Motorized Card Reader (with chip, 123) On-Site

Repair Manual

1 Introduction
2 Troubleshooting
3 Diagnostics
4 Repair
5 Cabling
6 Circuit Card Assemblies (CCA) Connectors and Pinouts
7 Preventive Maintenance
8 Parts
Figures
Tables
Motorized Card Reader (with chip, 123)
On-Site Repair Manual
Copyright ©Diebold, Incorporated
TM-000034-001C PD 5390
October 2007

CONFIDENTIAL - Trade Secret Material

Only Diebold and entities granted an express written license by Diebold may possess
or use this material. Unauthorized possession or use is illegal and is punishable by
fine and/or imprisonment.

Important - click here for terms and conditions governing the use of this document.

Document History
Document
Number Date Remarks
TM-000034- 5/2003 Original edition
001A
TM-000034- 7/2007 ASD (Advanced Skimming Detection)
001B included.
TM-000034- 10/200 Review of Table 1-1 and Table 8-1.
001C 7

Section 1
Introduction

1.1 General Description

This document covers the components in the motorized card reader (with chip, 123).
Section 1.2 provides brief descriptions of the card reader and its components.

1.1.1 Product Structure

The motorized card reader has the following components:

 The Base module incorporates:

o Card transport
 o Throat
o Devices to read/write the magnetic stripe and the chip
 Retained card BIN
 Options:
o Backup power device (Return Card or Enhanced Return Card on Power
Failure)
o External Security Access Module (SAM) CCA (4)
o Predisposition CIM86 (predisposition is an adapter only, CIM86 is
provided locally)
o Stripe-up mounting

Figure 1-1 Module Composition

1 Retained card bin

2 Motorized card
reader
3 Module tray

Figure 1-2 Card Reader Options

1 CIM86 Adapter Device
2 External Security Access Module
(SAM) CCA
3 Enhanced return card on power
failure

1.1.2 Configurations

Table 1-1 provides the configurations of motorized card read/write base module.

Table 1-1 Motorized Card Read/Write Base Module Configurations

Anti- Chip Tamper PIN Advanced Skimming
Model Basic Functions fishing Sensor Protection Detection
2R ---- ---- ---- X
123 Read/Write, Chip X X X X
123 Read/Write Hi- X X X X
coercivity, Chip
123 Read/Write with X ---- ---- X
Anti-fishing
123 Read/Write Hi- ---- ---- ---- ----
coercivity [1]
[1]
123 Read/Write ---- ---- ---- ----
[1]
2R Chip ---- X ---- ----
123 Read/Write, X ---- ---- ----
Watermark [1]
2R, Chip with Anti- X X X ----
fishing [1]
[1]
Obsolete

1.1.3 Basic Functions

The motorized card reader provides the following basic functions:

 Handling of ISO 7810 cards short edge first

 Read/write the ISO 7811 magnetic cards
 Read/write the ISO 7816 chip cards and memory cards
 Support Watermark
 Support SAMs
 Predisposition for CIM86
 Can operate mounted horizontally and in the range ± 30 degrees. from
horizontal
 Can operate stripe-up or stripe-down.

1.2 Motorized Card Reader Components

Section 1.2.1 through Section 1.2.6 describe the motorized card reader components.

Figure 1-3 Components of the Motorized Card Reader

1 DC Motor 3 IC Contact
 Block
2 Read/Write 4 Bezel
CCA Assembly

1.2.1 Terminal Interface

The card reader has an interface to the processor terminal, according to USB,
version 2.0 or 1.1, and uses USB full-speed transfer rate (12 Mbit/s).

1.2.2 Bezel Assembly

The entry gate is a shutter that completely closes the card entry slot. The slot
allows cards that comply with ISO 7810 standard dimensions to be inserted. The
gate area includes a sensor to detect a card of the correct width and includes a pre-
head to detect encoding on track two or track three. The firmware uses these
sensors to indicate when to open the entry gate.

Some models have a throat with a sensor to detect the chip on the card.

The shutter, when closed, prevents card fishing or trapping from outside (with or
without tools) and signals when fishing or trapping occurs. Some models have an
anti-fishing function that prevents card fishing also when the shutter is open.

NOTE

The pre-head does not detect encoding on Track 1. For security purposes, the gate
includes a gate home switch sensor to indicate when the shutter is completely
closed.

1.2.3 Return Card on Power Fail Devices

Return Card on Power Failure Device

With the Return Card on Power Failure device, the reader detects a power supply
failure and uses a capacitor to return the card to the front of the reader. If the power
fails during writing, the reader will not complete the write operation.

Enhanced Return Card on Power Failure Device

In case of a power failure or when a USB VBUS is off, the module provided with a
battery recovery device does the following:
 Terminates the writing on magnetic stripe or on chip/SAM and ejects the card.
After the ejection, the module monitors the card withdrawal for a maximum of
10 seconds. If the card is not withdrawn, the module retracts and captures the
card.
 Stores the recovery result in a non-volatile memory.
  Reports at the restart that a recovery has been executed.
 Reports, by terminal processor enquiry, the recovery result.

WARNIN
G

A hazardous stored charge may be present on the capacitors or in the battery of the
card return on power fail module.

1.2.4 Updating Firmware

The firmware can be downloaded over the primary communications channel.

1.2.5 Chip Card Handling

The chip card device has the following features:

 Read/write chip cards ISO 7816 with asynchronous protocols T=0 and/or T=1
 Support chip cards that require different power voltages: 5V, 3V
 Support baud rate communication to and from the chip, up to 38.400 baud
 Support only the ISO 7816 front-side lower-position of chip.
 Read/write chip cards with synchronous protocol (memory cards), compliant
with ISO 7816-10
 Protection against short circuit of contacts
 Capability to report problems of chip powering (short circuit, extra-current)
reporting
 OPTIONAL external CCA with 4 SAMs ID-000 sized
 Capability to report:
o Carte Bancaire approval number
o EMV Type Approval Number
o IFM Type

1.2.6 Retained Card Bins

The motorized card reader has an open or a locked retained card bin to store the
captured cards.

Open Bin Capacity

The open bin has a capacity of 50 no-embossed flat cards.

Locked Bin Capacity

The locked bin has the following capacity:
 100 no-embossed flat cards, in the case of stripe-down card readers
 50 no-embossed flat cards, in the case of stripe-up card readers

Section 2
Troubleshooting

2.1 General Trouble Shooting

1. Insert the card.

2. Does the shutter open?
o If yes, go to Step 3.
o If no, go to the bezel assembly diagnosis in Section 2.2.
3. Is the card captured?
o If yes, go to Step 4.
o If no, go to the transport diagnosis in Section 2.3
4. Is the data read?
o If yes, go to Step 5.
o If no, replace the card reader.
5. Is the data written?
o If yes, go to Step 6.
o If no, replace the card reader.
6. Is the card ejected?
o If yes, go to Step 7.
o If no, go to the transport diagnosis in Section 2.3.
7. IC contact RW?
o If yes, go to Step 8.
o If no, replace the card reader.
8. END

2.2 Bezel Assembly Diagnosis

1. SW1 signal (refer to Figure 6-1, point A). Check ON/OFF?

o If yes, go to Step 2.
o If no, SW1 needs adjustments or replacement (Section 4.5 )
 If recovered, go to Step 1.
 If not recovered, replace the card reader.
2. Pre-Head signal (refer to Figure 6-1, point GP). Check ON/OFF.
 o If yes, go to Step 3.
o If no, replace the card reader
3. Solenoid section signal (refer to Figure 6-1, point D). Check ON/OFF.
o If yes, go to Step 4.
o If no, solenoid needs adjustments or replacement (Section 4.7 )
 If recovered, go to Step 3.
 If not recovered, replace the card reader.
4. SW2 signal (refer to Figure 6-1, point C) Check ON/OFF
o If yes, go to Step 5.
o If no, SW2 needs adjustments or replacement (Section 4.6 )
 If recovered, go to Step 4.
 If not recovered, replace the card reader.
5. END

2.3 Transport Diagnosis

1. Sensor ON/OFF Check (refer to Figure 6-1).

Points: F1 for PD1, F2 for PD2, F3 for PD3, Fi for PDi.

a. If yes, go to Step 2.
b. If no, replace the card reader.
2. Motor ON. Check point E (refer toFigure 6-1).
a. If yes, go to Step 3.
b. If no, motor needs replacement and adjustments (Section 4.1 )
 If recovered, go to Step 2.
 If not recovered, replace the card reader.
3. Slipping Roller #1 - #4 Check
a. If yes, go to Step 3.
b. If no, perform roller cleaning (Section 7).
 If recovered, go to Step 3.
 If not recovered, adjust roller gap (Section 4.8 ).
 If recovered, go to Step 3.
 If not recovered, replace the card reader.
4. END

2.4 LEDs

The red and green LEDs are for diagnostic purposes.

Figure 2-1 Red and Green LEDs

1 Red LED
2 Green
LED
Table 2-1 LED Description
Card Reader Condition Green LED Red LED
Card Reader Switched OFF OFF OFF
During CPU Reset ON ON
Card Reader CPU Reset USB ON OFF if no error or is
Switched ON successfully disconnected (V- in Supervisor
Terminated BUS OFF) program
USB connected Regular
(V-BUS ON) blinking at: Patterned blinking
if error (see Table
2-2)
5 Hz in
Supervisor
Program

1 Hz in User
Program
Table 2-2 Pattern Blinking
Related Error Pattern
Condition Code Number
Recovery 30-37 1
Card moved forcibly 16 2
Short card inserted 14 3
Long card Inserted 13 4
Shutter failure 11 5
Card jam 10 6
ICC contact error 41 7
Retrieve error 17 8
Motor error 51 9
Enhanced anti-fishing 54, 55 10
error
Sensor error 12 11

The LED blinks in patterned mode:

 LED blinks at 2 Hz for the number of times indicated in the "Pattern number"
column and then stays ON for 1500 msec.
 This is repeated continuously until abnormal conditions are not cleared. When
abnormal conditions are cleared, the LED goes OFF.

Figure 2-2 shows an example of pattern number 3 (LED blinks 3 times).

Figure 2-2 Example of Pattern Number 3

1 20 Hz
2 1500
msec

2.5 ASD (Advanced Skimming Detection) Diagnosis

To perform ASD (Advanced Skimming Detection) it is recommended to use system-

level diagnostics tool related to the motorized card reader and identify the problem.
Refer to the appropriate diagnostic manual for system-level diagnostic information.

The diagnostic tool shall identify the status on Table 2-3 for the ASD (Advanced
Skimming Detection).
 Table 2-3 ASD (Advanced Skimming Detection) Troubleshooting
Status/Problem Probable Cause Corrective Action Refer to...
Advanced Not Configured Enable ASD (Advanced ACU (Agilis
Skimming Skimming Detection) Configuration
Detection is option in FDD Utility).
disabled configuration screen.
Failure ASD (Advanced Plug the ASD (Advanced Section 4.13
Skimming Skimming Detection)
Detection) sensor sensor connection cable
connection cable with the expansion board.
(with the
expansion board)
is unplugged
ASD (Advanced Replace the card reader. Appropriate terminal
Skimming operating guide for
Detection) sensor information on the
connection cable location of the card
(with the readers in the
expansion board) terminal.
is damaged
ASD (Advanced Replace the card reader. Appropriate terminal
Skimming operating guide for
Detection) sensor information on the
is damaged location of the card
readers in the
terminal.
Fraud Skimmer device is 1. Remove the fraud Section 2.6
installed 2. Click the
LatchReset button
and check the
Foreign Device
Detection Status of
the reader again.

ASD (Advanced Perform the procedure to Section 7.2

Skimming clean the card reader
Detection) sensor lead-through Indicator
is dirty cover
ASD (Advanced Replace the card reader Appropriate terminal
Skimming operating guide for
Detection) sensor information on the
is damaged location of the card
readers in the
terminal
2.6 Advanced Skimming Detection Fraud Verification and Removal

1. Fraud verification

If there is NO fraud device on the reader, it is possible to see the lead-through

indicator. If you cannot see the lead-through indicator, there is probably a
fraud device on the reader. Remove the fraud. Refer to Table 2-3 and follow
the Corrective Actions.

Figure 2-3 Motorized Card Reader Parts

1 DC Motor 3 IC Contact Block

2 Read/Write 4 Lead-through
CCA indicator

2. FDD Latch Configuration

a. To verify the Latch status (ON/OFF), go to the FDD (Foreign Device
Detection) device configuration screen on the diagnostic tool.
b. Refer to the Opteva Service Diagnostics+ User's Guide (TM-000192-
001F) for futher guidance.
3. FDD LatchReset button
a. Go to the FDD Status & Test screen on the diagnostic tool.
b. Click the LatchReset button to clear the Foreign Device Detection
Status of the reader. Refer to Opteva Service Diagnostics+ User's Guide
(TM-000192-001F) for further detail.

Section 3
Diagnostics
System-level diagnostics exercise the various components related to the motorized
card reader and identify the problem. Refer to the appropriate diagnostic manual for
system-level diagnostic information.

Section 4
Repair

This section covers the repair and adjustment procedures for the motorized card
reader. Most procedures in this section are based on the assumption that the
motorized card reader is pulled out of the terminal to its fully extended position, or is
removed from the terminal.

WARNIN
G

Practice all safety requirements when working on the terminal. Be sure to follow the
shutdown and startup procedures provided in the appropriate on-site module removal
and replacement manual before performing any of the procedures in this manual.
Failure to practice all safety requirements or to follow the shutdown and startup
procedures can result in bodily injury or death.

Disconnecting cables without first turning off the terminal's switched power can
cause bodily injury or death from electrical shock or damage the module or the
terminal. To prevent bodily injury or equipment damage, DO NOT disconnect or
reconnect any module cables without first turning off the terminal's switched power
as described in the shut-down procedure for modules provided in the appropriate on-
site module removal and replacement manual.

CAUTIO
N

 Wear a properly grounded, anti-static wrist strap whenever CCAs are handled.
Use an anti-static carrier to store the CCAs before installation and after
removal.
 Before removing cable tie straps or disconnecting cables as part of the
procedures in this section, take note of cable routing or bundling and tie strap
locations. If cables are not routed or secured properly, they may sustain
damage that affects terminal operation.

NOTE

In conjunction with the replacement procedures in this section, always remember to

do the following actions:

 Run the appropriate terminal-level diagnostics.

 Test the operation of the terminal after any repairs.
4.1 Motor Assembly - Replacement

4.1.1 Read/Write CCA - Disassembly

Tools: Screwdriver (M2.5)

Remove the Read/Write CCA per the instruction below (refer to Figure 4-1):

1. Remove screws, (item 2) from the CCA.

2. Disconnect all connectors from the CCA.

Figure 4-1 Read/Write CCA Assembly - Disassembly

1 Maylar 3 Case
Sheet
2 Screws 4 CCA
Assembly

4.1.2 Motor Assembly - Disassembly

Tools: Screwdriver (M3) and Scale and Tension gauge, (in case of no tension gauge,
refer to the note below).

NOTE

In case there is no tension gauge for adding the pressure, mark the fixing position
before the replacement and fix screw to fit the position to the mark when replaced.

1. Remove the timing belt.

2. Remove screws securing the motor and remove the motor.
3. Replace the motor assembly.
Figure 4-2 Motor Assembly - Replacement

1 Screws
2 Motor Assembly
3 A=B 10-30gf (0.1 -
0.3N)

4.1.3 Read/Write CCA and Motor - Assembly

Assemble the module by performing the steps in Section 4.1.2 in reverse order.

4.1.4 Check Points

1. Belt Tension (refer to Figure 4-2).

a. Loosen screws (item 1) to adjust belt tension. At this time, the belt
must have flexibility , &dgr; by 0.6 mm at the mid-point (A=B) and its
flexibility requires the load ranging 10-30 gf.
b. Fasten screws (item 1) at 74cN.m (7.5kgf.cm) and check if the belt has
the appropriate flexibility or not. If the flexibility is not sufficient or is
excessive, readjustment is required. If the flexability is appropriate, put
a mark on those screw heads, indicating that adjustment has been
done.
2. Read/Write operation

Check if Read/Write operation has been done without any problems. If a

problem happened, readjust belt tension. If there is still a problem, a different
motor may be required.

NOTE

In case of no tension gauge for adding the pressure, mark the fixing position before
the replacement and fix screw to fit the position to the mark when replacement.
4.2 Timing Belts - Replacement

4.2.1 Disassembly and Assembly

Tools: Screwdriver (M3) and Scale and Tension gauge (in case of no Tension gauge
refer to the note on the following page), E-Clip Tool (E5). CE Clip Tool (CE6).

1. (Refer to Figure 4-3). Remove timing belt 2 (item 11).

2. Loosen screws (item 9) and decrease the tension of timing belt 1 (item 2)
3. Remove the screw (item 5) securing the capture roller (item 4).
4. Remove the retaining rings (item 6, 7) and the washer (item 12).
5. Pull out the pulley assembly (item 1) in the direction shown with the arrow in
Figure 4-3.
6. Replace timing belt 1 (item 2), then reverse the order of Step 5 through Step 1.

NOTE

 Be sure to insert the locking pin into the roller (item 8).
 Fit the tooth form of timing belt 1 (item 2) and the pulley (item 10) when
assembling.
 The retaining ring (item 6) and (item 7) might become deformed by removing.
If deformed, the part(s) should be replaced by new one.

Figure 4-3 Timing Belt - Replacement

1 Pulley 7 Ring
Assembly
2 Timing Belt 1 8 Roller
3 Pin 9 Screws
4 Capture 1 Pulley
Roller 0
5 Screw 1 Timing
1 Belt 2
6 Ring 1 Plain
2 Washer

4.2.2 Adjustment

1. (Refer to Figure 4-4). Loosen screws (item 1) and add pressure between 400
and 500 gf to the position of the tension pulley, shown in Figure 4-4.
2. Fix the screw, under the condition that the above mentioned pressure is
added.

NOTE

In case of no tension gauge for adding the pressure, mark the fixing position before
the replacement and fix the screw to fit the position to the mark when replaced.

Figure 4-4 Timing Belt Adjustment

1 Screws
2 Position to add pressure : 3.9-4.9N
(400-500gf)

4.3 Changing Stripe-down to Strip-up

Tools: Screwdriver (M3)

 1. (Refer to Figure 4-5). Remove the screws (item 5) and disassemble the cover
(item 3).
2. Rotate the cover (item 3) to fit the "R" shaped part (item 4) to the solenoid
side and mount it with the screws (item 5).
3. Use the screws (item 2) to mount the stripe-up bracket (item 1).

Figure 4-5 Stripe-Up Bracket

1 Stripe-Up
Bracket
2 Screws
3 Cover
4 "R" Shaped
part
5 Screws

4.4 Bezel Assembly - Disassembly

Tools: Screwdriver (M3)

1. (Refer to Figure 4-6). Remove screws (item 1) and (item 3) and disassemble
the bezel assembly (item 2) .
2. Reassemble the bezel assembly by reversing the order in Step 1.

Figure 4-6 Bezel Assembly - Disassembly

1 Screw
2 Bezel
Assembly
3 Screw

4.5 SW1 - Replacement (micro switch for card detector)

4.5.1 SW1 - Replacement

Tools: Screwdriver (M2), ST-SW Card and Soldering iron.

1. (Refer to Figure 4-7). Disassemble the bezel assembly as described in Section

4.4 .
2. Remove screws (item 1 and item 6).
3. Remove lead wires along the ditch.
4. Remove the soldered 2 parts for the wires with a soldering iron (lead wires red
and brown).
5. Replace the micro switch and solder the lead wires, as shown in Figure 4-7
(thermal shrink tube has to be inserted).
6. Assemble by reversing the order of Step 5 through Step 1.

Figure 4-7 SW1 - Replacement

1 Screws 7 Micro Switch
2 Plate 8 Tube
Assembly
3 Detect lever 9 Red wire
4 Plate 1 Brown wire
0
5 Micro 1 Connector
Switch 1 Assembly
6 Screws

4.5.2 SW1 - Adjustment

1. Insert the ST-SW card into the card throat slowly. When position B of the ST-
SW card contacts the micro switch actuator (see Figure 4-8), a click will come
from the switch. This sound indicates that the SW1 detected the card (SW1
ON). At this position, fasten the adjusting screws for SW1.
2. Next, pull out the ST-SW card a little bit. A click will come from the SW1 again
when position A of the ST-SW card goes by the micro switch actuator. This
sound indicates the switch turned OFF.
3. Confirm if the SW1 works correctly at each ST-SW card position.

Figure 4-8 SW1 - Adjustment

1 ST-SW-Card
2 Position B (53.5
mm)
3 Position A (52.7
mm)
4 SW1 Lever
5 Adjusting Screw for
SW1

4.6 SW2 - Replacement (Micro Switch for shutter)

4.6.1 SW2 - Replacement

Tools: Screwdriver (M2), Shaft 2 mm diameter and Soldering iron)

1. (Refer to Figure 4-9). Disassemble the bezel assembly as described in Section

4.4.
2. Remove screws (item 1 and item 5).
3. Remove lead wires along the ditch.
4. Remove the soldered 2 parts for the wires with a soldering iron (lead wires red
and brown).
5. Replace micro switch and solder the lead wires (the thermal shrink tube has
to be inserted).
6. Assemble by reversing Step 5 through Step 1.

Figure 4-9 SW2 - Replacement

1 Screws 6 Micro Switch
2 Micro 7 Tube
Switch
3 Plate 8 Red wire
4 Plate 9 Brown wire
Assembly
5 Screws 1 Connector
0 Assembly

4.6.2 SW2 Adjustment

1. (Refer to Figure 4-10). Insert the shaft (item 2) of 2 mm diameter into the bezel
hole (item 5) through the plate hole (item 4).
2. Loosen the screw (item 3).
3. Set the micro switch (item 1) (SW2) ON (OFF to ON) and fix it with the screw
(item 3).
4. Checkpoint: After setting SW2 OFF (ON to OFF) by moving the solenoid
plunger, the shutter will fully close the card entry gate of the bezel. In
addition, after returning the solenoid plunger, SW2 will be set ON.
5. Reassemble the bezel assembly.

Figure 4-10 SW2 Adjustment (micro switch for shutter)

1 Micro Switch
(SW2)
2 Shaft
3 Screw
4 Plate Hole
5 Bezel Hole

4.7 Shutter Solenoid - Replacement

4.7.1 Shutter Solenoid - Disassembly

Tools: Screwdriver (M3), Shaft 2 mm diameter

1. (Refer to Figure 4-11). Disassemble the bezel assembly as described in

Section 4.4.
2. Remove the screws (item 2) and disassemble the shutter solenoid
3. Assemble the new shutter solenoid, using the screws (item 2) previously
removed.

Figure 4-11 Shutter Solenoid - Disassembly

1 Shutter
Solenoid
2 Screw

4.7.2 Shutter Solenoid - Adjustment

1. (Refer to Figure 4-12). Loosen the screw (item 1). When the solenoid is fully
plunged, adjust the solenoid to coincide the plate hole (item 5) with the bezel
hole (item 4). (Insert the shaft 2 mm diameter into the bezel hole B through
plate hole P). After this adjustment is done, fix the solenoid with the screw
(item 1).
2. Checkpoint: When the solenoid is plunged, the shutter should be fully open.
3. Reassemble the bezel assembly.

Figure 4-12 Shutter Solenoid - Adjustment

1 Screws
2 Bezel Assembly
3 Fully plunged
position
4 Bezel Hole
5 Plate Hole

4.8 Pad-Roller Gap Adjustment

Tools: Screwdriver (M3), Spanner (M3), Thickness gauge (0.1 mm), 0.25mm Card (see
Table 8-7).

1. Disassemble the bezel assembly. as described in Section 4.4.

2. (Refer to Figure 4-13). Loosen the attachment screws (item 3), then fasten the
screws at the position where gap A (item 1) and gap C (item 4) look equal to
each other.
3. Adjust gap A (item 1) and gap C (item 4) with nuts (item 2), to be at 0-0.1mm.
Check the gap:
a. Maximum less than 0.1 mm: 0.1 mm thickness gauge cannot be inserted
gap A (item 1) and gap C (item 4).
 b. Minimum over 0 mm: Pad Roller (item 5) can rotate smoothly when it is
rotated by hand.
4. Confirm if a test card (thickness = 0.25 mm) can transport back and forth.
5. Reassemble the bezel assembly.

Figure 4-13 Pad-Roller Gap Adjustment

1 Gap 4 Gap C
A
2 Nut 5 PAD
Roller
3 Scre
ws

4.9 Locked Card Bin - Replacement

Tools: Screwdriver (M3)

1. (Refer to Figure 4-14). The locked retained card bin has a lid that has to be
opened with a special key. Open the bin (item 1) by turning the key (item 2)
and lift up the lid.
2. Remove the screw (item 3) that fastens the bin to the tray.
3. Free the bin by pushing it to the left and remove it from the tray.
 4. Replace the bin and reassemble it, reversing the order of Step 3 through Step
1.

Figure 4-14 Locked Card Bin - Replacement

1 Locked Card
Bin
2 Key
3 Screw

4.10 CIM 86 USB-RS232 CCA Adapter - Removal and Replacement

Tools: Screwdriver (M3)

The CIM 86 USB-RS232 CCA Adapter is located inside a box fixed over the CIM 86
module.

Figure 4-15 CIM 86 USB-RS232 CCA Adapter Box Removal

1 CCA
Box
2 Screws

1. (Refer to Figure 4-15). Loosen the two screws (item 2).

2. Free the CCA box by pushing it to the right (see Figure 4-15) and remove it.
3. Disconnect the CIM 86 USB-RS232 CCA Adapter connectors.
4. Remove the four screws (see Figure 4-16, item 4). Keep the screws and take
out the CCA.
5. Replace the CIM 86 USB-RS232 CCA and reassemble the module, reversering
the order of Step 4 through Step 1.

Figure 4-16 CIM 86 USB-RS232 CCA Adapter - Removal and Replacement

3 CIM 86 USB-RS232 CCA
Adapter CCA
4 Screws

4.11 SAM CCA Adapter - Removal and Replacement

There are two versions of the SAM CCA:

 SAM CCA with short connection cable, fixed on the Read/Write CCA case.
 SAM CCA with long connection cable, not fixed on the card reader module but
on a different terminal location.

4.11.1 SAM CCA with Short Connection Cable - Removal and

Replacement

Tools: Screwdriver (M3)

1. (Refer to Figure 4-17). Disconnect the SAM CCA (item 1) short connection
cable (item 3).
2. Remove the three screws (item 2). Keep the screws and take out the CCA.
3. Replace the SAM CCA and reassemble the module, reversing the order of Step
2 and Step 1.

Figure 4-17 SAM CCA with Short Connection Cable - Removal and Replacement

1 SAM CCA
2 Screws
3 Short connection
cable

4.11.2 SAM CCA with Long Connection Cable - Removal and

Replacement

Tools: Screwdriver (M3)

1. Refer to Figure 4-17). Locate the CCA on the terminal and disconnect the SAM
CCA (item 1) long connection cable (item 3).
2. Remove the two securing screws (item 2), keep the screws and take out the
CCA.
3. Replace the SAM CCA and reassemble the module, reversing the order of Step
2 through Step 1.

Figure 4-18 SAM CCA with Long Connection Cable - Removal and Replacement

1 SAM CCA
2 Two securing
screws
3 Long connection
cable

4.12 Backup Power Device - Removal and Replacement

There are two backup power device versions:

 Return Card on Power Failure device

 Enhanced Return Card on Power Failure device

The device location depends on the terminal.

4.12.1 Return Card on Power Failure Device - Removal and

Replacement

Return Card on Power Failure Device composition:

 Return Card on Power Failure Device Box

 Cable

To remove and replace the backup power device, proceed as follows:

1. (Refer to Figure 4-19). Locate the Return Card on Power Failure device (item 1)
on the terminal , disconnect the device connection cable (item 2),
2. Rremove the box securing screws, keep the screws and and take out the
device.
3. Replace the Return Card on Power Failure device and reassemble the module,
reversing the order of Step 2 through Step 1.

Figure 4-19 Return Card on Power Failure Device - Removal and Replacement
1 Return Card on Power Failure
Device
2 Cable

4.12.2 Enhanced Return Card on Power Failure Device - Removal and

Replacement

Enhanced Return Card on Power Failure Device composition:

 Battery
 Battery Charger CCA
 Cables

To remove and replace the battery, the battery charger CCA or the Enhanced Return
Card on Power Failure Device assembly proceed as follows:

1. (See Figure 4-20). Locate the Enhanced Return Card on Power Failure device
on the terminal.
2. Disconnect the battery charger CCA and card reader cable (item 3),
3. Disconnect the battery (item 1) cable from battery charger CCA (item 2) .
4. Replace the battery or the battery charger CCA and reassemble the module
reversing the above removal procedure.
Figure 4-20 Enhanced Return Card on Power Failure Device - Removal and
Replacement

1 Battery
2 Battery Charger CCA
3 Battery Charger CCA-Card
Reader Cable

4.13 ASD (Advanced Skimming Detection) Sensor cable connection

1. 1. Locate the ASD (Advanced Skimming Detection) sensor connector on the

rear side of the Expansion CCA (Figure 4-21).
2. 2. On the card reader's Expansion CCA connect carefully the sensor
connector.
3. 3. Push the Card Reader into the Terminal.

Figure 4-21 Expansion CCA rear side

1 ASD (Advanced Skimming Detection) sensor
connector

Section 5
Cabling

Refer to Figure 5-1 for information about cabling and connections.

Figure 5-1 Motorized Card Reader Cabling and Connections

1 Read/Write CCA (Card Reader External 1 ISO track 1,2,3 Head

 cables) 3
2 Read/Write CCA (Card Reader Internal 1 Motor
cables) 4
3 Chip Contact (ICC) CCA 1 USB Interface
5
4 Shutter solenoid 1 Terminal Power distribution
6
5 Pre-head 1 Return Card on power fail device
7
6 Lead-through indicator CCA 1 Enhanced Return Card on power
8 fail CCA
7 Card position sensor (LED) CCA 1 Battery
9
8 Gate lock sensor CCA 2 Optional SAM CCA
0
9 Gate lock stepping motor 2 Expansion CCA flat cable
1
1 IC chip detect sensor CCA 2 Enhanced Return Card on power
0 2 fail cable
1 Expansion CCA 2 SAM CCA flat cable
1 3
1 Card position sensor (Photo
2 transistor) CCA

Section 6
Circuit Card Assemblies (CCA) Connectors and Pinouts

6.1 Read/Write CCA View, Test Points and Diagnostic LEDs

Figure 6-1 shows the outside view of Read/Write CCA test points.

Figure 6-1 Outside View of Read/Write CCA Test Points and Diagnostic LEDs
1 Green
LED
2 Red LED

6.2 Read/Write CCA Connectors (card reader external cables)

Figure 6-2 Read/Write CCA Connectors (Card Reader External cables)

1 J13 - USB Interface
2 J2 - Terminal Power distribution
3 JC - Return Card on power fail device
4 JB - Enhanced Return Card on power
fail CCA
5 J803 - Optional ext. SAM CCA
Table 6-1 Read/Write CCA Connections (card reader external cables)
Connect
or Cable Destination
J13 USB Terminal Controller
J2 Power Terminal Power distribution
JC Capacitor External Capacitor
JB Enhanced Return Card on power Enhanced Return Card on power fail
fail CCA CCA JB
J803 SAM CCA flat cable SAM CCA J1
Table 6-2 Read/Write CCA Pinout Information (card reader
external cables)
Connector Pin Number Signal Name
J13 1 VBAS
2 D-
 3 D+
4 SGN
J803 1 SEDCT
2 PWRON
3 MCINT
4 RDYMOD
5 RDST
6 IO
7 SGN
8 N.C
9 SYNCLK
10 CSE
11 CSA
12 CSB
13 SEIN
14 SECON
15 +23V
J2 1 +24V
2 GND
JB 1 +23VVCC
2 PG
3 BATC1
4 BATC2
5 BATON
6 NPDOWN
7 24VM
8 BATM
9 +5VVCC
10 SGN
11 SGN
12 BDS
JC 1 BPS
2 PGN
3 CDS
4 SGN
6.3 Read/Write CCA Connectors (card reader internal cables)

Figure 6-3 Read/Write CCA Connectors (Card Reader Internal cables)

6 J7 - Motor 1 J5 - Card Position Sensor (LED)

0
7 J302 - IC Chip & SIM1 1 CN5 - Expansion CCA (Chip detect,
1 anti-fishing)
8 J301B - Shutter 1 J4 - Card Position Sensor (Photo
Solenoid 2 transistor)
9 JM -Lead through 1 J6 - ISO Track 1, 2, 3 Head
indicator 3
Table 6-3 Read/Write CCA Connections (card reader
internal cables)
Connector Cable Destination
J7 Motor cable Motor
J302 SIM1 flat cable SIM1 PWB
J301B Shutter Shutter solenoid
JM Lead-through indicator Lead through indicator)
J5 Sensor flat cable 1 Card position sensor
CCA
CN5 Expansion CCA flat Expansion CCA CN1
cable
J4 Sensor flat cable 2 Card position sensor
CCA
J6 Head flexible cable ISO Track 1, 2, 3 head
Table 6-4 Read/Write CCA Pinout Information (card reader
internal cables)
Connector Pin Number Signal Name
J7 1 VCC
2 TACO
3 SGN
4 OUT1
5 OUT2
J302 1 +5VVCC
2 ASYCLK
3 SYNCLK
4 SGN
5 IO
6 RST
7 RDYMOD
8 MCINT
9 PWRON
10 SIM1
11 FUSE
12 PROG
13 PDOUT
14 ICC
15 N.C.
16 PI2
17 +12VVCC
18 +23VVCC
19 IC-CON
J301B 1 +23VVCC
2 SHUTTER1
3 SGN
4 PI1
5 SGN
6 SW1
JM 1 LEDMR
2 LEDMG
3 N.C.
4 +23V
J5 1 •12VVCC
2 HFLT
3 LEDON
4 PHDN
5 PHDPN
6 FGB
7 SGN
8 HDS1
9 HDS2
10 HDS3
CN5 1 +5VVCC
2 SGN
3 SENSIN
4 N.C
5 +12VVCC
6 +23VVCC
7 SGN
8 CCLOCK
9 CHIPDCT
10 N.C
11 N.C
12 N.C
13 SGN
14 F2FWWI
15 RDSTO
16 WMDCTI
17 FSCK
18 FSAT
19 FSEN
20 FS1
21 GTLDCT
 22 N.C
J4 1 N.C
2 PD3
3 PD2
4 PDI
5 PD1
6 N.C
7 +5V
J6 1 FGA
2 ISO3RP
3 ISO3WA
4 ISO3RN
5 ISO3WB
6 ISO2WA
7 ISO2RN
8 ISO2WB
9 ISO2RP
10 ISO1WA
11 ISO1RN
12 ISO1WB
13 ISO1RP
14 FGA

6.4 Card Position Sensor LED CCA

Figure 6-4 Card Position Sensor LED CCA Connectors

1 J22 - Pre Head

2 Sensor Flat Cable -
Soldered
Table 6-5 Card Position Sensor (LED) CCA
Connections
Connecto
r Cable Destination
J22 Pre-head flexible Pre-head
cable
Soldered Sensor flat cable 1 Read/Write CCA
J5
Table 6-6 Card Position Sensor (LED) CCA Pinout
Information
Connector Pin Number Signal Name
J22 1 PHD-
2 PHD+
3 FG2
Sensor flat cable 1 1 •12VVCC
2 HFLT
3 LEDON
4 PHDN
5 PHDP
6 FGB
7 SGN
8 HDS1
9 HDS2
10 HDS3

6.5 Card Position Sensor (photo transistor) CCA

Figure 6-5 Card Position Sensor (Photo Transistor) CCA Connectors

1 Sensor Flat Cable -

Soldered
Table 6-7 Card Position Sensor (photo transistor) CCA
Connections
Connector Cable Destination
Soldered Sensor flat cable 2 Read/Write CCA J4
 Table 6-8 Card Position Sensor (photo transistor) Pinout
Information
Connector Pin Number Signal Name
Sensorflat cable 2 1 N.C
2 PD3
3 PD2
4 PDI
5 PD1
6 N.C
7 +5V

6.6 Lead-through Indicator CCA

Figure 6-6 Lead-through Indicator CCA Connectors

1 Lead-through indicator Cable - Soldered

2 Soldered ASD (Advanced Skimming Detection) sensor
cable - Soldered
Table 6-9 Lead-through Indicator CCA Connections
Connect
or Cable Destination
Soldered Lead-through indicator cable Read/Write CCA
JM
Soldered ASD (Advanced Skimming Detection) Expansion CCA
sensor cable CN33
Table 6-10 Lead-through Indicator CCA Pinout Information
Pin
Connector Number Signal Name
Lead-through indicator cable 1 LEDMR
2 LEDMG
 3 N.C
4 +23V
ASD (Advanced Skimming Detection) CN4-1 IR LED (Emitter) anode
sensor cable CN4-2 IR LED (Emitter) cathode
CN4-3 Photo diode (Detector)
anode
CN4-4 Photo diode (Detector)
cathode
CN4-5 GND

6.7 IC Chip Contact (ICC) CCA

Figure 6-7 IC Chip Contact (ICC) CCA Connectors

1 ICC Flat Cable -

Soldered
Table 6-11 IC Chip Contact (ICC) CCA
Connections
Connector Cable Destination
Soldered ICC Flat Cable SIM1 CCA J2
Table 6-12 IC Chip Contact (ICC) CCA Pinout
Information
Connector Pin Number Signal Name
ICC flat cable 1 +5VVCC
2 ASYCLK
3 SYNCLK
4 SGN
5 IO
6 RST
7 RDYMOD
8 MCINT
9 PWRON
 10 FUSE
11 PROG
12 PDOUT
13 ICC
14 VPP

6.8 SIM1 CCA

Figure 6-8 SIM1 CCA Connectors

1 J2 - IC Chip Interface
2 J3 - IC Contact
Solenoid
3 SIM1 Flat Cable -
Soldered
Table 6-13 SIM1 CCA Connections
Connect
or Cable Destination
J2 IC chip flat cable ICC CCA
J3 IC cotact solenoid ICC contact
cable solenoid
Soldered SIM1 flat cable Read/Write CCA
J302
Table 6-14 SIM1 CCA Pinout
Information
Pin Signal
Connector Number Name
J2 1 +5VVCC
2 ASYCLK
3 SYNCLK
 4 SGN
5 IO
6 RST
7 RDYMOD
8 MCINT
9 PWRON
10 FUSE
11 PROG
12 PDOUT
13 ICC
14 VPP
J3 1 SOL+
2 SOL-
SIM1 flat 1 +5VVCC
cable 2 ASYCLK
3 SYNCLK
4 SGN
5 IO
6 RST
7 RDYMOD
8 MCINT
9 PWRON
10 SIM1
11 FUSE
12 PROG
13 PDOUT
14 ICC
15 N.C
16 PI2
17 +12VVCC
18 +23VVCC
19 IC-CON

6.9 IC Chip Detect Sensor CCA

Figure 6-9 IC Chip Detect Sensor CCA Connectors

1 ICC chip detect sensor cable-
Soldered
Table 6-15 IC Chip Detect Sensor CCA
Connections
Connect
or Cable Destination
Soldered IC Chip detect sensor Expansion CCA
cable J2
Table 6-16 IC Chip Detect Sensor CCA Pinout
Information
Signal
Connector Pin Number Name
IC Chip detect sensor 1 CSENS
cable 2 SGN
3 DRV1
4 DRV2
5 SGN

6.10 Gate Lock Sensor CCA

Figure 6-10 Gate Lock Sensor CCA Connectors

1 Gate Lock Sensor cable -

 Soldered
Table 6-17 Gate Lock Sensor CCA
Connections
Connect
or Cable Destination
Soldered Gate Lock Sensor Expansion CCA
cable CN31
Table 6-18 Gate Lock Sensor CCA Pinout
Information
Signal
Connector Pin Number Name
Gate Lock sensor 1 LED
cable 2 Tr-C
3 SGN

6.11 Enhanced Return Card on power fail CCA

Figure 6-11 Enhanced Return Card on power fail CCA Connectors

1 JB - Read/Write CCA
Interface
2 J111 - Battery
Table 6-19 Enhanced Return Card on Power Fail CCA
Connections
Connector Cable Destination
JB RBB cable Read/Write CCA JB
J111 Battery cable Battery
Table 6-20 Enhanced Return Card on power fail Pinout
Information
Connector Pin Number Signal Name
JB 1 +23VVCC
 2 PGN
3 BATC1
4 BATC2
5 BATON
6 NPDOWN
7 24VM
8 BATM
9 +5VVCC
10 SGN
11 SGN
12 BDS
J111 1 BAT+
2 BAT-

6.12 Expansion CCA

Figure 6-12 Expansion CCA Connectors - front side

1 CN1 - Read/Write CCA 3 CN32 - gate lock stepping

interface motor
2 CN31 - gate lock sensor 4 J2 - Chip detect sensor
Table 6-21 Expansion CCA Connection
Connect
or Cable Destination
CN1 Expansion CCA flat Read/Write CCA
cable CN5
CN31 Gate lock sensor cable Gate lock sensor
CCA
CN32 Gate lock stepping Stepping motor
 motor cable
J2 Chip detect sensor cable Chip detect sensor
CCA
Table 6-22 Expansion CCA Pinout Information -
front side
Connector Pin Number Signal Name
CN1 1 +5VVCC
2 SGN
3 SENSIN
4 N.C
5 +12VVCC
6 +23VVCC
7 SGN
8 CCLOCK
9 CHIPDCT
10 N.C
11 N.C
12 N.C
13 SGN
14 F2FWWI
15 RDSTO
16 WMDCTI
17 FSCK
18 FSAT
19 FSEN
20 FS1
21 GTLDCT
22 N.C
J2 1 CSENS
2 SGN
3 SGN
4 DRV1
5 DRV2
6 SGN
7 CHIPDET
8 SGN
CN31 1 FS1
2 LED
3 N.C
4 N.C
5 SGN
6 N.C
CN32 1 PH1
2 PH2
3 PH3
4 PH4
5 COM

Figure 6-13 Expansion CCA connectors - rear side

1 Skimmer
sensor
Table 6-23 Expansion CCA Connection - rear side
Connect
or Cable Destination
CN33 ASD (Advanced Skimming Detection) Lead Through
sensor cable Indicator CCA
Table 6-24 Expansion CCA Pinout Information -
rear side
Connector Pin Number Signal Name
CN33 1 EA
 2 EK
3 DA
4 DK
5 GND
6 SKMDCT
7 FGA

6.13 SAM CCA

Figure 6-14 SAM CCA Connectors

1 J1 - Read/Write CCA
Interface
2 Not used
Table 6-25 SAM CCA Connections
Connect
or Cable Destination
J1 SAM CCA flat Read/Write CCA
cable J803
Table 6-26 SAM CCA Pinout
Information
Connecto Signal
r Pin Number Name
J1 1 SEDCT
2 PWRON
3 MCINT
4 RDYMOD
5 RDST
6 IO
 7 SGN
8 N.C
9 SYNCLK
10 CSE
11 CSA
12 CSB
13 SEIN
14 SECON
15 +23V

Section 7
Preventive Maintenance

7.1 Rubber Roller Cleaning

Tools: alcohol liquid (ethanol etc.), cloth (felt, swab)

Cloth penetrated with some alcohol liquid is used for cleaning up the roller when the
cleaning card is not effective.

Cleaning should be done at periodical checks or inspections.

Cleaning point of rollers are showed on the Figure 7-1

Figure 7-1 Cleaning Point of Rollers

1 Roller 3
2 DC
 Motor
3 Gate
4 Roller 1
5 Roller 2

7.2 ASD (Advanced Skimming Detection) Sensor Cleaning

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

Cloth penetrated with some alcohol liquid is used for cleaning the cover of the lead-
through indicator.

Cleaning should be done when the ASD sensor value with object is decreasing
significantly.

Working time: 1minutes

Cleaning frequency: about 6 month (normal condition: Indoor use )

Section 8
Parts

This section covers the field replaceable parts for the motorized card reader

Table 8-1 Motorized Card Reader and Locked Bins - Version Part Numbers
Part Part
Number Description Number Description
1 49-209537- 2R Card Reader 1 49-209543- 123 Read/Write Waterm.
000B 000A Card Reader
49-201324- 123Read/Write Card 49-209544- 123 Read/Write with
000A Reader 000B Antifish. Card Reader
49-201325- 2R Chip Card Reader 49-201397- 2R with Antifish. Card
000A 000B Reader
49-209540- 123 Read/Write Chip Card 2 00-104514- Locked Bin for stripe-down
000B Reader 000A
49-201327- 123 Read/Write HiCo Card 00-104515- Locked Bin for stripe-up
000A Reader 000A
49-209542- 123 Read/Write HiCo Chip
000B Card Reader

Figure 8-1 Motorized Card Reader Group Composition

 Table 8-2 Motorized Card Reader Parts
Part Number Description Part Number Description
1 49-201479- Timing Belt 1 5 49-201478- Lead-through indicator Cover
000A 000A
2 49-201480- Timing Belt 2 6 49-201332- Stripe Up bracket
000A 000A
3 49-201483- Motor Assembly 7 49-201481- SW1, Micro Switch for card
000A 000A detector
4 49-201485- Shutter Solenoid SW2, Micro Switch for
000A Assembly shutter

Figure 8-2 Motorized Card Reader Parts

 Table 8-3 Security Access Module (SAM) CCA Parts
Part Number Description
1 49-201333- Security Access Module CCA with
000A short cable
2 49-201484- Security Access Module CCA with
000A long cable

Figure 8-3 External Security Access Module (SAM) CCA Parts

 Table 8-4 Enhanced Return Card on Power
Failure Device
Part Number Description
1 49-201398- 24 V Battery
000A
2 49-201399- Battery Charger CCA
000A
3 49-201401- Battery Charger CCA-Card reader
000A Cable
Table 8-5 Return Card on Power Failure
Device
Part Number Description
4 00-101291- Capacitor Group
00B
5 49-201399- Capacitor Group-Card reader
000A Cable

Figure 8-4 Backup Power Devices Parts

 Table 8-6 CIM-86 Predisposition Assembly
Parts
Part Number Description
1 49-202019- USB-RS232 CCA adapter
000A
2 49-014301- Terminal +24V cable
000A
3 49-014303- Terminal USB cable
000A
4 49-201339- CCA Adapter -CIM 86 module
00A cable

Figure 8-5 CIM-86 Predisposition Assembly Parts

 Table 8-7 On-site Maintenance
Tools
Part Number Description
49-201487- Cleaning Card
000A
49-201477- Pad-roller Gap check
000A Card
49-201482- ST-SW card
000A
49-201476- Hybrid Test Card
000A
19-013622- Magnetic LoCo Card
000A
19-013622- Magnetic HiCo Card
000B
49-201530- Watermark test card
000A