test card - (Sankyo TMD-OT-024-08 T8) GRO-TOL0012 NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 5 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 G00A900A01 Speed and start sentinel test card - (Tool P/N : GRO-TOL0073) EGCMC0119 Width switch test card - (Tool P/N : GRO-TOL0014) Bezel oversized test Card - (Tool P/N : GRO-TOL0015) ADJUSTMENT TOOLS SANKYO: DMJ-AD-348-11: Feeler pin for Shutter Plate (Ø 2.0 mm) – (Tool P/N : GRO-TOL0016) DMJ-AD-348-16: Feeler pin for Shutter Plate (Ø 1.5 mm) – (Tool P/N : GRO-TOL0017) DMJ-GA-149: Shutter Tool IMCRW– (Tool P/N : GRO-TOL0018) DMJ-IN-265-01: IC contact height adjustment block assembly, DMJ-IN-265-03 Height adjustment of IC contact block assembly (2) – (Tool P/N : GRO-TOL0019) ADDITIONAL TOOLS: Feeler gauges set (0.05-1mm x 0.05 steps) – (Tool P/N : GRO-TOL0020) Shore (Durometer) Hardness Testing tool (eg:BAXLO Type A DIN 53505) – (Tool P/N : GRO-TOL0021) Force Gauge (Push-pull) : 0.0 – 5.0N (0 – 500gf) – (Tool P/N : GRO-TOL0022) Analogue Dynamometer PCE-SN 10 or similar– (Tool P/N : GRO-TOL0023) Power Supply (24V) for DMJ-IN-265-01 to apply power to SCB NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 4.0 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 6 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 MANDATORY CHANGING PARTS: MODULE MANDATORY PART LIST SL:NO: PART NUMBER 1 009-0005147 CAUTION PART DESCRIPTION Foam Gasket QTY 1 LESS THAN 1YEAR X 1-2 2-3 3-4 4-5 Unknown YEARS YEARS YEARS YEARS X X X X X ALL CIRCLIPS REMOVED FOR REPAIR OR REFURBLISH, NEEDS TO BE REPLACED WITH NEW ONE ANY PARTS IDENTIFIED AS DAMAGED AND WORN OUT SHOULD BE REPLACED WITH NEW ONE NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 5.0 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 7 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 REPAIR PROCESS: NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 5.1 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 8 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 DISMANDLING GUIDE LINES: • Card readers must be repaired and cleaned to an as new condition. • Repair all missing, broken or worn parts that would affect the long term reliability of the IMCRW module. • Do not use salvaged wear parts for repair (Guide Plates, Pre-heads, Heads, bushings, bearings, springs, belts, etc...) or reuse parts from other units. • Use only NCR approved detailed parts obtained from OEM for repairing NCR proprietary parts, except parts approved by NCR from local sources. • Check SDC and SCIF board for batteries manufactured by Keeper II; this type of battery should always be replaced by a new one. • Check the CROPF battery both voltages 7.2V and 24 volt with a load. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 5.2 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 9 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 CLEANING GUIDE LINES: • Compressed air may be used to clean the belts, frame, shafts, rollers, etc... • Remove any contamination around the head, bezel shutter guide assembly upper and lower sensors. Do not remove manufacture labels that contain serial number, tracer numbers, ID numbers, etc. • Perform the following tasks as a standard procedure: o Clean the sensors. o Clean the path of the magnetic card. o Clean the bezel of the card reader from dust and all other disreputable things. o Use Isopropyl Alcohol for cleaning rubber rollers, heads guides as advised by Sankyo. NOTE: Isopropyl Alcohol is approved to remove adhesive residue or dirt buildup on rollers 5.3 LUBRICATION GUIDE LINES: • Refer to DM1-0198 and FM-547 for a detailed description of the lubrication procedures and points. • Use a brush or similar application to apply lubricant. Does not use spray type application as overspray which can attracked dirt and cause future failures. • Lubricants can cause serious deterioration of rubber. Avoid contamination of drive belts and drive rollers. • Remove any old oil and dirt before applying new lubricant. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 10 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 o Apply only a small amount of lubricant. Avoid excessive lubrication. o Lubricant should be applied only to the specified points. Wipe off excess lubricant. o Use only specified or equivalent lubricant. • Do the lubrication of the following parts : o Shutter o Solenoids hinge point o The three brass bearings fitted on RH-side frame with a very little drop of lubricant. NOTE 1: When describing the amount of oil / lubrication required on “rebuild” we advise the following : o Wipe the bearing surface (Shaft) with a clean lightly oiled cloth. o Wipe the inside of a bearing with a clean lightly oiled cloth. o Discard oiled cloths regularly to ensure that any dirt/contamination does not transfer amongst parts. NOTE 2: Brass bearings or “Oilite Bearings” , which are pre-lubricated, contain oil. It is not allowed to clean these bearings in an ultrasonic cleaning bath as this will remove the internal lubrication. If these bearings have become noisy or do not rotate freely, they should be replaced. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 5.4 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 11 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 DISASSEMBLY & ASSEMBLY: PART IDENTIFICATION NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 12 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.1 DISASSEMBLY: • TOOLS Ct. Points PICTURES Remove screws “I” shown in the picture from the board. • Disconnect all connectors from the board. • Remove the r/w amp Board NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. • PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 13 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS Remove screws “e” fixing TOOLS Ct. Points PICTURES the motor to the frame. • Remove the Motor. Belt tensions need to be adjusted once the motor is removed or the belt has been replaced. • Remove the Bezel Assy. • Remove 2 screws from R/W Head Guide block and screw “m” under flexible cable of the Head. • Remove R/W Head Guide Block Assy. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. • PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 14 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS Remove screws shown on picture from the Guide Assembly upper side. • Remove Guide Assy. TOOLS Ct. Points PICTURES REF SECTION 8.4 FOR MAGNETIC HEAD REPLACEMENT CRITERIA & PART NUMBER DETAILS. ALERT DOCUMENT GRO-ALT0055 (RCN-0464) CONTENT INCORPORATED IN THIS DOCUMENT (REFER SECTION 8.4) NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 15 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.2 BEZEL ASSEMBLY (Throat / Shutter): • TOOLS Ct. Points PICTURES Check the bezel for wear and/or any broken parts and replace when necessary. • Check the shutter plate for wear and/or burrs and replace when necessary. 5.4.2.1 Bezel base plate assy: • Due to its construction, with the solenoid sitting underneath, the metal plate holding the plastic bezel can easily bend. Three small metal bridges hold the solenoid in place. Check Wear on throat assembly : Replace worn parts if an oversized card of 55.97mm can be inserted into the card reader. The width of a normal card is 53.97mm. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 16 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS TOOLS Ct. Points Little pressure, when applied to PICTURES (shutter base plate Sankyo p/n MBF 379402) the bezel, can deform the metal plate which can result in misalignment and intermitted shutter failures. Other causes for a deformed shutter plate are: • Misalignment to fascia. • Vandalism from outside. • Transit damage. See also chapter 8.0 for card reader handling guidelines. NOTE: Change part by Sankyo P/N MBF 379402 if unable cannot repair. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 17 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.2.2 Bezel disassembly: TOOLS Ct. Points PICTURES • Remove and discard the Foam Gasket. • Remove the metal bezel, clean off any remaining residue or dirt. • Disassemble the upper and lower bezel parts and clean carefully; pay attention to the internal/detailed parts of the bezel. • Replace any damaged or worn parts. • Replace the white pad if worn more than 0.14mm (C) or if the top is equal to the surface of the bezel. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 18 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.2.3 Pre-head: TOOLS Ct. Points PICTURES Pre-Head disassembly : • Check the Pre-head for wear. Replacement is necessary when the top of the head shows a flat surface/trapezium > 3mm. Pre-Head assembly: • Refer to the picture to verify if the Pre-head is fitted correctly. • Distance A will have to be equal to distance B. Distance C will have to be equal to distance D which needs to be > 0.5mm. • If necessary, loosen screw (e) and move the Pre-Head until A = B. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 19 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.2.5 Bezel assembly: • TOOLS Ct. Points PICTURES Assemble in the reverse order. • Install the bezel protection metal using adhesive tape. • Install a new Foam Gasket P/N 0090005147 • The torque to be applied to all of the bezel screws is 3.5 kgf.cm or 0.34 Nm. TORQUE 3.5 kgf.cm or 0.34 Nm. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 20 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3 MAIN TRANSPORT: TOOLS Ct. Points PICTURES Cleaning: • Carefully clean all parts of the module using compressed air and a small brush. Visual Inspection : • Check the main assy for any worn or damaged parts. • Replace any loose, broken or cut wires. • Adjust bent parts and replace broken parts. Main transport disassembly: • Remove the Magnetic Head Guide assembly. • Clean the Guide assembly and Magnetic Head with alcohol and a clean cloth. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 21 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.1 Magnetic Head: • Check the head for wear. Replacement is necessary when the top of the head shows a flat surface/trapezium > 3mm. TOOLS Ct. Points Only use Read/Write or Read heads from the original OEM Manufacturer Sankyo. Non-OEM Read/Write or Read heads are not permitted to be used and should be replaced when fitted. PICTURES NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 22 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.2 5.4.3.1 Guide assembly: • Remove the screws as TOOLS Ct. Points PICTURES shown in the picture to remove the Guide upper and the Plate assembly. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 23 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS • TOOLS Ct. Points PICTURES Clean the Guide assembly and all sensors. • Good & Bad example shown. • Replace when worn. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 24 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.3 Guide plate : Check the Guide plate for wear TOOLS Ct. Points PICTURES and grooves (use fingernail to check). Replace the Guide plate when: • There are multiple grooves on the wear mark. • The groove on the mark is >0.03mm. • The groove is visible through the backside of the Guide plate. See pictures to the right. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 25 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.4 Rubber rollers: • Loosen the 3 shafts of the TOOLS Ct. Points PICTURES rollers by removing the E-type circlip to the right side of the module. • Remove any dirt from inside the Bushing. • Clean all white rollers with alcohol. • Check all rollers run free. • Clean the rubber surface of all rollers with Isopropyl alcohol. • Measure the hardness of the rollers at 3 different spots of the roller. • Replace the rollers if the hardness is <70 shore. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 26 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.5 Belts: • Clean the motor belts with TOOLS Ct. Points PICTURES a dry brush. Replace when worn, damaged, broken or cracked. See picture to the right. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 27 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.6 PAD-ROLLER GAP TOOLS Ct. Points PICTURES ADJUSTMENTS : Loosen screws “e”, and • then refasten screws “e” at the position where Gap A and Gap C are equal. Adjust the Gap A and C • with nut “b” to 0.0mm ~ 0.1 mm. Verify manually, back and • forth, free transportation with a card. • Seal the screws. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 28 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.7 TIMING BELT ADJUSTMENT : • Timing belt tension should be between 400-450gf. • To adjust the belt TOOLS Ct. Points PICTURES Ensure the drive belt Tension pressure, loose the screws showed on picture and adjust the position of Tension Pulley If Main motor is replaced, Belt Tension adjustment is required : • Loosen screws, “e” and to adjust belt tension. At this time, the belt must have flexibility, δ by 0.6mm at the mid-point (A~B) and its flexibility δ requires the load ranging 10~30gf. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. • PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 29 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS To fasten screws, “e” at TOOLS Ct. Points PICTURES 74cN.m (7.5kgf.cm) and check if the belt has appropriate flexibility or not. If not sufficient or excessive, adjustment must be carried out. • If appropriate, put any kinds of mark on those screw heads indicating adjustment has been done • After any adjustments, seal the adjustment screws using red tamper seal. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 30 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.8 SENSOR CALIBRATION : • First, turn off power of the IMCRW. Set the DIP Switch (DSW2) that is on the main PCB to Nº 7 (hex) (DIP 1,2,3 to ON; DIP 4 to OFF). • Turn on power again. The IMCRW checks each sensor level and adjusts slice level automatically. • Adjusted values are stored to flash ROM. After performance of storing, the Red LED blinks 0.5Hz cyclically, and the Green LED indicates Test ID 7 (hex) number with blinking. • If it fails during adjustment and storing, error number is displayed on the Green- LED. TOOLS Ct. Points PICTURES NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 31 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS TOOLS Ct. Points PICTURES NOTE: • Adjustment and Check must be done without any Test ID hex presence of card. • After check and adjustment, please turn off power of the IMCRW and set to Description Test result (pass/Error Code) PD Sensor 00 = Pass 01 = Calculated value out of range for PD1. 02 = as above PD2. 03 = as above PD3 04 = as above PD4 05 = as above PD5/I 06 = unable to preserve the data to flash ROM Slice Level Adjust Test. 0x07 0 (hex) the dipswitch. • If any error occurs during the adjustment process, refers to NCR Service Manual for more details. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 32 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.9 LUBRICATION : • Before white rollers on RH- TOOLS Ct. Points PICTURES side frame are fitted lubricate studs with a very little lubricant. • Remove any excess of lubricant. Assemble the Main Frame : • Assemble in reverse order to the above disassembly. • Pay attention in the Head assemble, it must be parallel respect to the guide. NOTE : Never use electric screwdrivers for the head assemble. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 33 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.10 MOTOR : • Check Motor bearings; replace motor if bearings not fix to the shaft. • Old motors have Fujitsu connector (Non RoHS) and were discontinued. • New motors have JST TOOLS Ct. Points PICTURES NEW MOTOR 9980914467 COMPATIBLE FOR LISTED CARDREADERS SANKYO P/N NCR P/N ICT1Q3-1R5340 445-0653788 ICT3Q5-2R1A5440 445-0653789 ICT3Q5-3A5240 445-0653790 ICT3Q5-3A6241 445-0653932 MCT1Q3-1R0340 445-0645655 MCT3Q5-2R1A0440 445-0704481 MCT3Q5-A30240 445-0645657 MCT3Q8-3A2341 445-0693331 connector (RoHS). • The New Motor P/N 9980914467(Sankyo P/N S35A210A10.) is compatible with the listed Part Numbers card readers only. NOTE : See next page for check the motor NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 34 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS CHECK THE MOTOR: • Remove the belt and check that the motor is not blocked or that the shaft does not move TOOLS Ct. Points PICTURES Ensure condition of the torque motor when trying to move longitudinally. • Then check the consumption of motor under no load, connecting to a 24V source. Consumption should not exceed 70mA. • Put the belt motor again (then test the consumption of the motor under load), that is assembled on the Main Frame. Consumption should not exceed 300mA. If more, the main frame is not correctly adjusted or the motor is defective NOTE : ANY UNIVERSAL INDUSTRIAL STANDARD INSTRUMENT CAN BU USED FOR THIS TESTING. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 35 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.11 SPEED ADJUSTMENT : • Speed adjustment to 190mm/s (+2%/-2%). This Check needs the card • Sankyo P/N: G00A900A01. TOOLS Ct. Points PICTURES TEST ID HEX 0x08 DESCR IPTIO N Motor Speed Test TEST RESULT (PASS / ERROR CODE) 00 = Pass 01 = 02 = Card Jammed. 03 unable to measure (Out of Range). Turn off power of the • IMCRW. Set the DIP Switch (DSW2) that is on the main PCB to Nº 8 (hex) (DIP 4 to ON; DIP 1,2,3 to Off). Turn on power. Then insert • this card to the IMCRW. The IMCRW accepts the card, reads magnetic data and ejects the card. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. • PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 36 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS In that time, the IMCRW TOOLS Ct. Points PICTURES calculates speed. After this performance, the Red LED blinks 0.5Hz cyclically, and the Green LED indicates Test ID number 8 (hex) with blinking. • If this speed is out of range, error number is displayed on the Green-LED. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 37 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.3.12 START SENTINEL POSITION ADJUSTMENT : • This Check needs the card Sankyo P/N: G00A900A01. • Turn off power of the IMCRW. Set the DIP Switch (DSW2) that is on the main PCB to Nº 9 (hex) (DIP 1,4 to ON; DIP 2,3 to Off). • Turn on power. Then insert this card to the IMCRW. The TOOLS Ct. Points PICTURES TEST ID 0x08 HEX DESCRIP TION Adjustmen t Start Sentinel Position TEST RESULT (PASS / ERROR CODE) 00 = Pass 01 = not Standard Card or Read Error occur 02 = Card Jammed. 03 = unable to measure (Out of Range). 06 = Un-able to preserve the data to Flash ROM normally. IMCRW accepts the card, reads magnetic data 4 times and ejects the card. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. • PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 38 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS In that time, the IMCRW TOOLS Ct. Points PICTURES measures position of Start Sentinel and calculate the adjustment value. After performance storing, the Red LED blinks • 0.5Hz cyclically, and the Green LED indicates Test ID number 9 (hex) with blinking. • If it fails during adjustment and storing, error number is displayed on the Green-LED. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 39 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.4 SMART CARD BLOCK: TOOLS Ct. Points PICTURES • Disassemble the SMCB module : • Disassemble the IC Card Block • Check Contacts Smart Card Block 5.4.4.1 CLEANING: • Clean carefully any rest of dust from the pins. • Compressed air and isopropyl alcohol are to be used for cleaning the SMCB. • If any pin broken or damage, replace entire ICcontacts. • Inspect both 2 rows are aligned correctly. • Clean all contact pins assembly. • Upgrade the SMCB if necessary. (Ref 5.4.6.1) NOTE : Condition pins smart card block. Bended or worn pins are not permitted. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 40 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.4.2 REPLACEMENT OF SA BLOCK ICB PIN ASSEMBLY 9980914613 IN CONTACT BLOCK: TOOLS Ct. Points PICTURES (APPLICABLE ONLY FOR THE CONTACT BLOCK P/N: 0090028982) DIS-ASSEMBLY: Obtain the SMCB module in which the ICB Pin Assy to be replaced. • Remove the Screw as shown. • Lift the PCB and disconnect the Flex & the power connector. • Ensure the locks in the connectors are lifted properly to release the flex 1 cable out( Ref 1) NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. • PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 41 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS Remove the solenoids by TOOLS Ct. Points PICTURES removing the 2 screws as indicated. • Remove the 2 screws indicated from the side frame. • Remove the E-clip & Washer as indicated to separate the ICB Pin Assy from side frames. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 42 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS ASSEMBLY: • Obtain the disassembled TOOLS Ct. Points PICTURES parts and the New ICB Pin Assy P/N: 998-0914613 to be replaced. • Fit the Pin Assy in to the side frames as indicated ICB Pin Assy NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 43 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS • TOOLS Ct. Points PICTURES Assemble the washer & E- Clip to the frames as indicated. • Mount the side frames with screws as shown. • Fit the Flex cable & the solenoid cable as shown. • Fit the screw to the PCB as shown. Ensure the locks in the connectors are lifted properly before fit the flex cable in the connector and lock it once fitted ( Ref 1) 1 NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 44 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.4.3 ASSY & ADJUST TO SMCB : • If to repair the SMCB have TOOLS Ct. Points PICTURES to remove the solenoid, to assembly again, you should adjust it with the screws "B" following this process. ASSY & ADJUST TO SMCB : • Assemble IC Contact Block into DMJ-IN-265-03 with two screws (A) fully to the left. Disconnect “J3”. See photo. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 45 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS ASSY & ADJUST TO SMCB : TOOLS Ct. Points PICTURES Place the block DMJ-IN- • 265-03 (13) top DMJ-IN-265-01 block. ASSY & ADJUST TO SMCB : Connect the power supply • at connector of the solenoid “J3”. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 46 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS ASSY & ADJUST TO SMCB : • TOOLS Ct. Points PICTURES Place the block DMJ-IN- 265-03 (13), under the "Part A" as shown in the photo. ASSY & ADJUST TO SMCB : • Switch on the power supply and check that all 8 pins SMCB are in contact in the top of the test bench. Otherwise adjust the solenoid with the screws "B". NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 47 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS ASSY & ADJUST TO SMCB : • TOOLS Ct. Points PICTURES Turn off the power and move the block DMJ-IN-265-03 (13) under the "Part B" as shown in the photo. Reconnect the power and ensure that only the 4 pins the right side are in contact as shown in the picture below. If not, readjust the solenoid with the screws "B" and repeat these last two points as many times as necessary until you do. NOTE : After setting the SMCB, support must be removed DMJIN265-03 (13) with the screws "A", disconnect the power connector "J3" and connect this to the board SMCB. Finally should be sealed screws "B". NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 48 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.4.4 IC Contact Block adjustment: • TOOLS Ct. Points PICTURES When assembling the IC- Contact assembly, attach the Block very right side of positioning emboss gap. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 49 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS Adjustment Checks: • TOOLS Ct. Points PICTURES Turn off power of the IMCRW. Set DIP Switch (DSW2) that is on the main PCB to No.0A(hex) (DIP 2,4 to ON; DIP 1,3 to Off). Turn on power. Then insert 009-0017008 ISO Test Card to the IMCRW. This card is ISO TEST CARD Smart Card and it has Magnetic data on the card. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 50 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS • The IMCRW accepts this card, performs “Write-Check” & “Reads-Check”, communicates to the Smartcard and ejects this card. If it fails, the IMCRW stops check and ejects this card and displays error number. • If the Smartcard error occurs, then go to Readjustment. TOOLS Ct. Points PICTURES Adjustment: • Shift the Smart card Block assembly a little bit to the left, and then attach the Block. • Follow the instruction (2) to (4) again. • O.K. -> finish (Set PCB to fasten screws). • Error -> exchange the Block and readjustment. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 51 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.5 RE-ASSEMBLY & TOOLS Ct. Points PICTURES ADJUSTMENT : • After repair and clean all modules of the IMCRW assemble the unit in reverse order to the above disassembly procedure NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 52 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.5.1 PRE-HEAD ADJUSTMENT: • Refer to below picture to TOOLS Ct. Points PICTURES check Pre-Head is set properly, with distance A equal to distance B. • Enter a card into the bezel several times to verify that the Pre-Head be always properly aligned. PRE-HEAD BASE NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 53 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.5.2 SHUTTER ADJUSTMENT: • When replacing shutter solenoid, the following adjustments are required. • The plunger of solenoid must be at the full energized (sucked in) position. • Fix the solenoid at the position where a shaft (Ø 2.0 + /-0.01 mm:DMJ-AD-348-11) can go through the hole, “Y” indicated in the below picture • Adjusting screws for shutter solenoid are shown below under pushing the solenoid toward the direction “G”. • Then remove a shaft (DMJAD-348-11). • Then adjust SW2. TOOLS Ct. Points PICTURES NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 54 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.5.3 SOLENOID POSITION : • At first bezel assembly TOOLS Ct. Points PICTURES maintain upside down shown in figure. • The plunger of solenoid must be at the full sucking position. • Tooling (DMJGA149) put on the lower bezel shown in below picture. • The shutter plate should touch the tool to ensure that the shutter plate is in a position to clear the card path NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 55 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.5.4 SWITCH SW1 WIDTH SWITCH : • Insert the ST-SW Card (EGCMC0119) into the card bezel slowly. When the position B of ST-SW card contacts micro switch • Actuator, 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. • 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. • Confirm if the SW1 works correctly at each ST-SW card position. TOOLS Ct. Points PICTURES ST-SW Card DWG No.EGCMCO119 NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 56 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.5.5 SWITCH SW2 SHUTTER SWITCH : • Hold the shutter plate at the position where a shaft (Ø 1.5 + /-0.02 mm: DMJ-AD-34816) can go through the hole, “X” indicated in the below figure. • Adjusting screws for SW2 are shown below under pushing the solenoid toward the direction “G”. • Adjust the SW2 at the position where SW2 turns ON (OFF->ON). • Confirm if SW2 turns OFF when Shutter hole agree with Bezel hole, “X” indicated in the pic. • To perform these adjustments use the THSTAT tool. ( see annex ). NOTE : TOOLS Ct. Points PICTURES After adjust both micro-switch, seal the adjustment screws using red tamper seal. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 57 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS 5.4.6 UPGRADES: Ct. Points PICTURES NCR P/N 445-0693328 SANKYO P/N ICT1Q8-1R0340 445-0693330 ICT3Q8-2R1A0340 445-0693332 ICT3Q8-3A2341 compliant (iMCRW). 445-0704480 ICT1Q8-1R0345 009-0028982 contact 445-0704482 ICT3Q8-2R1A0345 block is RoHS compliant 445-0704484 ICT3Q8-3A2345 5.4.6.1 SMCB partnrs: • 009-0022326 contact block is non-RoHS • TOOLS (NEMO). • 998-0914613 ICB PIN ASSY is the spare pin block for 009-0028982 only. See also chapter 5.4.4.2. 009-0028982 998-0914613 NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. • PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 58 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS Connection between TOOLS Ct. Points PICTURES flexible cable and PCB is fixed by soldering and it has enough strength to meet IMCRW specification. (Confirmed the reliability with testing 600,000 passes). In order to prevent the cable from coming off by any possibility, Sakyo will add epoxy adhesive after the soldering. The adhesive will reinforce the connection. Type name of adhesive: CEMEDINE EP-330. NOTE : Ensure that cables do not obstruct any moving parts. Ensure cable positioning NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 6.0 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 59 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 TESTING: NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 60 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 6.1 APTRA TEST RIG: Services : (RS-232) : o Ensure that following 4 Services from Windows Administrative Tools are in “Manual” Start-up Type : o NCRRS232IMCRWDrv Manual o NCRRS232IMCRWLdr Manual o NCRRS232IMCRWMgr Manual o NCR Serial Detector Manual Services : (USB): o Ensure that following 2 Services from Windows Administrative Tools are in “Manual” Start-up Type : o NCRUSB IMcrwDrv Manual o NCR USB IMcrwMgr Manual 6.2 SET REGISTRY KEY WINDOES: o Use Regedit and follow this path to Operational Parameters: HKEY_LOCAL_MACHINE\SOFTWARE\NCR\APTRA Self-Service Support (NCR Features)\RS232IMCRW\Operational Parameters. o Hi-Co -> Auto-Detect (1). Set key ENABLE HICO FUNCTION to 1 for Auto-Detect HiCo Cards.= 0 (Always LoCo), 1 (Auto-Detect HiCo), 2 (Always HiCo). o Configure ECD -> JITTER Test (1) Set CONFIGURE ECD key to 1 for Standard jitter.0 (Off), 1 (Standard jitter), 2 (Maximum Jitter). NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 61 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 6.3 TEST PROCESS: o Install Card Reader to the APTRA TEST RIG. o Turn on the computer. o Install USB key. o Launch APTRA software. o Enter User Key code. o Remove USB key. o Settings ATM properties menu will be displayed. Press Cancel. o System application main will be displayed. o Select “1” (Device Diagnostic). o Select IMCRW. / USB Motorised Card Reader Writer. (USB). o Perform the following Test depending on the type of IMCRW and associated modules installed. o If test passes properly, a “successful” message will be displayed. o Otherwise, if any error is detected during the test process, Card reader has to be returned to repair area and fully tested again. 6.4 ALL CARD READERS (T2, T123, 3T LoCo & Hico): JITTER (ECD) Test : o When Test Card is inserted, check that it cannot be pushed smoothly into the transport and Card Reader is taking the test card jittering. o Identify the Card Reader and test the Card Reader accordingly. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 62 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 6.5 TEST PROCEDURE FOR TRACK 2: Enable “Halt On Error” option: o From Device Diagnostics Menu, select “Control Menu”. o Halt On Error: Enabled (Use TOGGLE icon to change the status). o Press OK, to come back to Diagnostics Menu. Run to Run 2 test (1 loop) : o Enter card Test. o Test Card P/N 009-0017008 ISO. o IMCRW Capture the Card (IMCRW moves the card to the capture bin). o Exit from Run to Run 2 tests. Run to Run 3 test (10 loops) : o (If test stops during any part of the process, check the error displayed and record). o LOOP = ON. o Perform to Run to Run 3 test o Enter Test Card. o Test Card P/N 009-0017008 ISO. o Read Track 2. o Smart Card tests (if Smart module installed). o EJECT the Card Test. o IMCRW move the card to the Bezel, waiting to be removed. o Remove the card just when all 10 loop tests have been passed. (Go to 6.9 Initialize NVRAM to finish the test process) NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 63 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 6.6 TEST PROCEDURE FOR TRACK 123: Enable “Halt On Error” option: o From Device Diagnostics Menu, select “Control Menu”. o Halt On Error: Enabled (Use TOGGLE icon to change the status). o Press OK, to come back to Diagnostics Menu. o Write ISO Track3 test (10 loops). o Enter Test Card. o Test Card P/N 009-0017008 ISO. o LOOP = ON. o Write ISO Track3 (10 loops). Run to Run 2 test (1 loop) : o Enter Test card. o Test Card P/N 009-0017008 ISO. o IMCRW Capture the Card (IMCRW moves the card to the capture bin). o Exit from Run to Run 2 tests. Run to Run 3 test (10 loops) : o (If test stops during any part of the process, check the error displayed and o record). o LOOP = ON. o Perform Run to Run 3 test NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 64 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 o Enter Test Card o Test Card P/N 009-0017008 ISO. o Read Tracks 1, 2 and 3. o Smart Card tests (if Smart module installed). o EJECT the Card Test. o IMCRW move the card to the Bezel, waiting to be removed. o Remove the card just when all 10 loop tests have been passed. o Go to 6.9 ( Initialize NVRAM to finish the test process). 6.7 TEST PROCEDURE FOR 3 TRACK & LoCo: Enable “Halt On Error” option: o From Device Diagnostics Menu, select “Control Menu”. o Halt On Error: Enabled (Use TOGGLE icon to change the status). o Press OK, to come back to Diagnostics Menu. o Write ISO Track3 test (10 loops). o Enter Test Card. o Test Card P/N 009-0017008 ISO o LOOP = ON. o Write ISO Track3 (10 loops). o Write 3 Buffer Tracks Test (10 loops). Write Buffer Track 1, 2 and 3 o Check Magnetic Head is writing correctly on all 3 tracks, Track 1, 2 and 3. o Run to Run 2 test (1 loop) : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 65 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 o Enter card Test. o Test Card P/N 009-0017008 ISO. o IMCRW Capture the Card (IMCRW moves the card to the capture bin). o Exit from Run to Run 2 tests. o Run to Run 3 test (10 loops) : o (If test stops during any part of the process, check the error displayed and record). o LOOP = ON. o Enter Card o Test Card P/N 009-0017008 ISO. o Read all Tracks 1, 2 and 3. o Smart Card tests (if Smart module installed). o EJECT the Card Test. o IMCRW move the card to the Bezel, waiting to be removed. o Remove the card just when all 10 loop tests have been passed o Go to 6.9 Initialize NVRAM to finish the test process. 6.8 TEST PROCEDURE FOR 3 TRACK & HiCo: o Enable “Halt On Error” option: o From Device Diagnostics Menu, select “Control Menu”. o Halt On Error: Enabled (Use TOGGLE icon to change the status). o Press OK, to come back to Diagnostics Menu. o Write ISO Track3 test (10 loops). NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 66 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 o Enter Test Card. o Test Card P/N 009-0016436 (3T HiCo). o LOOP = ON. o Write ISO Track3 (10 loops). o Write 3 Buffer Tracks Test (10 loops). Write Buffer Track 1, 2 and 3 - Check Magnetic Head is writing correctly on all 3 tracks, Track 1, 2 and 3. o Run to Run 2 test (1 loop) : o Enter card Test. o Test Card P/N 009-0016436 (3T HiCo). o IMCRW Capture the Card (IMCRW moves the card to the capture bin). o Exit from Run to Run 2 tests. o Run to Run 3 test (10 loops) : o (If test stops during any part of the process, check the error displayed and record). o LOOP = ON. o Enter Card. o Test Card P/N 009-0017008 ISO. o Read Tracks 1, 2 and 3. o Smart Card tests (if Smart module installed). o EJECT the Card Test. o IMCRW move the card to the Bezel, waiting to be removed. o Remove the card just when all 10 loop tests have been passed. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 67 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 6.9 TEST PROCEDURE FOR MEI: The purpose of the test is to confirm the PCB is working with the MEI option. o Obtain the MEI Part Numbers suggested below. 0090023198 - U-IMCRW UPPER AND LOWER MEI ASSEMBLY 0090022327 (Sankyo PN SBW235701) MEI (PCB Top) 0090022329 (Sankyo PN S02A531A01) MEI (PCB Lower) o connect MEI to main PCB and then connect Power supply 24V to J31 connector. o Apply power to J31 for 2-3 sec. o If the LEDs glows, then it is Passed. o If the LEDs not glows, then it’s a PCB error. MEI J31 NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 6.10 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 68 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 TEST PROCEDURE FOR SW1 & SW2 3rd CONNECTOR: The purpose of the test is to confirm the 3rd connector of SW1 & SW2 in the PCB is working, which is used to activate the antiSkimming devices. o Run any type of card reader tests (enter card/shutter test/…etc) o Obtain a multimeter & Choose buzzer or Ohm for connectivity checking o Connect AV-meter probes to SW1 and SW2 (3rd connection) o During shutter open/close it should be showing connectivity between SW1 and SW2. o Otherwise it is understood that the micro switch or PCB is having problem. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 6.11 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 69 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 INITIALIZE NVRAM: o After Card Reader has passed successfully all tests, reinitializing the Flash ROM from the Main PCB is mandatory. o Turn off power of the IMCRW. Set the DIP Switch (DSW2) that is on the main PCB to No4 (hex) (DIP 3 to ON; DIP 1, 2 & 4 to Off) o Turn on power, the IMCRW will enter download mode. This function makes the Flash ROM of the IMCRW to the condition of shipping from Sankyo. o In that time, the Red LED blinks 0.5Hz cyclically, and the Green LED is fixed ON. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 70 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 Test ID hex Description Test result (pass/Error Code) 00 = Pass 0x04 Clear Flash ROM 01 = Unable to clear. 02 = NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 6.12 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 71 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 SUMMARY OF TEST ID’S : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 72 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 73 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 7.0 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 74 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PACKING: NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 75 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS PACKING: • TOOLS Ct. Points PICTURES Ensure the the unit has completed the repair process and ready for packing NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. • PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 76 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS To avoid deformation of TOOLS Ct. Points PICTURES the shutter during the transport, place a piece of cardboard as shown in the picture. NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 77 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS PACKAGING ITEMS : • TOOLS Ct. Points PICTURES EPE foam 2 No’s For MCRW & I-MCRW : Size: (hxw) 450x275x275 Material: PE 35 kg/m³ Amount per set 2 Weight N/A Printed No mm Kg NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 78 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS PACKAGING ITEMS : • TOOLS Ct. Points PICTURES Inner Foam Box 1 No For MCRW: Size: (hxw) Material: 450x275x275 192 Amount per set 1 Weight Printed N/A No mm Kg For I-MCRW: Size: (hxw) Material: Amount per set Weight Printed 250x155x158 192 1 N/A No mm Kg NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 79 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 WORK ELEMENTS PACKAGING ITEMS : • TOOLS Ct. Points PICTURES Outer carton Box 1 No For MCRW: Size: (hxw) Material: 450x275x275 Amount per set 1 mm 210 Weight N/A Printed BLACK Kg For I-MCRW: Size: (hxw) Material: 350x275x275 mm 192 Amount per set 1 Weight N/A Printed No Kg NOTE : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 80 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 BOM- Bill of materials : Item : Description: 1 2 3 Outer Cardboard box Cushioning Foam Inner box 4 2 6 Outer Cardboard box Cushioning Foam Inner box FEFCO Code Material: Qty/ Set: 0201 N/a 0473 210 PE 35 kg/m³ 192 1 2 1 0201 N/a 0473 210 PE 35 kg/m³ 192 1 2 1 MCRW i-MCRW Material Prosperities / Spec : Out-liner Wave Liner between Wave Inner-liner 186 Craft 140 ICS N/a N/a 190 Test 200 Craft 127 HSC N/a N/a 200 Craft 120 Craft 110 ISC 120 Test 110 ISC 120 Test 140 Craft 110 ISC 120 Test 110 ISC 140 Test 186Craft 110 ISC 210 Test 140 ISC 186 Craft EPE. Expanded Poly Ethylene, Closed cell structure. Used for foam corners 150x150x150 /50mm, density 25kg/m³. PP Poly Propylene, Closed cell structure. Used for foam corners 110x110x110/30mm density 25kg/m³. PE Poly Ethylene, Open cell structure. Used for all other type of foam inserts 35kg/m³. EPS Expanded Polystyrene. NOT IN USE FOR ANY INSERTS OR CORNER BLOCKS. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 81 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PLASTIC BOX Packing (Applicable for specific Repair suppliers only): Plastic Box Spec: 497-0504344 Assy Plastic Pack - Black, ATM Card Reader Small 11 1/4" x 6 5/8" x 7 3/16" 497-0504345 Assy Plastic Pack - Black, ATM Card Reader Large 13 3/16" x 7 3/16" x 7 13/16" NOTE: The New NCR Plastic box packing is applicable for the below listed Small & Large card readers. Carton Box packing can be used, during the non-availability of Inventory. MODULE P/N,s DESCRIPTION 445-0595863 445-0698787 MCRW-TRACK 123 ASSY Card Reader (Large) 445-0607705 445-0698787 MCRW TRACK 123 BASE ASSY Card Reader (Large) 445-0607707 445-0698787 READER-MAG R/W TK123 & SDC Card Reader (Large) 445-0617453 445-0698787 READER-MAG R/W TK231 & SDC Card Reader (Large) 445-0618441 445-0698787 READER-MAG CARD TK 1/2/3 PRE VE Card Reader (Large) 445-0625414 445-0698787 READER-ASSY MCRW/SE TRACK 123 Card Reader (Large) 445-0625596 445-0698787 MCRW/SE TK 123 ASSY Card Reader (Large) 445-0630547 445-0698787 MCRW-SE TK 123 ASSY Card Reader (Large) 445-0645387 445-0698787 MCR-ASSY TK 1/2/3 Card Reader (Large) 445-0698787 445-0698787 MCR-ASSY TK 1/2/3 Card Reader (Large) 445-0704479 445-0737836 U-IMCRW TK 2 - STANDARD SHUTTER Card Reader (Small) 445-0704480 445-0737836 UIMCRW-2TRACK W/SMART/STANDARD SHUTTER USB Card Reader (Small) 445-0724621 445-0737836 UMCRW-2TRACK READ + SMART USB Card Reader (Small) 445-0737836 445-0737836 NU-MCRW TRACK 2 READ + SMART Card Reader (Small) NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 82 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 445-0704481 445-0737837 U-IMCRW TK 123 - STANDARD SHUTTER Card Reader (Small) 445-0704482 445-0737837 U-IMCRW TK 123 WITH SMART - STANDARD SHUTTER Card Reader (Small) 445-0704484 445-0737837 U-IMCRW 3 TK HICO WITH SMART - STANDARD SHUTTER Card Reader (Small) 445-0723882 445-0737837 MCRW-3TRACK HICO + SMART USB Card Reader (Small) 445-0737837 445-0737837 NU-MCRW 3TK R/W HICO + SMART Card Reader (Small) 445-0745511 445-0737837 NEMO 3TK R/W HICO + SMART Card Reader (Small) 445-0664127 445-0743080 IMCRW T2 W STD SHUTTER Card Reader (Small) 445-0664128 445-0743080 IMCRW T2 SMART W STD SHUTTER Card Reader (Small) 445-0693327 445-0743080 IMCRW T2 W STD SHUTTER Card Reader (Small) 445-0693328 445-0743080 IMCRW T2 SMART W STD SHUTTER Card Reader (Small) 445-0743080 445-0743080 IMCRW T2 SMART W STD SHUTTER Card Reader (Small) 445-0664129 445-0743081 IMCRW T123 W STD SHUTTER Card Reader (Small) 445-0664130 445-0743081 IMCRW T123 SMART W STD SHUTTER Card Reader (Small) 445-0693329 445-0743081 IMCRW T123 W STD SHUTTER Card Reader (Small) 445-0693330 445-0743081 IMCRW TRK 123 - W SMART-STANDARD SHUTTER Card Reader (Small) 445-0743081 445-0743081 IMCRW TRK 123 - W SMART-STANDARD SHUTTER Card Reader (Small) 445-0664132 445-0743082 IMCRW 3T HICO SMART W STD SHUTTER Card Reader (Small) 445-0693332 445-0743082 IMCRW 3 TRK HICO W SMART STANDARD SHUTTE Card Reader (Small) 445-0743082 445-0743082 IMCRW 3 TRK HICO W SMART STANDARD SHUTTE Card Reader (Small) NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 8.0 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 83 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 SPECIAL INSTRUCTIONS: 8.1 PROCESS MISSION: 8.1.1 Purpose Statement: The purpose of this section to provide special instructions required during IMCRW repair. 8.1.2 Scope: This process will be applied for MCRW Products repaired for NCR, at Repair suppliers. 8.2 HANDLING INSTRUCTIONS: 8.2.1 Improper Handling: This instruction will shows the cause which will possibly cause damages or Defect to the unit due to the improper handling. 8.2.2 Proper Handling: This instruction will shows the Places / Positions to handle Properly. 8.2.3 Sensitive Area Handling : This instruction will shows the Sensitive Area in Red(Do not Touch) & Yellow (Can be held, but do not pressure). NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 84 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PICTURES FOR THE IMPROPER HANDLING Do not push Pre-head terminals and FPC cable. Do not hold up IMCRW using one hand. It cause a damage on FPC cable between PWB and IC contact block. "SW 1" = Switch 1 is fitted under the bezel. Do not push Magnetic head terminals and FPC cable. Do not break or deform insulation cover. Do not touch "SW 1" = Switch 1. Shutter solenoid is bent when it is applied a force by pulling, grabbing. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 85 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PICTURES FOR PROPER HANDLING No issues that if it carries with Gate Top Edge and Rear Side Shaft. No issues to carry the bottom of the product. Do not put stress on Pre Head Pay Attention to the stress for PCB NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 86 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PICTURES TO HIGHLIGHT SENSITIVE AREAS Motor Label Head SIM Connector and Cable Head Cable Pulley Screw CE label Product Label Pre Head P/N Label Rev Label NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 87 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 Pulley PCW Shutter SW Screw 8.2.4 Proper Handling of PCB: INSTRUCTIONS PICTURE PCB and electrical components should be handled by the area where electrical discharge measurement (GND) and wearing wrist strap on. Do not place the card readers facing PCB bottom side. Do not hit PCB to the other items. Do not plug in and plug out while the product power is ON. Do not remove PCB cover PCB Side NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 88 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PICTURES TO SHOW PCB DAMAGES (RS TYPE & USB TYPE) RS TYPE PCB NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 89 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 USB TYPE PCB PICTURES TO SHOW PLASTIC BAG PACKAGING OK OK Pay Attention to the stress for PCB Prohibited because of Shock to PCB. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 90 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PICTURES TO SHOW PACKAGING WORK TO STYRENE BOX OK OK Carry Bezel Bottom Face and Rear Shaft NG Carry Bezel Top Edge and Rear Shaft PICTURES TO SHOW OPEN BOX WORK FROM STYRENE BOX OK Carry Bezel Plate and Rear Shaft OK Carry Bezel Edge and Rear Shaft NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 91 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PICTURES TO SHOW CARTON PACKAGING HANDLING Out of Warranty, 1m or higher which is out of packaging specification Warranty, 60cm which is the drop height limitation of packaging specification NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 92 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 8.2.5 Carton Box Handlin Instructions: In case that the carton box is dropped off, it possibly causes the product deforming, damaged and the effectiveness of the product performance. Regarding to single box handling, please pay attention in delivery. It is strictly prohibited the carton throw and catch. Same as above, it possibly causes the product deforming and damaged. If the carton box was dropped off from the higher than 60cm in package specification, please inform Sankyo of it, and we recommend that you will return it to Sankyo. The returned unit will be gone through performance test and appearance inspection. If there is no problem, we will re-ship to the customer. In case that we could find out any failures, we will consult with the customer how to deal with this unit. 8.2.6 Pictures to show Damage & Deforming (Sample Pictures of the Returned Units): Refer following pictures for the damages & Deforming due to Handling. NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 93 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 Picture Side A SW Damage Shutter Plate Deforming Shutter Plate Deforming Bottom Plate Deforming Shutter Solenoid : Tape Scratch MEI &Pre-HD Plate Deforming SW1 Lead Wire Cut SW1 Read Deforming NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 94 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 SW1 Read Deforming IC Contact Block Flex Cable Scratch Lead Wire Cut Solenoid Scratch Bezel Dent Pre-HD Plate Deforming SW1 Read Deforming SW2 Lever Damaged NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 95 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 Picture Side B PCB：IC Damaged PCB：Element Damaged MEI PCB Deforming Bottom Plate Deforming PCB : Element Damaged PCB：Element Damaged Bottom Plate Deforming PCB : Element Damaged NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PCB Cracked PCB : Element Damaged PCB : Element Damaged PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 96 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 PCB : Connector Pin messed up PCB Broken PCB : Element Damaged PCB : Element Damaged PCB : Element Damaged PCB : Connector Damaged PCB : Element Damaged NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 97 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 Picture Rear Side Connector Damaged Product Damaged/Deforming PCB Folded Connecter Damaged PCB Folded and Scratched Connector Damaged PCB Folded Motor Shaft Damaged Returned Good NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 98 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 Motor PCB Cracked PCB : Connector Deforming PCB : USB Connector Pin Deforming Motor Shaft Damaged PCB : USB Connector Deforming Motor Pulley Dent PCB Broken Motor Shaft Deforming PCB Broken PCB : USB Connector Pin Deforming NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 8.3 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 99 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 ANTI-EAVES DROPPING PROTECTION IN MCRW: THE FOLLOWING IMPROVEMENTS HAVE BEEN DONE ON THE MCRW TO ENSURE “ANTI-EAVES DROPPING PROTECTION”. BLACK GLUE APPLIED ON THE SOLDER SIDE OF THE PCB TO PROTECT THE TRACK 2 SIGNAL DESCRIPTION: MODULE (PART NOs & DESCRIPTION) READ/WRITE HEAD GUIDE BLOCK, GAP CHANGED FROM 2.4MM TO 1.35MM TO COUNTERACT INTERNAL SKIMMING COMPONENT DETAILS KEY NOTES ATTACHMENT REFER THE ATTACHMENT AREA FOR THE NEW PART Glue Area Indicated NUMBERS, WHICH WILL BE HAVING THIS FEATURE INCLUDED AT SANKYO MFG, ITSELF. MCRW PCB & READ / WRITE NOTE: NO ACTION HEAD GUIDE BLOCK REQUIRED FROM OUR Gap between Lower & Upper Guide block indicated SIDE ON THE SUBJECTED CHANGES. JUST FOR AN INFORMATION PURPOSE THIS ALERT IS BEEN PUBLISHED. MAIN MODULES NEW NEMO TRACK 2 READ + SMART 445-0765156 NEMO 3TK R/W HICO + SMART 445-0765157 NEMO (MFR) MCRW TRACK 2 READ + SMART 445-0765158 NEMO (MFR) 3TK R/W HiCo + SMART 445-0765159 OLD 445-0764437, 4450754999 and below 445-0764436, 4450755000 and below 445-0764439, 4450754646 and below 445-0764438, 4450754648 and below NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 8.4 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 100 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 CARD READER MAGNETIC HEAD REPLACEMENTS CRITERIA: THE READ HEAD FOR READ-ONLY CARD READERS HAS NOW BEEN RELEASED BY SANKYO AS A SERVICE REPLACEMENT PART. IT IS THEREFORE NO LONGER REQUIRED TO REPLACE THE HLA BLOCK GUIDE ASSY IN A READ-ONLY CARD READER. FOR READ/WRITE CARD READERS, SANKYO DO NOT AUTHORIZE TO REPLACE OR SWAP OVER JUST MAGNETIC HEADS ONLY. IN EVERY CASE IT IS THE BLOCK GUIDE ASSY THAT MUST BE REPLACED WHEN THE MAGNETIC HEAD IS WORN IN A READ/WRITE CARD READER. FOR ALL MAGNETIC HEADS THE GUIDANCE FROM SANKYO IS TO REPLACE THE BLOCK GUIDE ASSEMBLY OR HEAD WHEN THE HEAD IS WORN MORE THAN 3MM (SEE CARD READER REPAIR PROCEDURE FOR DETAILS). NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. 8.5 PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 101 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 REFERENCE: NCR DOCUMENTS: FM-547 Service Aids Mini Manual (SAMM). DM1-0198 NCR 56XX/Personas hardware module description manual. 5474209 Level 0 Diagnostics – Magnetic Card Reader Writer. 5474309 Level 1 Diagnostics – Magnetic Card Reader Writer. Chapter 9_15 IMCRW RS232. Flyer FLR 000108 - IMCRW F-ROM EMEA.doc SANKYO DOCUMENTS: ASR-NP-03133-01 - Specification IMCRW AMR-NP-03133-01 - Service Manual IMCRW. AOA-NP-03133-43 - EC Magnetic Head Guide block. AOA-NP-09275-02 – EC Shutter Solenoid standardization. AOA-NP-03133-41 – EC SMCB REV D. SOFTWARE & FIRMWARES : APTRA XFS 04.05.00 Software. FE USB Keys Drivers. Firmware and Driver files ver. 2.85 (file: IMCRW ver. 2.85.zip(RS-232). Firmware and Driver files ver. 3.35 (file: U-IMCRW ver. 3.35(USB). NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 102 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 IDENTIFICATION IMCRW ASSY : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 103 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 IDENTIFICATION U-MCRW ASSY : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 104 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 IDENTIFICATION NU-MCRW ASSY : NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 105 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 MODULES & ACCESSORIES: NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION. PROCESS NAME : MOTORIZED CARD READER REPAIR PROCEDURE DOC. NUMBER GRO-PRD0011 PAGE 106 of 106 PROCESS OWNER & ORG. : PROCESS ENGINEER – REPAIR OPERATIONS CURRENT REV. J REV. DATE 08-FEB-2018 For Assistance please contact: NCRREPAIR.PROCESS@ncr.com To download this document please click: https://ncrwss3.ncr.com/sites/repairprocesses/default.aspx REFERED.DOCUMENTS Doc.Name Doc.Number Motorized Card Reader Repair process T0017 NCR Approved Packing IMCRW Handling Manual MCRW Pre-Ve / VE 445-9001383 Repair Best practices REV 03 Vol 3 2.10 NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION.