WHISTLE STOP OWNER S MANUAL. Version WS-1.15

Transcription

1 WHISTLE STOP OWNER S MANUAL Version WS-1.15 BAY-TEK INC East Glenbrook Drive Pulaski, WI service@bay-tek.com Web site: Service:...(920) ext Parts:... (920) ext Fax:... (920) Service Fax:... (920) Sales:... (920)

2 TABLE OF CONTENTS OPERATION AND SETUP SECTION... 3 Safety Precautions... 3 How the Game Works... 3 Service Connections... 4 Unpacking, Assembly and Installation... 4 Loading Prizes... 5 Alarm/Sounds... 5 Counters... 5 Factory Settings... 6 Accessories... 6 PROGRAMMING SECTION... 7 Programmable Dipswitches... 7 Group #1 (S1)... 7 Group #2 (S2)... 9 SETUP SECTION Mercy Ticket Setting (Mode 5) Ticket Value Setting (Mode 6) Prize Ejection Count (Mode 7) Skill Level Setting (Mode 8) Zone (Rack) Setup (Mode 9) LUBRICATION and PREVENTIVE MAINTENANCE SECTION TROUBLESHOOTING & DIAGNOSTICS SECTION Troubleshooting Strategy Diagnose Power Supply SERVICE AND REPAIR SECTION Ejector Assembly Repairs Removing Complete Assembly Limit Switch Replacement Ejector Gearmotor Replacement Installing Assembly Turntable Motor Replacement Turntable Chain Adjustment and Replacement Circuit boards Arrow, Arc and Credit Displays Main Circuit Boards ELECTRICAL DRAWINGS SECTIONS... 23

3 12 Volt Jumper Cable (J1) Connector Volume Cable (J2) Connector Jumper (J3) Connector Jumper (J3) Connector Jumper (J4) Connector Jumper (J5) Connector Gen 5 Main Board Schematics Communications Serial EEprom Input Section A Configuration Switches Input Section B Inputs RE, RC Output Section A Chase Lights, Q13 - Q Output Section B Q17 Q Output Section C Q5 Q Power Section Processor Section Input RD SPARE PARTS WHISTLE STOP WARRANTY INFORMATION LOG SHEET FOR PRIZE EJECTION COUNT Bay-Tek s FILL KIT INFORMATION NOTES Whistle Stop 2

4 OPERATION AND SETUP SECTION Safety Precautions CAUTION: Electrical Shock Hazard. Do not perform maintenance or repair of this equipment with power ON. Unplug the unit from the wall outlet or shut off power at the power strip inside the cabinet. CAUTION: Electrical Shock Hazard. Always plug game into a grounded circuit. CAUTION: Cutting Hazard. Always replace broken or scratched glass panels with tempered glass. Never use window glass in this game. CAUTION: Use of flammable substances can cause severe burns or personal injury. Always use non-flammable solvents for cleaning parts and surfaces of this game. Do not use flammable substances such as gasoline, kerosene or thinners. CAUTION: Choking Hazard. Small prizes, balls and marbles awarded by this game are not suitable for children under three years of age. How the Game Works Whistle Stop is a game of skill. There are 17 prize racks (called zones) of various sizes located on a turntable. As the turntable rotates, each prize zone passes by a Track of red LED lights forming an arc around a portion of the turntable. The red lights sequentially go on and off to indicate the location of the center of each prize zone. See figure on the next page. The player first determines the prize at the bottom of any zone that he or she wants to play for. When the single bank of red lights, for the desired prize zone, line up with the large green and yellow arrow on the control panel, the player presses the Push to Stop Train button. The turntable then slows to a stop. If the center lights of the prize zone stops in alignment with the bank of green LED lights of the Win Here station, the player wins that prize. The turntable will then automatically rotate to the discharge chute and dispense the prize. Games equipped with ticket dispensers can also be set up to dispense tickets for additional rewards or as compensation (mercy setting) for missed attempts. The owner can individually set the degree of difficulty, and ticket credits, for each zone. Whistle Stop 3

5 HIT THE BRAKES HERE TO STOP ON THE PRIZE ZONE HERE Figure 1 Track Layout Service Connections All Bay-Tek games are 110V or 220V(optional) and draw 2-3 amps at startup. Outlets should be rated for 20 amps or higher. IMPORTANT: Be sure that the electrical power outlets match the game requirements. See outlet labeling at rear bottom of game cabinet. Unpacking, Assembly and Installation 1. Inspect the game for any damaged, loose or missing parts. If damage is found please contact the carrier first. Then contact Bay-tek at: service@bay-tek.com, or phone (920) to order replacement parts. CAUTION: Lifting Hazard. Lifting heavy objects can cause back, neck and other injuries. Be sure adequate lifting and moving devices are available when unloading, unpacking and moving this game. 2. Place the game near the final location and remove the keys taped in the coin return and open the front door panel. 3. Uncoil the power cord and feed the cord through one of the holes in the bottom board at the back of the cabinet. Plug the power cord into the wall outlet. 4. Place the game in its final position and lock the front wheels to prevent movement. The game must be reasonably level to prevent unintended alarms due to game tilting. If Whistle Stop 4

6 leveling is necessary, use adequate shims and blocking to prevent tipping. 5. Open the front panel and remove the shipping screw and cardboard or foam blocking from under the turntable. Remove any tape securing lighting fixtures. Loading Prizes Power to the game must be OFF. Open the front panel and shut OFF power at the rear power strip before loading any prizes. Rotate the turntable by hand to load appropriate prizes at the top of each rack on the turntable. Prizes are always dispensed from the bottom of the rack. NOTE: Prizes must be loose in the racks. Snug fitting prizes may become jammed and be unable to drop into position properly. Figure 2 Power Strip with Circuit Breaker 6. Turn power ON at the power strip located inside the cabinet at the bottom of the rear panel. 7. If this game is setup for ticket dispensing, fill the ticket tray in the front door panel. 8. Load prizes as described below and play the game a few times to make sure that everything is working. (For testing, open the front panel and trip one of the coin count levers a few times to establish game credits). If something is not working properly, review the troubleshooting section first. If the problem cannot be resolved, contact the Bay-tek service department at: service@baytek.com, or phone (920) Once everything is set and working properly, close and lock the front panel. Use glass cleaner and a soft clean cloth to clean all the glass on the game. Do not use solvents to clean the game decal surfaces. The game is now ready to play. IMPORTANT: Whistle Stop is equipped with a prize storage box located inside the game under the turntable. While critical circuit boards are covered with clear plastic for protection, care must be taken when inserting or removing this box not to accidentally damage any components or wiring inside the cabinet. When all prizes are loaded, turn ON the power at the power strip to return to normal operating mode. IMPORTANT: Observe the alignment of the red LED zone lights as the various zones pass the track arc. If, after one full revolution of the turntable, the lights are not aligned properly, the turntable must be re-aligned to the home position. See Setup Section on page 10 for an explanation of alignment. Alarm/Sounds A plum bob mechanism will sound an audible alarm if the game is tilted too hard. When tilted, a prize cannot be won. The game will automatically reset the alarm and re-calibrate the turntable home position for the next credit to be played. A voice chip announces play results and other game information to enhance the visual effects of the game. Counters Two counters are mounted on the inside back wall of the game above the power strip. One counter tracks the number of games played and the other counter tracks the total number of prizes dispensed. The counters cannot be reset. Whistle Stop 5

7 They are called out in the Setup Section on page 10 of this manual. This setting can be changed at any time. The number of coins played per credit and the mercy setting (free tickets per miss) can also be changed. See the Programming Section on page 7. Accessories Figure 3 Game Counters Factory Settings A coin and dollar bill acceptor security bar is available. This bar extends across the coin and dollar bill acceptors to deter thief. Order Whistle Stop Security Package part number AAWS-SP. Whistle Stop is sent from the factory with preset skill level settings for each type of prize zone. Figure 4 Security Package Whistle Stop 6

8 PROGRAMMING SECTION Programmable Dipswitches The number of coins required for each game credit, dollar bill setup, and attract mode are programmable by dipswitches located on the main circuit board. See programming instructions for details. Dipswitches are located on the main circuit board on the inside back wall of the cabinet. Be sure power is off before setting these switches. Figure 5 Location of dipswitches on Main Circuit Board IMPORTANT: Power must be OFF to the game when setting dipswitches. Turn OFF the power strip inside the cabinet. Set the dipswitches to the desired settings, wait 30 seconds and then turn ON power at the power strip. ON GROUP #1 (S1) MAIN BOARD ON GROUP #2 (S2) X Closed or ON position O Open or OFF position * - Indicates the default setting Group #1 (S1) COINS TO PLAY SWITCH # COINS DESCRIPTION O O O O O X O X O O X X X O O X O X X X O X X X 1 2 * S1 ON Dipswitches # 1, # 2 and # 3(S1) are used to set the number of coins or tokens that are required to get one credit on the game. The drawing to the left shows a factory default setting of 2. This setting would represent $0.50 or two tokens. Factory default settings vary with customer requirements. Whistle Stop 7

9 3 PLAY DOLLAR (if equipped with DBA) SWITCH # DBA DESCRIPTION 4 O X Disable * Enable ON S Dipswitch # 4 (S1), when enabled, allows the DBA (Dollar Bill Acceptor) to award one extra game credit when more than the cost of a single game is inserted into the DBA. For example, when the coins per play is set to 2 (default setting) the player is awarded 3 credits for the first dollar inserted. Another extra game credit is not allowed until all game credits are cleared. The drawing to the left shows the default factory setting of disable. UNUSED DIPSWITCHES SWITCH # DESCRIPTION 5 6 O O X X Disable * Enable S1 ON Dipswitches # 5 and # 6 (S1) are not used on this game and should remain in the disabled/off position. ATTRACT MODE SWITCH # ATTRACT DESCRIPTION 7 O X Disable Enable * S1 ON When dipswitch # 7 (S1) is enabled, the game will run in Attract mode for 2.5 minutes every 5.5 minutes. During the Attract mode, the attraction lighting will light up, and the audio will play select tracks from the audio bank embedded in the software. The drawing to the left shows the default factory setting of enable. UNUSED DIPSWITCH SWITCH # DESCRIPTION 8 O X Disable * Enable S1 ON Dipswitch # 8 (S1) is not used on this game and should remain in the disabled/off position. Whistle Stop 8

10 Group #2 (S2) (These switches are not used or are for factory testing only as described below). X Closed or ON position O Open or OFF position * - indicates the default setting SWITCH # O O O O O O X X X X X X Disable* Enable ON S2 UNUSED DIPSWITCH DESCRIPTION DIPSWITCHES # 1 THRU #6 (S2) are UNUSED AND MUST REMAIN IN THE OFF/DISABLED POSITION. SWITCH # 7 O X Disable* Enable ON QC TEST ONLY DIPSWITCH DESCRIPTION DIPSWITCHES #7 (S2) is used for quality control testing only and sets all game parameters to the easy (200 difficulty) S2 mode IMPORTANT: Activation for QC testing can only be made with the dipswitch set to the OFF position when power to the game is turned ON, then moving the dipswitch to the ON position. The QC mode will remain active until the dipswitch is set to OFF or until power to the game is turned OFF. This switch should be placed in the OFF/DISABLED position for normal play. EJECTOR TEST SWITCH # TEST DESCRIPTION 8 O X Disable * Enable S2 ON Dipswitch # 8 (S1) is used to test the operation of the prize ejector assembly. IMPORTANT: Power to the game MUST be turned OFF at the power strip near the main circuit board. Move Dipswitch # 8 to the open/on position then turn the power strip ON. The turntable will rotate, then slow down and stop at one of the prize zones. The prize will be ejected. To return to normal game mode, shut off power, move Dipswitch # 8 to disabled/off position and turn power back on. Whistle Stop 9

11 SETUP SECTION Mercy Ticket Setting (Mode 5) (Ticket Dispensing Games Only) This setting is used to dispense up to 10 tickets for missed plays. The default setting for this mode is zero (0). 1. Locate the setup panel on the inside of the front door. The value (number) of tickets dispensed for each prize zone can be changed from 0 to Locate the setup panel on the inside of the front door. See Figure Push the Setup button once to enter the setup mode and display a zero (0) on the Credits display. 3. Press the Up or Down button until the number 6 appears on the credit display. Figure 6 Setup Panel 2. Push the Setup button once to enter the setup mode and display a zero (0) on the credits display. 3. Press the Up or Down button until the number 5 appears on the credit display. 4. Press the Push to Stop Train button, on the front panel, once. The credits display will change to zero (0), the ticket number value. 5. Press the Up or Down button until the desired number of tickets to be dispensed is displayed. Zero (0) to 10 tickets can be dispensed. 6. Press the Push to Stop Train button again to accept the selected number of tickets and end the Mercy Ticket mode. The Credits display will change to four dashes and after 10 seconds, the game will return to the normal play mode of operation. Ticket Value Setting (Mode 6) (Ticket Dispensing Games Only) 4. Press the Push to Stop Train button once. The turntable will then slow down and stop with zone 1 lined up with the green and yellow arrow on the control panel. The credits display will indicate the ticket value for zone 1. Default setting is zero (0). NOTE: If the zone 1 rack does not line up with the green and yellow arrow, it means that the turntable must be re-aligned before ticket values can be set. Exit mode 6 by pressing the Setup button once. See Zone (Rack) Setup (mode 9) procedures on page Press the Up or Down button until the desired ticket value is displayed. Zero (0) to Press the Push to Stop Train button again to accept the new value and rotate the turntable to the next zone to be changed. Skip zones if desired simply be continuously pressing the Push to Stop Train button. Use the Up and Down button only for the zones to be reset. 7. Once all values are set, press the Setup button to end the Ticket Value mode and rotate the turntable. The Credits display will change to four dashes and after 10 seconds, the game will return to the normal play mode of operation. Whistle Stop 10

12 Figure 7 Prize Rack Zone Layout Prize Ejection Count (Mode 7) The prize ejection counter function records the number of prizes ejected for each prize zone since the game was originally set up at the factory. This includes factory test ejections, any ejections done for testing at the business location, and normal play ejections. For this reason you may want to keep records of all prize ejections on a regular basis. A prize ejection log sheet has been included in this manual. Please make copies of this sheet before recording information. 1. Locate the setup panel on the inside of the front door. See Figure Push the Setup button once to enter the setup mode and display a zero (0) on the Credits display. 3. Press the Up or Down button until the number 7 appears on the credit display. 4. Press the Push to Stop Train button once. The turntable will then slow down and stop with zone 1 lined up with the green and yellow arrow on the control panel. The credits display will indicate the number of ejections for zone 1. NOTE: If the zone 1 rack does not line up with the green and yellow arrow, it means that the turntable must be re-aligned before ejections values can be read accurately. Exit mode 7 by pressing the Setup button once. See realignment procedures on page Press the Push to Stop Train button for each zone to be read. Continue around the track until all zones have been recorded. Whistle Stop 11

13 6. Once all counts are read, press the Setup button to end the Prize Ejection mode and rotate the turntable. The Credits display will change to four dashes and after 10 seconds, the game will return to the normal play mode of operation. NOTE: If the zone 1 rack does not line up with the green and yellow arrow, it means that the turntable must be re-aligned before skill levels can be reset. Exit mode 8 by pressing the Setup button once. See re-alignment procedures on page 13. Skill Level Setting (Mode 8) The skill level for each prize zone can be set from 1 to 255. One (1) is the hardest level and 255 is the easiest level. This setting increases or decreases the length of time the player has to correctly Push to Stop Train to win. It is important to remember that 1 and 255 are extreme settings and may not be practical for game play. More expensive prizes should be harder to win than less expensive prizes. The factory default setting is as follows. Zone Zone Zone 2 6 Zone 11 8 Zone Zone 12 8 Zone 4 8 Zone Zone 5 8 Zone Zone Zone Zone 7 12 Zone 16 6 Zone Zone 17 6 Zone 9 6 See Figure 7 for Zone layout. Change the default settings as follows. 1. Locate the setup panel on the inside of the front door. See figure Push the Setup button once to enter the setup mode and display a zero (0) on the Credits display. Figure 8 Skill Level Setup SKILL LEVEL 5. Press the Up or Down buttons to reset the value for zone 1 if desired. Then press the Push to Stop Train button to rotate the turntable to the next zone to be changed. Skip zones if desired simply be continuously pressing the Push to Stop Train button. Use the Up and Down button only for the zones to be reset. 6. Once all values are set, press the Setup button to end the Ticket Value mode and rotate the turntable. The Credits display will change to four dashes and after 10 seconds, the game will return to the normal play mode of operation. 3. Press the Up or Down button until the number 8 appears on the Credit display. 4. Press the Push to Stop Train button once. The turntable will then slow down and stop with zone 1 lined up with the green and yellow arrow on the control panel. The credits display will indicate the skill level for zone 1. Whistle Stop 12

14 Zone (Rack) Setup (Mode 9) The turntable was aligned at the factory, however, it can become misaligned due to shipping, moving, tilting, machine repair, etc. CENTER PRIZE RACK ON THE THREE ALIGNMENT ARROWS To check alignment, observe the red LED lights as the prize zones pass by. It is easiest to check the small zones. If the lights do not appear to line up with the center of the zone, calibrate as follows. 1. Locate the setup panel on the inside of the front door. See Figure Push the Setup button once to enter the setup mode and display a zero (0) on the Credits display. 3. Press the Up or Down button until the number 9 appears on the Credit display. 4. Press the Push to Stop Train button once. The turntable will then slow down and stop with zone 1 lined up with the green and yellow arrow on the control panel. The credits display will show four dashes. Three rows of red LED lights will light up in front of the green/yellow arrow. Figure 9 Rack Alignment 5. Press the Up button to rotate the turntable clockwise or the Down button to rotate the turntable counter-clockwise. Rotate the turntable until the zone 1 rack is centered on those three LED light rows. 6. Once zone 1 has been aligned, press the Push to Stop Train button. The turntable will rotate and the Credits display will clear. After 10 seconds, the game will return to the normal play mode of operation. 7. Observe the game for at least two complete revolutions and check the center lights for all zones. If the lights do not appear to be aligned properly, repeat the steps above to re-calibrate the turntable. Whistle Stop 13

15 LUBRICATION & PREVENTIVE MAINTENANCE SECTION Maintenance Chart Use the following maintenance schedule as a guide only. Actual maintenance will depend on usage and environmental conditions at the location of the game. Keep a log of all inspections, even if no problem exists, with date and time of inspection, action taken. IMPORTANT: Do not use cleaning solvents on game graphics. Use only a mild soap solution and dry with a clean lint free cloth. IMPORTANT: The game should be shut OFF for cleaning and maintenance. Check prizes and fill as necessary. Inspect game for physical damage. Repair as necessary. Test to insure game is working properly. Clean outside surfaces and glass Fill ticket tray (Ticket dispenser games only) Empty coin tray/dollar bill acceptor if necessary. Clean/vacuum the prize dispensing chute. Open game and clean prize racks and inner surfaces as necessary. Clean dollar bill acceptor with bill reader cleaning card (DBA models only) Inspect all lamps, chase lights, track lights and LED displays. Replace or repair as necessary. Test the prize-dispensing sensor. Inspect stepper motor belt and insure it is tight. Check all hardware for tightness. Check operation of the prize ejection assembly. Check alignment of the prize racks. Check turntable drive chain tension Grease top and bottom turntable bearings* Oil turntable drive chain** * When greasing these bearings, use a lithiumbased grease. Bearings are sealed so only a small amount is required. Always use a hand grease gun and avoid excessive pressure that would break the seals. Wipe off excess grease. Daily Weekly 3 Month Yearly X X X X X X X X X X X ** Use a thin oil that will penetrate the links of the chain. Do not over lubricate. Wipe excess oil from the chain and gears before putting the game back into service. X X X X X X X Whistle Stop 14

16 TROUBLESHOOTING & DIAGNOSTICS SECTION Troubleshooting Strategy Use common sense and a systematic method of troubleshooting to determine the exact problem, probable cause and remedy. Use the process of elimination to find the faulty component. Always check for the simple and obvious causes first such as unplugged, loose or broken wires and bad sensors, bent, pinched, stuck or jammed components. Troubleshooting Chart Problem Probable Cause Remedy No power to the game. a. Unplugged. b. Blown fuse c. Game circuit breaker tripped. d. Building circuit breaker tripped. d. Check building circuits. No Audio Prize ejector does not dispense prizes. Prize rack turntable does not stay aligned. a. Volume too low. b. Loose wire. c. Main circuit board malfunction. a. Plumb Bob shorted. b. Ejector arm malfunction. c. Ejector motor malfunction. d. Prize rack out of alignment. a. Turntable obstruction or interference with travel. b. Drive motor chain broke too loose. c. One or both chain sprockets loose. d. Stepper motor not operating properly. a. Check wall outlet. b. Check transformer fuse (220 volt applications only). c. Reset power strip breaker switch on inside rear wall. a. Increase the volume at the volume control at the inside of the front door panel. b. Check audio cable connections to speaker, volume control and main circuit board. c. Replace main board with a spare Gen 5 board if possible to isolate the problem to the main circuit board. a. Check and replace pinched or broken wiring from plumb bob to main circuit board. b. Cycle ejector arm and repair if necessary. Check for obstruction. c. Check operation of the motor and replace if necessary. Check wiring and connections. d. Re-calibrate prize rack. a. Check for prize stuck under turntable or ejector arm malfunction. b. Check tension of stepper motor chain. Replace or tighten as necessary. c. Tighten sprockets on motor shaft and turntable shaft. d. See next item. Repair or replace stepper motor. Whistle Stop 15

17 Troubleshooting Chart Problem Probable Cause Remedy a. Bad connection to diode circuit board. b. Malfunctioning diode. c. Pinched, broken or disconnected wiring. d. Main circuit board malfunction. Stepper motor not operating properly. Attraction lighting not working properly. Dollar Bill Acceptor not functioning. a. Cable problem. b. Poor jumper board connections. c. Main circuit board malfunction. b. Dirt or debris in acceptor slot. c. Other problems. a. Check and repair. b. Visually check and replace diode as necessary. c. Check wiring from main circuit board to stepper motor. Repair or replace wiring harness. d. Replace main board with a spare Gen 5 board if possible to isolate the problem to the main circuit board. a. Check and repair black telephone cable to main board. b. Check and repair jumper board connections. c. Replace main board with a spare Gen 5 board if possible to isolate the problem to the main circuit board. a. Clean with bill reader cleaning card included with game. b. Refer to troubleshooting section of dollar bill acceptor manual included with this game or the diagnostics label of the back of the unit. Error Code - Err 0 Ejector limit switch problem. a. Switch must make contact with the ejector arm at the back of its travel. If not, repair or adjust. b. Check and repair wire harness and connectors from limit switch to main circuit board. c. Replace limit switch. Error Code Err 1 Memory chip faulty. a. Replace memory chip. b. Replace main board with a spare Gen 5 board if possible to isolate the problem to the main circuit board. Error Code Err 2 Stepper motor malfunction. a. Check rotation of the motor shaft. If not operating correctly, replace motor. If operating correctly, change the optical sensor. For games with ticket dispenser only. Error Code LO Tickets are low. Add tickets to ticket tray. Whistle Stop 16

18 Troubleshooting Chart Problem Probable Cause Remedy Tickets do not dispense. b. Faulty cable to dispenser. c. Faulty cable to main circuit board. d. Main circuit board malfunction. b. Check for pinched, broken or disconnected cable. Replace as necessary. c. Check for pinched, broken or disconnected cable to main circuit board. d. Replace main board with a spare Gen 5 board if possible to isolate the problem to the main circuit Wrong number of tickets dispensed. b. Dirty opto-sensor on ticket dispenser. c. Faulty ticket dispenser. d. Main circuit board malfunction. board. a. Clean with compressed air and if necessary wipe with isopropyl alcohol on a cotton swab. b. Replace with like dispenser from another game to isolate the problem to the dispenser. c. Replace main board with a spare Gen 5 board if possible to isolate the problem to the main circuit board. Whistle Stop 17

19 Diagnose Power Supply Use the following procedure to check the power supply for Gen 5 games. Check the small green LED light on the power supply circuit board. If the light is out there is a short somewhere. If the light dims, there is an overload in one of the circuits such as a bad motor. 12 V OUT Turn power OFF. Disconnect all 12 volt output wires only. Turn power ON. LIGHT Green LED Light comes ON. Green LED Light remains OFF. Figure 10 Power Supply Replace Power Supply. Turn power OFF. Unplug all outputs from Main Circuit Board. Reconnect the 12 volt output wires to the Power Supply. Turn power ON. Green LED Light comes ON. Green LED Light remains OFF. Short in Main Board - Replace. Turn power OFF. Reconnect the outputs at the Main Circuit Board one at a time. Wait 3 minutes between tests to turn power ON. Green LED Light comes ON. Green LED Light remains OFF. Green LED Light dims. That cable is OK. That cable or related component is shorted out. See Jumper Cable Pin-Outs to see which component might be at fault. A related component such as a motor is causing an overload. See Jumper Cable Pin-Outs beginning on page 23 to see which component might be at fault. Whistle Stop 18

20 SERVICE AND REPAIR SECTION CAUTION: Static electricity could harm circuit boards and processor chips. Always ground yourself by cable or by touching metal surfaces prior to removing or servicing electronic equipment in this game. Avoid working on carpeted surfaces. CAUTION: Electrical Shock Hazard. Do not perform maintenance or repair of this equipment with power ON. Unplug the unit from the wall outlet or shut off power at the power strip inside the cabinet. Removing Complete Assembly 1. Unplug the dispenser motor wiring harness at the connector near the assembly. 2. Remove the four bolts, lock washers, and plain washers from the mounting flange and lower the ejector assembly out of the hole in the playfield base. Be careful not to damage the ejector arm on the top of the unit. Remove the wires to the limit switch. Limit Switch Replacement 1. Remove the two machine screws securing the switch to the ejector assembly. Ejector Assembly Repairs The ejector assembly gearmotor and limit switch are easily replaced by lowering the ejector assembly out of the bottom of the playfield base. Use the following method to remove the ejector assembly from the game. NO WIRE ON THIS TERMINAL LIMIT SWITCH Figure 12 Ejector Limit Switch 3. Install the new switch. REMOVE FASTENERS TO LOWER UNIT OUT OF HOLE Figure 11 Ejector Assembly Removal 4. Re-attach the two wires to the limit switch. (NOTE: one terminal is empty. Either wire can go to either of the other two terminals). Ejector Gearmotor Replacement 1. Remove the setscrew at the end of the ejector connector cam and pull the cam off the gearmotor shaft. Whistle Stop 19

21 FOUR MOUNTING BOLTS & NUTS SETSCREW CONNECTOR CAM SLOTTED HOLES Figure 13 Motor and Gearbox Removal 2. Remove the four lock nuts and bolts that secure the gearmotor assembly to the ejector frame. 3. Install the new gearmotor with the four machine bolts and lock nuts. The hole in the connector cam is flat on one side so the gearbox shaft may have to be rotated slightly to allow the cam to be installed on the shaft. Secure with the setscrew. Installing Assembly 1. To re-install the ejector assembly into the game, raise the assembly back into position in the hole in the playfield. Take care not to damage the limit switch or ejector rod. Secure with the four bolts, lock washers and plain washers. 2. Reconnect the ejector gearmotor wiring harness. Turntable Motor Replacement The turntable step motor is quite durable and generally never should need replacement. Review other causes of problems prior to replacement of this motor. The motor is accessible under the playfield by opening the front door panel. PLUG Figure 14 Stepper Motor Mounting. 1. Disconnect the motor wiring harness at the connector on the small circuit board just above the main circuit board. 2. Loosen the motor mounting bolts in the slotted holes where the motor frame mounts to the underside of the playfield. 3. Loosen and remove the chain. 4. Remove the mounting bolts, lock washers and plain washers and entire motor / frame assembly from the unit. 5. Remove the four nuts and star lock washers that secure the motor to the mounting frame. 6. Install a new motor and secure with the four star lock washers and nuts. 7. Reposition the motor / frame assembly under the playfield and install but not tighten the four bolts, lock washers and plain washers. 8. Install and tighten the chain by moving the motor mounting frame in the slotted holes, then tighten the four mounting bolts. Whistle Stop 20

22 9. Plug in the wire harness connector at the circuit board. The stepper motor replacement will require the prize racks to be re-aligned. See Setup Section on page 10. Turntable Chain Adjustment and Replacement. The chain should always be snug and ride smoothly on the drive and idler gears without any jerking. single mounting board under the turntable. The board can be removed for testing or replacement of the circuit boards by following these steps. 1. Loosen the large knob on the back of the Train Signal and pull the upper part of the signal off its base. 2. Unplug the white phone cord from the main circuit board and remove the cord from the clips mounted to the underside of the playfield. LOOSEN Figure 15 Drive Chain Adjustment To tighten or remove the chain; 1. Loosen the stepper motor mounting bolts and slide the motor in the slotted holes. When installing the chain, the chain must be snug with no slack but not over-tight which may damage the motor. 2. Re-tighten the motor mounting bolts. A new master link may be ordered from Bay- Tek to fix a broken chain. Install the master link to connect the ends of the chain then reinstall the chain in the game. Figure 16 Removing the Train Signal LOOSEN KNOB 2. Remove the four screws holding the left interior acrylic panel and three screws holding the right interior acrylic panel in place. See next two figures. IMPORTANT: Be careful not to scratch the acrylic or damage the circuit boards under them. Circuit boards Arrow, Arc and Credit Displays The track lighting ( Arrow and Arc ) and the Credit display circuit boards are attached to a Whistle Stop 21

23 6. Re-align the racks as explained under Zone (Rack) Setup and test after re-assembly to insure proper operation. Main Circuit Boards Replacing the main Gen 5 circuit board. 1. Carefully unplug the various connectors, black chase lighting cables and the white display cable. Figure 17 Left Acrylic Removal 2. Remove the four Phillips head screws at the four corners of the board and remove the board from the mounting panel. 3. Before installing the new board, check to be sure that the dipswitches are set in the same position as the old board. NOTE: If swapping the circuit board with a spare Gen 5 board for testing purposes, be sure to also swap out the software chip. Use extreme care to prevent static electricity and to prevent bending socket pins. 4. Install the board and reconnect the wiring connectors, black chase lighting cables and the white display cable. SOFTWARE CHIP Figure 18 Right Acrylic Removal 3. Remove the five wood screws holding the black board and lift the board from the game. Lay the black board assembly on a clean work surface to remove the faulty circuit board. 4. Carefully unplug and remove the faulty circuit board and replace with a new one. Be careful not to over-tighten the screws securing the circuit boards. Figure 19 Main Circuit Board Replacement 5. Re-test the game. 5. Re-install the circuit board and acrylics in reverse order being careful not to overtighten acrylic fasteners. Whistle Stop 22

24 ELECTRICAL DRAWINGS SECTIONS J2 J3 J4 J1 J5 View Direction All connector drawings are as Viewed from the pin out position. DISPLAY & CHASE Figure 20 Gen 5 Main Board Reference 12 Volt Jumper Cable (J1) Connector PIN OUT Volume Cable (J2) Connector PIN OUT IN FROM POWER SUPPLY, TO MAIN BOARD 12 VOLT INPUT WHITE 12 VOLT GROUND GREEN 12 VOLT INPUT WHITE AUDIO OUTPUT RED AUDIO GROUND BLACK 12 VOLT GROUND GREEN Whistle Stop 23

25 Jumper (J3) Connector Setup Switches and Tilt Cable PIN - OUT TILT SENSOR GROUND GREEN TILT SENSOR INPUT YELLOW UP BUTTON INPUT WHITE/BLACK DOWN BUTTON INPUT BLUE SET-UP BUTTON INPUT ORANGE/RED SET-UP SWITCHES GROUND BLACK/RED EJECTION MOTOR HOME INPUT WHITE EJECTION MOTOR HOME GROUND BLACK Whistle Stop 24

26 Jumper (J4) Connector Control Box Cable PIN OUT GAME COUNTER OUTPUT BLUE/BLACK STOP LIGHT OUTPUT GREEN/WHITE COUNTER 12 VOLT WHITE/RED STOP LIGHT 12 VOLT RED/GREEN TICKET COUNTER OUTPUT BLUE/WHITE BILL ACCEPTOR OUTPUT GREEN/BLACK BILL ACCEPTOR INPUT ORANGE BILL ACCEPTOR GROUND BLUE/RED WHEEL SENSOR INPUT WHITE STOP SWITCH INPUT ORANGE/BLACK COIN DOOR GROUND BLACK BILL ACCEPTOR 5 VOLTS RED/WHITE TABLE SENSOR RED STOP SWITCH GROUND BLACK/WHITE WHEEL SENSOR BLACK RIGHT COIN DOOR INPUT WHITE LEFT COIN DOOR INPUT GREEN COIN DOOR 12 VOLTS RED TICKET DISPENSOR GROUND BLACK TICKET NOTCH BLUE TICKET DISPENSOR ENABLE WHITE TICKET DISPENSER 12 VOLTS RED Whistle Stop 25

27 Jumper (J5) Connector Ejector and Diode Board Cable PIN - OUT STEPPER MOTOR 12 VOLT OUTPUT WHITE STEPPER MOTOR PHASE B BLUE STEPPER MOTOR PHASE A GREEN STEPPER MOTOR PHASE B RED STEPPER MOTOR PHASE A BLACK STEPPER MOTOR + 12 VOLT OUTPUT ORANGE EJECTOR MOTOR FORWARD GOUND BLACK EJECTOR MOTOR FORWARD 12 VOLT OUPUT RED EJECTOR MOTOR REVERSE GROUND ORANGE EJECTOR MOTOR REVERSE +12 VOLT OUTPUT GREEN Whistle Stop 26

28 Gen 5 Main Board Schematics Whistle Stop 27

29 Communications Serial EEprom Whistle Stop 28

30 Input Section A Configuration Switches Whistle Stop 29

31 Input Section B Inputs RE, RC Whistle Stop 30

32 Output Section A Chase Lights, Q13 - Q16 Whistle Stop 31

33 Output Section B Q17 Q24 Whistle Stop 32

34 Output Section C Q5 Q12 Whistle Stop 33

35 Power Section Whistle Stop 34

36 Processor Section Input RD Whistle Stop 35

37 SPARE PARTS WHISTLE STOP Always use genuine Bay-Tek replacement parts. For 24 hour pricing and ordering visit our web site at Description Part # Bill Acceptor... A5AC9091 Cleaning Card For Acceptor... A5CC9000 If no bill acceptor, use this plate...a5pl9097 Push to Stop Train button...a5pb9000 Red Push Button...A5PB6900 Black Push Button... A5PB6905 Speaker...A5SP1050 Caster Wheel... A5CA1001 Caster Wheel with Brake... A4CA1002 Railroad Crossing Sign...A5SI1000 Crossing Sign Red Lamp... A5LA1001 Tilt Plumb Bob... A5TI1001 Ejector Motor Assembly... AAEM6900 Stepper Motor... AAMO6901 Chain, Link... A5CH1000 Connector, Link Chain... A5LI1002 Sensor, Reflective Optical... A5E0001 Front Door Lock Handle... A5HA1001 Front Door Lock Plug...A5LK1001 GLASS Side Tempered Glass... A5TG1001 Front Tempered Glass... A5TG1000 FACEPLATES Faceplate Instruction Plate... A5FP1050 Faceplate Left Side... A5FP1051 Faceplate Right Side... A5FP1052 DECALS Sides, Bottom... A5DC1008 Front, Front-glass... A5DC1005 Front, Bottom-glass... A5DC1006 Sides, Top... A5DC1007 Safety Warning... A5DC1011 Prize Door... A5DC1010 Train Station... A5DC1009 Whistle Stop 36

38 PRIZE WHEEL Capsule Holder... A5RA1001 Jar Holder... A5RA1002 Box Holder... A5RA1005 CD Holder... A5RA1004 Watch Holder... A5RA1003 LIGHTING Chase Lighting 30 inch... AACL6900 Chase Lighting 50 inch... AACL6906 Chase Lighting 50-1/2 inch... AACL6905 Halogen Lamp Assembly...AALA6900 Lamp, Halogen 12 volt, 20 watt... A5LA9050 Fluorescent Light Assembly...AAFL6901 Lamp, Fluorescent... A5FL1001 ELECTRONIC BOARDS Power Supply...A5PS1001 ARC Display Board... AABD1051 Arrow Display Board... AABD1052 Credit Display Board... AABD1053 Chase Light Connection Board... AABD1055 Diode Board... AABD1054 Main Board... AAMB5A Audio EPROM... AAEP-WS Microcontroller... AAMC-WS Whistle Stop Security Package... AAWS-SP Whistle Stop 37

39 WARRANTY INFORMATION Bay-Tek, Inc. warrants to the original purchaser that the game will be free of defects in workmanship and materials for a period of six months from the date of installation. Bay-Tek, Inc. will, without charge, repair or replace at its option defective product or component parts upon notification to the factory service department. Serial number identification will be required for warranty consideration. Warranty replacement part(s) will be shipped immediately via ground service, along with a Return Material Authorization (RMA) number for the return of the defective part(s). Defective parts must be shipped back to Bay-Tek, Inc. unless otherwise instructed. This warranty does not apply in the event of any misuse or abuse of the product, or as a result of any unauthorized repairs or alterations. This warranty does not apply if the serial number is altered, defaced or removed from its original position. Should your game need servicing, determine the serial number from the logic unit of the game, and call or service@bay-tek.com REPAIR OF NON-WARRANTY UNITS Should your game need servicing, determine the serial number from the logic, and call or service@bay-tek.com. An estimate of repair charges will be quoted to you for approval. Proceed in one of the two following ways: Request immediate shipment of advanced replacement parts. Send in the defective unit for repair and return. If advanced replacement(s) are requested, you will receive with your parts an RMA number for the return of the faulty part(s). You must return defective parts within 14 days to avoid additional charges. Should you choose to return parts for repair, include the following: Name, address and phone number including area code. Game serial number information. A purchase order number, work order number or signed authorization to perform service. Repair and Return parts will be shipped back using the same mode of transportation under which they were received. Repairs are warranted for a period of thirty (30) days from the date installed into service. For future reference; Date of Installation Serial number Installed by Whistle Stop 38

40 LOG SHEET FOR PRIZE EJECTION COUNT Game Number Game Serial Number Period Beginning: Ending Zone Number Product Value Difficulty Beginning Counter Ending Counter Cost of Goods Sold Total Cost of Goods Sold Total Cash Earned = Payout Percentage Whistle Stop 39

41 LOG SHEET FOR PRIZE EJECTION COUNT Game Number Game Serial Number Period Beginning: Ending Zone Number Product Value Difficulty Beginning Counter Ending Counter Cost of Goods Sold Total Cost of Goods Sold Total Cash Earned = Payout Percentage Whistle Stop 40

42 LOG SHEET FOR PRIZE EJECTION COUNT Game Number Game Serial Number Period Beginning: Ending Zone Number Product Value Difficulty Beginning Counter Ending Counter Cost of Goods Sold Total Cost of Goods Sold Total Cash Earned = Payout Percentage Whistle Stop 41

43 LOG SHEET FOR PRIZE EJECTION COUNT Game Number Game Serial Number Period Beginning: Ending Zone Number Product Value Difficulty Beginning Counter Ending Counter Cost of Goods Sold Total Cost of Goods Sold Total Cash Earned = Payout Percentage Whistle Stop 42

44 Bay-Tek s FILL KIT INFORMATION Contact this quality supplier for game prize refill kits. Noel Industries Chris Noel PO Box 727 Ozona, FL Phone: Fax: cno@prodigy.net Kits available for: Red Zone Whistle Stop Winners Edge Whistle Stop 43

45 NOTES Whistle Stop 44

46 NOTES Whistle Stop 45