PROCESS NAME :
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DOC. NUMBER
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PAGE
1 of 106
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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:
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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
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1.0
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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
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3.0
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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 :
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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
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4.0
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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
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5.0
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REPAIR PROCESS:
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5.1
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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.
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5.2
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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.
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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.
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5.4
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DISASSEMBLY & ASSEMBLY:
PART IDENTIFICATION
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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.
•
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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.
•
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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 :
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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.
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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.
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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.
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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 :
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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 :
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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.
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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 :
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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 :
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WORK ELEMENTS
•
TOOLS
Ct. Points
PICTURES
Clean the Guide assembly
and all sensors.
•
Good & Bad example
shown.
•
Replace when worn.
NOTE :
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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 :
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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 :
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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 :
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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 :
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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 :
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•
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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 :
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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 :
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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 :
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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.
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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
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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.
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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 :
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•
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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 :
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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 :
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•
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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 :
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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.
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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 :
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•
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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 :
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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 :
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•
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 :
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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 :
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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 :
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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 :
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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".
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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 :
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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 :
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•
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 :
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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 :
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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 :
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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 :
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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
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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
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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.
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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
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•
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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
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6.0
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TESTING:
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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).
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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.
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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)
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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
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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) :
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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).
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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.
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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
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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.
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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.
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Test ID hex
Description
Test result (pass/Error Code)
00 = Pass
0x04
Clear Flash
ROM
01 = Unable to clear.
02 =
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6.12
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SUMMARY OF TEST ID’S :
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7.0
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PACKING:
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WORK ELEMENTS
PACKING:
•
TOOLS
Ct. Points
PICTURES
Ensure the the unit has
completed the repair process
and ready for packing
NOTE :
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•
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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 :
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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 :
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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 :
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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 :
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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.
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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)
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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)
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8.0
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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
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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
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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
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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.
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IDENTIFICATION IMCRW ASSY :
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IDENTIFICATION U-MCRW ASSY :
NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION.
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IDENTIFICATION NU-MCRW ASSY :
NCR INTELLECTUAL PROPERTY - THIS DOCUMENT IS SUBJECT TO REVISION CONTROL REQUIREMENTS – USER SHOULD VERIFY LATEST VERSION.
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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.