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DataCard CP60 Service Manual

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Datacard
CP60™ and CP60 Plus
®
Card Printers

Service Manual

May 2007
Part No. 539358-002, Rev C

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Summary of Contents for DataCard CP60

  • Page 1: Service Manual

    Datacard CP60™ and CP60 Plus ® Card Printers Service Manual May 2007 Part No. 539358-002, Rev C...
  • Page 2 Liability Statement This product has been built to the high standards of Datacard Group. Please do not attempt to operate or repair this equipment without adequate training. Any use, operation, or repair in contravention of this document is at your own risk.

  • Page 3: Table Of Contents

    Contents Chapter 1: Introduction __________________________________________________________ 1-1 Intended Audience_________________________________________________________________ 1-2 Avoiding Electrostatic Discharge ____________________________________________________ 1-2 Symbol Conventions ________________________________________________________________ 1-3 Chapter 2: Theory of Operation___________________________________________________ 2-1 Printer Components ________________________________________________________________ 2-2 Functional Block Diagram _____________________________________________________ 2-2 Sensors _______________________________________________________________________ 2-3 Motors _______________________________________________________________________ 2-5 Miscellaneous ________________________________________________________________ 2-6 LCD Menu Diagram ___________________________________________________________ 2-7 Sequence of Operation_____________________________________________________________ 2-8 Open Card Printer Differences______________________________________________________2-10...
  • Page 4 General Troubleshooting Procedures ________________________________________________ 4-2 Non-Clearing Repetitive Messages _____________________________________________ 4-2 Troubleshooting Sensors _______________________________________________________ 4-3 Troubleshooting Motors________________________________________________________ 4-4 Testing General DC Motors ______________________________________________ 4-4 Testing the Ribbon and Pick Motors_______________________________________ 4-5 Testing the Cam Motor __________________________________________________ 4-5 Testing the Printhead Fan ________________________________________________ 4-6 Testing Transport and Duplex Motors______________________________________ 4-6 Troubleshooting Other Devices ________________________________________________ 4-6 Testing the Smart Card Solenoid__________________________________________ 4-6...
  • Page 5 YMC, K, T, and F Power and Base Power _________________________________5-14 Duplex Infeed Offset ___________________________________________________5-14 Duplex Home Offset ____________________________________________________5-15 Duplex Print Return Offset _______________________________________________5-15 Duplex Handoff Offset __________________________________________________5-15 Smart Card Registration Offset __________________________________________5-15 Image Clipping Leading and Trailing ____________________________________5-16 Setting Printer Options ________________________________________________________5-17 Viewing Printer Status ________________________________________________________5-18 Testing Motors _______________________________________________________________5-19 Testing Motor Functions ______________________________________________________5-20...
  • Page 6 Cam Sensor _________________________________________________________________6-21 Card Hopper Empty Sensor ___________________________________________________6-22 Motors ____________________________________________________________________________6-23 Transport Motor ______________________________________________________________6-23 Pick Motor___________________________________________________________________6-24 Cam Motor__________________________________________________________________6-26 Ribbon Motor and Gear ______________________________________________________6-27 Transport Assembly ________________________________________________________________6-29 Main Control Board __________________________________________________________6-32 Transport Timing Belt _________________________________________________________6-36 Belt Tensioner Pulley and Tension Spring _______________________________________6-37 Drive and Idler Pulleys ________________________________________________________6-38 Cleaning Rocker Assembly ___________________________________________________6-39 Front Rocker Assembly _______________________________________________________6-40...
  • Page 7 Revision Log Datacard CP60 and CP60 Plus Card Printers Service Manual Revision Date Description of Changes March 2006 First release of this document. June 2006 Update part numbers for RoHS compliance. May 2007 Update for release of CP60 Plus printers.
  • Page 8 Safety Issues All Datacard products are built to strict safety and reliability specifications in accordance with UL60950-1 and CUL requirements; therefore, safety issues pertaining to operation and repair of Datacard equipment are primarily environmental and human interface. The following basic safety tips are given to ensure safe installation, operation, and maintenance of Datacard equipment and are not to be considered as comprehensive on all matters of safety.

  • Page 9: Chapter 1: Introduction

    Chapter 1: Introduction This chapter provides an introduction to the Datacard® CP60 and CP60 Plus card printers. Intended Audience______________________________________________________________ 1-2 Avoiding Electrostatic Discharge _________________________________________________ 1-2 Symbol Conventions _____________________________________________________________ 1-3 CP60 and CP60 Plus Service Manual...

  • Page 10: Intended Audience

    Intended Audience This manual is intended for use by authorized representatives of Datacard who are responsible for the maintenance, service, and repair of the CP60 and CP60 Plus card printers. The service representatives must complete an authorized Datacard service training course prior to servicing the printer.

  • Page 11: Symbol Conventions

    This symbol indicates a reminder message or other additional information for the technician. Graphic callouts with a colored background provide incidental information about the graphic itself. Graphic leaders with a colored background indicate a direction of movement or similar information. CP60 and CP60 Plus Service Manual...
  • Page 12 Introduction...

  • Page 13: Chapter 2: Theory Of Operation

    Chapter 2: Theory of Operation This chapter provides the theory of operation for the CP60 and CP60 Plus card printers. Printer Components______________________________________________________________ 2-2 Functional Block Diagram _____________________________________________________________ 2-2 Sensors _______________________________________________________________________________ 2-3 Motors _______________________________________________________________________________ 2-5 Miscellaneous ________________________________________________________________________ 2-6 LCD Menu Diagram___________________________________________________________________ 2-7...

  • Page 14: Printer Components

    Printer Components Functional Block Diagram Theory of Operation...

  • Page 15: Sensors

    Sensors All of the optical sensors in the CP60 and CP60 Plus printers are of the open collector type, and are configured to be active-low with a pull-up resistor on the output. When the sensor is not active (or not connected at all) the control board sees a high voltage (5V) at the Signal input.
  • Page 16 Name Function Magnetic Stripe This is a reflective sensor that locates the leading edge of the card for Registration magnetic stripe encoding. When no card is present, the sensor beam reflects off a plate on the magnetic stripe rocker. When a card passes between the sensor and the reflector, the beam is broken (not reflected).

  • Page 17: Motors

    Motors The CP60 and CP60 Plus printers have up to five motors depending on the configuration. The three DC motors are all similar, with an integral reduction geartrain and 24-volt operation. The speed of the motors is controlled by pulse width modulation.

  • Page 18: Miscellaneous

    Miscellaneous Name Function Smart Card Solenoid The smart card solenoid retracts the smart card rocker downward so the contacts touch the card. When relaxed, a return spring lifts the rocker and contacts away from the card. Duplex Clutch The duplex clutch controls whether the duplex motor operates the drive rollers or rotates the whole flipper assembly.

  • Page 19: Lcd Menu Diagram

    LCD Menu Diagram CP60 and CP60 Plus Service Manual...

  • Page 20: Sequence Of Operation

    Sequence of Operation Power-on Initialization When the printer is plugged in, it begins its initialization routine. (There is no On/Off switch.) As the main control board initializes itself, the status light on the front of the printer will be steady amber. After the control board is initialized, the status indicator will cycle through Red, Amber, and Green.
  • Page 21 The card is re-registered by the input sensor and printing is completed on the back of the card in the same fashion as the front. After printing, the card is moved to the front of the printer and placed into the output hopper. CP60 and CP60 Plus Service Manual...

  • Page 22: Open Card Printer Differences

    Open Card Printer Differences There are several Datacard printers that support the Open Card format, but not all printers support the same functions. The table below lists the differences by printer model. Printer Model CP60 Item SE48 CP60 Plus @S character spacing...

  • Page 23: Graphics Printing

    Graphics Printing The information presented in the following section is not required for servicing the CP60 and CP60 Plus printers but is presented to augment the customer engineer’s training and knowledge base. The printhead is made up of 672 microscopic heating elements. Each of these thermal elements is made from a printed circuit conductor etched into the printhead substrate (metallic-like foil).

  • Page 24: Printhead Settings

    Printhead Settings A printed card is made up of 1013 discrete vertical (short edge of the card) columns printed across the length of the card. As each column is printed, the printhead circuitry activates the necessary pixels to transfer pigment from the ribbon to the card.
  • Page 25 The strobe setting value is a baseline number for a look-up table that the printer calculates for each printed column. The gray test card is used to detect strobe misadjustment. This test card is available only to the Advanced User in Diagnostics. CP60 and CP60 Plus Service Manual 2-13...

  • Page 26: Magnetic Cards

    Magnetic Cards The information presented in the following section is not required for servicing the CP60 and CP60 Plus printers but is presented to augment the customer engineer’s training and knowledge base. Magnetic Data Principles This discussion is intended to be a primer for those who are not completely familiar with the principles of writing data to and reading data from a magnetic stripe.

  • Page 27: Magnetic Media

    Ampere's Law, it is common practice in discussion to refer to the energy transfer as "induced current." This is appropriate as long as the conductor forms a closed circuit and Ohm's Law can be applied. CP60 and CP60 Plus Service Manual 2-15...
  • Page 28 Writing Data To write data to the magnetic material on a card, it is necessary to create a magnetic field near the stripe. This aligns all of the magnetic particles nearby in the same orientation (polarity). The Magnetic Write Head contains a small coil of wire wrapped around a semicircular iron core .
  • Page 29 For this reason, magnetic data is comprised of Transition Points where the polarity of the magnetism reverses, which results in North-to-North or South-to- South polarity. CP60 and CP60 Plus Service Manual 2-17...
  • Page 30 Magnetic Data The method for recording information on a magnetic stripe is called two- frequency, coherent phase encoding (also known as F/2F). Although the name is complex, the concept is simple: two signals are merged together and written as a single signal.

  • Page 31: Encoding Format

    The record length is the total number of binary words (characters) that can be stored on a magnetic track. Bit density, word length, and the physical length of the stripe determine the maximum record length. CP60 and CP60 Plus Service Manual 2-19...
  • Page 32 Parity Check A parity check is a method of determining if an error has occurred. This is accomplished by adding one extra bit to the end of a binary character code. The purpose of the parity bit is to make the sum of data bits in a binary word either even or odd.
  • Page 33 LRC word in the same manner as it would for any other character.) Parity Binary Char Code Name Char Start Sentinel Sample Data Sample Data Field Separator Sample Data Sample Data End Sentinel Pre-LRC Sum Post-LRC Sum CP60 and CP60 Plus Service Manual 2-21...

  • Page 34: Magnetic Stripe Primary Data Standards

    Magnetic Stripe Primary Data Standards The magnetic stripe on a card can store binary data in any form you wish; however, to maintain consistency, national and international standards are followed. A primary data standard is one that specifies how information is stored on a card.

  • Page 35: Multiple Record Format (Sds)

    Type II: A JIS Type II card is a single-track card, and does not have an ISO/IEC equivalent. In the past, this type of card has frequently been referred to as J-Stripe, J-Track, NTT, or simply JIS Type II. (JIS Type II is now preferred.) CP60 and CP60 Plus Service Manual 2-23...

  • Page 36: Magnetic Media Locations

    Magnetic Media Locations The physical location and size of the magnetic stripe on a card follows the specifications outlined in the two drawings below. The first graphic is for a two or three track card (ISO/IEC and JIS Type I). (Note that under the ISO and JIS standards, even if only one of the three tracks is used, the minimum track size follows this specification.) 2-24...

  • Page 37: Data Track Locations

    The positions where data can be recorded on a 3-track stripe are described in the graphic below. This applies to all three of the aforementioned standards, but does not apply to a JIS Type II card. CP60 and CP60 Plus Service Manual 2-25...

  • Page 38: Summary Of Specifications

    Summary of Specifications The preceding sections described where magnetic data can reside on a card. This section describes the general format of that magnetic data. The following table summarizes the data specifications for the primary standards. ISO/IEC 7811 JIS Type II JIS Type I Parameter Track 1...

  • Page 39: Character Encoding

    These 14 characters ! " & ' * + , : ; < = > @ _ are reserved for hardware control and cannot be part of the data content. (These may or may not be used by different device manufacturers.) Additional reserved characters. S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator CP60 and CP60 Plus Service Manual 2-27...
  • Page 40 5-bit Numeric Character Set as Defined by ISO/IEC 7811 Binary Note Char Parity < > Code Description These characters are used to control the hardware and cannot be part of the data content. (These may or may not be used by different device manufacturers.) S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator 2-28...

  • Page 41: Smart Card Technology

    Smart Card Technology The information presented in the following section is not required for servicing the CP60 and CP60 Plus printers but is presented to augment the customer engineer’s training and knowledge base. The underlying concept of smart cards is fairly simple: A chip is embedded inside a plastic card—the chip may be microprocessor based, or a simple...

  • Page 42: Contact Smart Cards

    HID Corporation and is shown here for educational purposes. The printed image on the card is an artist’s rendering. Contact Smart Cards A contact smart card needs to connect to an external interface to provide the processor with power and set up serial communication. The eight terminal contacts are described in the table below.
  • Page 43 With communication parameters known, the interface can begin to communicate with the card. Serial communication across the I/O line commences. If necessary, the voltage on Vpp is altered, and information can be written to the card. CP60 and CP60 Plus Service Manual 2-31...

  • Page 44: Non-Contact Smart Cards

    Non-Contact Smart Cards Types of Cards Whenever a new technology is developed by multiple manufactures, there tends to be multiple protocols for the device. For example, during the 1980’s there were as many personal computer types as there were manufacturers. In time, the number of computer types dwindled as designs were standardized.
  • Page 45 The following diagrams show a couple of the basic modulation schemes as well as the variants used by digital signals. The AM and FM modulation diagrams are shown with analog data signals, but phase-shift modulation is easiest to show with a digital signal. CP60 and CP60 Plus Service Manual 2-33...
  • Page 46 Signal Modulation Summary Diagram Amplitude Modulation: The magnitude (height) of the carrier signal is varied according to the height of the data signal. This is what is used in AM radio. Note: The blue data signal is shown here for clarity. It is not actually present in the actual modulated signal.
  • Page 47 ASK10 provides more power to the card because the modulated signal remains within 10% of the maximum amplitude. The tradeoff is that the difference between high and low amplitudes is minimal. This can lead to slightly more data transmission errors. CP60 and CP60 Plus Service Manual 2-35...
  • Page 48 Card to Reader Communication The communication method back to the reader is elegantly simple, but a little more complicated to understand. It is a passive communication because the card doesn’t really send a signal back to the reader—it modifies the signal emanating from the reader.
  • Page 49 (inverted). The subcarrier is permitted to invert only at its own transition points (which is why the frequencies are even multiples of each other). CP60 and CP60 Plus Service Manual 2-37...
  • Page 50 2-38 Theory of Operation...

  • Page 51: Chapter 3: Routine Maintenance

    Chapter 3: Routine Maintenance This chapter provides routine maintenance procedures for the CP60 and CP60 Plus card printers. Required Tools and Supplies______________________________________________________ 3-2 Routine Maintenance Procedure _________________________________________________ 3-3 Clean the Interior of the Printer ________________________________________________________ 3-3 Mechanical Inspection________________________________________________________________ 3-5 Run the Cleaning Card _______________________________________________________________ 3-8...

  • Page 52: Required Tools And Supplies

    Required Tools and Supplies The following tools and supplies are needed for routine maintenance procedures. Description Part Number Compressed air (canned) TUL001-018 General purpose, non-abrasive cleaner Lint-free cloth TUL001-020 Isopropanol cleaning pen 557492-001 Isopropanol cleaning card 552141-001 Cleaning sleeve 549288-002 Molykote DX grease 807421-001 Cleaners used on the printer’s exterior should not contain any abrasives, oils,...

  • Page 53: Routine Maintenance Procedure

    If the grease on the platen roller shaft has accumulated dirt and debris, wipe off the grease with a dry cloth, and re-grease the surfaces with Molykote DX grease. CP60 and CP60 Plus Service Manual...
  • Page 54 Use a cloth dampened with water to clean the sensor reflector on the printhead cartridge. Using an isopropanol cleaning pen, clean the thermal printhead by rubbing the isopropanol tip over the printing portion of the printhead. Sp35707s Routine Maintenance...

  • Page 55: Mechanical Inspection

    Inspect the drive pulleys for wear and broken teeth. • Inspect the platen roller gear and pulley for wear and broken teeth. Inspect the ribbon drive gear for wear and broken teeth. Make sure it is securely seated on the motor shaft. CP60 and CP60 Plus Service Manual...
  • Page 56 Inspect the ribbon cartridge. • Inspect the spindle gear for wear and missing teeth. If the cassette has a plastic encoder wheel, inspect it for scratches and • missing lines. • Check the spindles for proper movement, and that the clutches are providing a slight drag.
  • Page 57 Reassemble the printer. Wipe the exterior of the printer with a cloth dampened with a non-abrasive, general purpose cleaning solution. Let the printer dry before connecting power. CP60 and CP60 Plus Service Manual...

  • Page 58: Run The Cleaning Card

    Run the Cleaning Card Connect the printer to the computer and turn on the power. Remove the cleaning roller, print ribbon, and any cards from the input hopper. Open the Printer Toolbox Dialog, and click on Clean Printer. If additional cleaning is required, wipe the rollers with the isopropanol cleaning pen or 99% isopropanol.

  • Page 59: Chapter 4: Troubleshooting

    Chapter 4: Troubleshooting This chapter provides information for troubleshooting problems with the CP60 and CP60 Plus card printers. General Notes___________________________________________________________________ 4-2 General Troubleshooting Procedures _____________________________________________ 4-2 Non-Clearing Repetitive Messages_____________________________________________________ 4-2 Troubleshooting Sensors _______________________________________________________________ 4-3 Troubleshooting Motors _______________________________________________________________ 4-4 Testing General DC Motors ________________________________________________________ 4-4...

  • Page 60: General Notes

    General Notes The CP Series Info Central help file contains a great deal of information for troubleshooting the system--such as print quality and software communication problems. • To open Info Central, click on the icon installed to the desktop when the SmartDriver was installed on the computer.

  • Page 61: Troubleshooting Sensors

    If the replacement sensor is non-functional and other sensors in the printer are observed to be functional, then the main control board is defective. (If none of the sensors are functional, you may have a communication problem between the printer and Diagnostics.) CP60 and CP60 Plus Service Manual...

  • Page 62: Troubleshooting Motors

    Troubleshooting Motors The best way to determine if a motor has failed versus a main control board failure, is to swap the motor with a similar motor. If a motor has failed, then a replacement motor should function. Conversely, if the motor’s driver has failed, then a replacement motor will not function either.

  • Page 63: Testing The Ribbon And Pick Motors

    Using the motor tests diagnostics, operate the ribbon or pick motor and see if the cam motor rotates. CP60 and CP60 Plus Service Manual...

  • Page 64: Testing The Printhead Fan

    Testing the Printhead Fan To test the printhead fan, it can be connected to the cam motor’s connection. These two motors are not compatible, but the driver circuitry for the cam motor will operate the fan. CAUTION: You cannot connect the cam motor into the fan’s connector. The circuitry of the control board will be damaged.

  • Page 65: Testing The Duplex Clutch

    • If the duplex gear did rotate, then the most likely cause is a faulty interface board. The secondary cause is a faulty duplex clutch. CP60 and CP60 Plus Service Manual...

  • Page 66: Diagnosing The Duplex Interface Board

    Diagnosing the Duplex Interface Board CAUTION: Connecting or disconnecting the duplex interface cable from the main control board with the printer powered may result in immediate damage to the main control board. Never make modifications to the interface board with the printer powered. Whenever a problem arises that is related to the duplex module, the first thing to check is the cable between the duplex interface board and the main control board.

  • Page 67: Performance Problems

    The printer continually reports a The smart card contact contains a small mechanical switch. card jam at the smart card The switch contacts may be stuck. module, but no card is present. CP60 and CP60 Plus Service Manual...

  • Page 68: Card Jams At Card Input

    Card Jams at Card Input Symptom Comments A card is not picked from the • Clean the printer. input hopper. • Use graphic quality cards. • Fan cards properly. • Inspect the pick roller for buildup or debris. • Inspect the card gate to make sure it is securely fastened. •...

  • Page 69: Card Jams In Printing Area

    • Inspect the magnetic stripe rocker arm and springs for placement and damage. • Make sure the magnetic stripe head is firmly seated. • Inspect the rear card guide and spring for damage. CP60 and CP60 Plus Service Manual 4-11...

  • Page 70: Ribbon Break Errors

    Ribbon Break Errors Symptom Comments Ribbon did not break, but the • Clean the printhead. It may be preventing the ribbon from error is reported. advancing. • Check the ribbon encoder wheel. Verify that it is positioned in the sensor and is not damaged. •...

  • Page 71: Error Codes

    For example, if the printer is reporting a jammed card but the card is not located under the sensor, then the first place to begin troubleshooting is with the sensor (it is possibly unplugged). CP60 and CP60 Plus Service Manual 4-13...

  • Page 72: Driver Api (Ap)

    (tracks 1,2,&3). Check the data AP 00806 entered or the format selected. AP 00808 The application used a Datacard Select the CP60 or CP60 Plus printer. printer function with a printer other than the Datacard printer. AP 00809 Internal Datacard printer API error.
  • Page 73 DR 00912 The printer driver was not installed You may not have restarted Windows after you successfully. Click Help for steps to installed the driver. Restart Windows and try follow. printing a card. CP60 and CP60 Plus Service Manual 4-15...
  • Page 74 Error Message text Comments Code DR 00914 The printer driver was not started • Restart Windows, and then open the printing successfully. Close all applications application. and restart the PC. • Reinstall the driver: a. Uninstall the print driver from the PC. b.

  • Page 75: Input Errors (Is)

    Check the duplex interface cable and circuit board. ERR_FLP_NOT_INSTALLED The card is lost in the duplex module. The duplex entry sensor was not blocked when 00767 expected. ERR_FLP_CARD_LOST • Check the sensor. • Check the duplex motor. CP60 and CP60 Plus Service Manual 4-17...

  • Page 76: System Errors (Sy)

    System Errors (SY) Error Symptom Comments Code SY-01305 The setting sent to the printer does not Check settings and printer options. match printer features. ERR_SYS_CONFIG_OPTIONS SY-01306 The setting value you selected is not Check configuration setup in printer to make valid.

  • Page 77: Magnetic Stripe Errors (Ms)

    MS_T3_SS_ERR • Run the Calibrate MS Head in Diagnostics. • Check the magnetic stripe head. • Check the magnetic stripe optical encoder. • Check the magnetic stripe daughter board. CP60 and CP60 Plus Service Manual 4-19...
  • Page 78 Error Symptom Comments Code MS-01413 End Sentinel error reading data An error was encountered at the end of the data record. If this occurs frequently: MS-01414 track 1, 2, or 3. • Run a cleaning card. MS-01415 • Try different card stock. MS_T1_ES_ERR •...
  • Page 79 • Make sure cards are loaded correctly and that they are magnetic stripe cards. • Check data format. Printer and driver should match. • Verify that the coercivity setting matches the card stock. • Clean the magnetic stripe head. CP60 and CP60 Plus Service Manual 4-21...
  • Page 80 Error Symptom Comments Code • Check the magnetic stripe mechanical assembly. Possible failed components are the magnetic stripe head, the cable assembly, the magnetic stripe encoder cable assembly, the magnetic stripe control board, and the main control board. MS-01425 Unexpected magnetic stripe The coercivity value stored in the printer is out of coercivity value.
  • Page 81 • Power cycle the printer. application does not send If the error continues, replace the main or magnetic stripe data if no magnetic stripe control board. module is installed. ERR_MS_NOT_INSTALLED CP60 and CP60 Plus Service Manual 4-23...

  • Page 82: Print Errors (Pr)

    Print Errors (PR) Error Symptom Comments Code The printhead cam is not in the • Check the printhead cam sensor. 01703 correct position to print. • Inspect the cam gear for damage. • Test the cam motor. ERR_PRN_HEAD_POSITION The card is lost in the printer. The card was not seen by a sensor when it was 01705 expected.
  • Page 83 • Check antenna cable. ribbon or click OK to print one- • If the ribbon is a new type, the printer's firmware color (K) cards. may need to be updated to recognize it. ERR_PRN_RIBBON_TYPE CP60 and CP60 Plus Service Manual 4-25...

  • Page 84: Smart Card Errors (Sc)

    Smart Card Errors (SC) Error Message text Comments Code The smart card module is not • Verify that the smart card option is enabled using 01804 installed or detected. Make Diagnostics. sure the card creation • Check the smart card assembly. Possible failed application does not request components are the sensor, the cable, and the smart card programming.

  • Page 85: Chapter 5: Adjustments

    Chapter 5: Adjustments This chapter provides instructions for adjusting the CP60 and CP60 Plus card printers. General Notes___________________________________________________________________ 5-3 Installing Printer Diagnostics ______________________________________________________ 5-3 Using Printer Diagnostics _________________________________________________________ 5-5 Parts of the Diagnostics Window _______________________________________________________ 5-5 Menu Options ________________________________________________________________________ 5-6...
  • Page 86 Testing the Smart Card Option________________________________________________________5-27 Network Option Adjustments ____________________________________________________ 5-29 Software Adjustment Procedures ________________________________________________ 5-33 Saving and Restoring a Printer Configuration __________________________________________5-33 Start Sentinel Position_________________________________________________________________ 5-35 Card Registration Offset Adjustment __________________________________________________5-36 Ribbon Offset Adjustment ____________________________________________________________5-37 Updating the Printer Firmware ________________________________________________________5-38 Duplex Rotational Adjustment ________________________________________________________5-39 Adjustments...

  • Page 87: General Notes

    General Notes This document is organized sequentially for the customer engineer who is encountering an CP60 or CP60 Plus printer for the first time, and begins with installing the diagnostic software, navigating and using the software, and concludes with specific adjustment procedures for the printer.
  • Page 88 From the displayed window, click the Printer Diagnostics button. From the displayed window, click Next to begin the installation. You will see a prompt for changing the destination directory. It is recommended that you not change this setting. Click Next. You will then be asked to which program group the icon should be added.

  • Page 89: Using Printer Diagnostics

    The main Diagnostic window shows the near-real-time status of the printer’s sensors (there may be a communication delay). The lower right corner shows the current Logon Level (either Basic or Advanced). Menu options that are not appropriate for the printer are grayed out. CP60 and CP60 Plus Service Manual...

  • Page 90: Menu Options

    Menu Options The options on the menus are for the purposes outlined in the table below. Option Purpose File | Choose Printer Use this option to select the printer for which you plan to use Diagnostics. File | User Properties Use this option to set the access level for Diagnostics.
  • Page 91 The smart card test is a built-in routine to simulate smart card personalization. A card is picked from the hopper, personalized, and transported to the smart card module. See additional information in Testing the Smart Card Option. CP60 and CP60 Plus Service Manual...

  • Page 92: Changing Printer Values

    Changing Printer Values Use the Printer Values dialog box to change the operational parameters of the printer. For a description of each parameter and how to change it, refer to Setting Printer Value Parameters. For information on how to create a test script, refer to Working With Scripts.

  • Page 93: Viewing And Saving Values

    Save current values to file Writes all parameters and values currently saved in memory to a text file. View factory values Select to display the values that were permanently written into the printer at the factory. CP60 and CP60 Plus Service Manual...

  • Page 94: Working With Scripts

    Working With Scripts The scripting area allows you to create, load, and run scripts for adjusting printers. A configuration script is a group of settings that are saved to a text file. Make sure the configuration script does not contain a Printer ID listing or a Ribbon Type listing.

  • Page 95: Setting Printer Value Parameters

    Print ribbon breaks at the start of a printed panel • Increase the card registration offset because the printhead is heating up the ribbon but the card is not yet in position to absorb some of this heat. CP60 and CP60 Plus Service Manual 5-11...

  • Page 96: Card Strip Offset

    Viewing Printer Status. This will provide the ribbon type number as well as the Datacard part number. Ribbon Offset This parameter tells the printer how far to advance the print ribbon after the index mark is detected by the ribbon index sensor.

  • Page 97: Transport Speed

    The shaded area directly above and below the white square on the service test card prints dark. • Decrease the YMC strobe setting. K-panel horizontal lines drop out but vertical lines print properly. • Increase the K-strobe setting. CP60 and CP60 Plus Service Manual 5-13...

  • Page 98: Ymc, K, T, And F Power And Base Power

    YMC, K, T, and F Power and Base Power These settings control the print threshold of each of the print panels. K and T power settings can be made in the print driver, but YMC and F power can be modified only from Diagnostics.

  • Page 99: Duplex Home Offset

    If this position cannot be determined, set the offset so the trailing edge of the card covers the location of the magnetic head but does not cover the location of the magnetic head's pivot pin. CP60 and CP60 Plus Service Manual 5-15...

  • Page 100: Image Clipping Leading And Trailing

    Image Clipping Leading and Trailing These settings clip (truncate) the image so printing begins in the correct position. Range 0 to 1000 (in thousandths of an inch) Increase Value Increases the amount of unprinted space on the leading or trailing edge of the card. Decrease Value Decreases the amount of unprinted space on the leading or trailing edge of the card.

  • Page 101: Setting Printer Options

    During the diagnostic session, all messages are displayed. This option reverts back to Prioritize messages when Diagnostics is closed. Make sure the magnetic stripe and/or smart card options are enabled before returning the printer to production. CP60 and CP60 Plus Service Manual 5-17...

  • Page 102: Viewing Printer Status

    Print Ribbon information Select this option and click Query to display the type of ribbon detected by the printer in the display window Laminate information This option is not available for the CP60 and CP60 Plus printers. 5-18 Adjustments...

  • Page 103: Testing Motors

    Click Start to begin the test (Stop ends the test before it times out). Click Reset Printer as it is a good practice to reset the printer before returning to card production. Use the Printer values button if you want to check the settings. CP60 and CP60 Plus Service Manual 5-19...

  • Page 104: Testing Motor Functions

    Testing Motor Functions The Printer Motor Cycle Tests dialog box allows you to perform various operations with the printer to check functionality. Procedure Select from this list of available tests: • Pick and Eject Card Test: This test picks a card, moves it just past the printhead location, and sends it back out of the printer.

  • Page 105: Setting Up Step Tests For The Printer

    To create a procedure, check the appropriate boxes of routines to indicate the steps and then click on Run checked steps. It is very important that you use the Reset printer button every time you have completed a test. CP60 and CP60 Plus Service Manual 5-21...

  • Page 106: Running A Magnetic Stripe Test Card

    Running a Magnetic Stripe Test Card The Magnetic Stripe Test Card dialog box provides access to printing test cards for the magnetic stripe module. Only Advanced Users can read cards. Set the parameters for the test card using this dialog box. Track format Select the track format type (standard) from the list.

  • Page 107: Configuring The Magnetic Stripe Module

    Reverse: (default setting) In reverse mode, the card is read on its return from the back of the printer. This mode is faster, but it may result in more frequent read-back errors. CP60 and CP60 Plus Service Manual 5-23...
  • Page 108 Track format Select the printer’s default track format. Coercivity Encoding a LOCO card with a HICO setting will saturate the magnetic media and result in periodic errors. Encoding a HICO card with a LOCO setting may result in non-encoded cards, which will result in more frequent read back errors.

  • Page 109: Configuring Custom Track Formats

    Modify the settings as required using the boxes at the left. Click on Apply to send the changes to the printer. Click on Save to save the changes and use them when the printer is next powered on. CP60 and CP60 Plus Service Manual 5-25...

  • Page 110: Running Magnetic Stripe Diagnostics

    Running Magnetic Stripe Diagnostics The Magnetic Stripe Diagnostics dialog box provides access to functions for troubleshooting the magnetic stripe module. • Select a series of steps to perform, and click on the Run Checked Steps button. • If you want to use a test that picks a card and passes it through the magnetic stripe area multiple times, enter the number of times in the Number of cycles box and click Start.

  • Page 111: Testing The Smart Card Option

    Card in position The sensor that detects a card is located on the smart card connector. The icon turns red when a card is in place and fully inserted under the contacts. CP60 and CP60 Plus Service Manual 5-27...
  • Page 112 Card status results The status window displays the status of the test. “Success = 1” indicates the test was successful. All aspects of the test (including graphics printing and magnetic stripe encoding) must be completed for the test to be successful. Start Click the Start button to begin the test.

  • Page 113: Network Option Adjustments

    The MAC Address is a unique identifier for the physical printer. The first 6 digits of the MAC address are assigned to Datacard and cannot be changed. The remaining 6 digits are assigned to each individual printer. The MAC Address shown on the LCD display should match the address printed on the chassis.
  • Page 114 Press the Up or Down arrow to scroll to the parameter to change and press the Enter key. The image below shows the submenu options under the configuration menu. To switch between a DHCP assigned IP Address and a Static IP Address, use the Up or Down arrow to select the protocol and press the Enter Key.
  • Page 115 The MAC Address should match the sticker on the printer chassis. Use the Up or Down arrows to scroll to the MAC Address Menu and press the Enter key. When the Change Value option appears, press the Enter key again. CP60 and CP60 Plus Service Manual 5-31...
  • Page 116 To change the value, use the Up or Down arrows to change the hexadecimal value in each field, and press the Enter key to move to the next field. After the value has been changed, press the Enter key to apply the settings and reboot the printer.

  • Page 117: Software Adjustment Procedures

    From the Printer menu, select Values. Click on the Save current values to file button. Name the text file with a unique name using the printer serial number and current date (for example, S0004-09-30-06.txt). CP60 and CP60 Plus Service Manual 5-33...
  • Page 118 If this procedure resulted in a duplicate instance (Null serial number) of the driver, the only way to fully remove this instance is to uninstall ALL Datacard printers from the PC, at which time the Clean-up Utility removes leftover files.

  • Page 119: Start Sentinel Position

    If the customer requires a custom start sentinel position, alter the numeric entries for each track in the entry boxes. Since this is custom, you will have to refer to the customer’s procedure for this setting. CP60 and CP60 Plus Service Manual 5-35...

  • Page 120: Card Registration Offset Adjustment

    Card Registration Offset Adjustment Use the Card Registration Offset adjustment to set the distance a card travels after being detected by the Card Input sensor. Procedure In Printer Diagnostics, click on the Printer menu and select Values. Record the current customer settings for image clipping, and then set both values to zero.

  • Page 121: Ribbon Offset Adjustment

    Verify the settings with a new ribbon and also with a near-empty ribbon, as the spool diameters may impact the results. Click Save to Power-on defaults to store the new value permanently. Enter 42360 in response to the password prompt. CP60 and CP60 Plus Service Manual 5-37...

  • Page 122: Updating The Printer Firmware

    • If Datacard has provided you with a flash update file that is newer than the firmware utility in the printer driver. Update the firmware using Diagnostics if an *.fls file is used. After selecting the *.fls file, the rest of the procedure is automated.

  • Page 123: Duplex Rotational Adjustment

    Handoff offset should be 77 units larger than the Home offset. Parameter Change Sample Duplex Home Offset Baseline Duplex Print Return Offset Add 6 Duplex Handoff Offset Add 77 Save the values to Power-on defaults. CP60 and CP60 Plus Service Manual 5-39...
  • Page 124 5-40 Adjustments...

  • Page 125: Chapter 6: Removal And Replacement

    Chapter 6: Removal and Replacement This chapter provides instructions for removal and replacement of assemblies and parts in the CP60 and CP60 Plus card printers. General Notes___________________________________________________________________ 6-3 Symbols ______________________________________________________________________________ 6-3 Required Tools ________________________________________________________________________ 6-3 Screw Torque Specifications ___________________________________________________________ 6-3...
  • Page 126 Main Control Board __________________________________________________________________6-32 Transport Timing Belt _________________________________________________________________6-36 Belt Tensioner Pulley and Tension Spring _______________________________________________6-37 Drive and Idler Pulleys ________________________________________________________________6-38 Cleaning Rocker Assembly ___________________________________________________________6-39 Front Rocker Assembly _______________________________________________________________6-40 Rear Rocker Assembly _______________________________________________________________6-41 Ribbon Guide _______________________________________________________________________6-42 Pick Roller ___________________________________________________________________________6-44 Cleaning Drive Roller_________________________________________________________________6-46 Front Drive Roller _____________________________________________________________________6-48 Rear Drive Roller _____________________________________________________________________6-50 Platen Roller _________________________________________________________________________6-53...

  • Page 127: General Notes

    Screw Location Torque (in-lbs) Pick motor 8±0.8 Transport motor 8±0.8 Cam motor 8±0.8 Ribbon take-up motor 8±0.8 680 coupler cable screws 0.9±0.1 Magnetic stripe encoder set screw 1.2±0.1 Magnetic stripe encoder mounting screws 0.9±0.1 CP60 and CP60 Plus Service Manual...

  • Page 128: Front Wire Routing

    Front Wire Routing Removal and Replacement...

  • Page 129: Duplex And Printhead Wire Routing

    Duplex and Printhead Wire Routing CP60 and CP60 Plus Service Manual...

  • Page 130: Functional Block Diagram

    Functional Block Diagram Removal and Replacement...

  • Page 131: Exterior Components

    Place your fingertips under the back of the cover and pull back to release the retaining tab. Push the cover toward the swingarm latch, and then rotate it upward to release the forward retaining tab. Pull the cover back and lift it off the swingarm. CP60 and CP60 Plus Service Manual...

  • Page 132: Main Enclosure

    Main Enclosure Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Swingarm Cover (p. 6-7). Close the swingarm, but do not latch it. There are three retaining tabs on each side of the enclosure. Using your fingertips, pry the enclosure away from the locking tabs and begin to lift the enclosure.

  • Page 133: Card Hopper

    Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly. If the printer is equipped with an LCD display in the hopper, disconnect the cable from the main control board. CP60 and CP60 Plus Service Manual...
  • Page 134 Simultaneously pull back on the transport chassis and forward on the card hopper. Remove the hopper from the chassis. 6-10 Removal and Replacement...

  • Page 135: Lcd Display

    Remove the Main Enclosure (p. 6-8). Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly. Disconnect the LCD cable connector from the main control board. CP60 and CP60 Plus Service Manual 6-11...
  • Page 136 Remove the card hopper by simultaneously pulling back on the transport chassis and forward on the card hopper. Remove the LCD from the hopper: Reach in from the back of the hopper and press down on the retaining tab. Lift the LCD away from the retaining tab. Tilt the LCD inward over the top of the retaining tab.

  • Page 137: Swingarm Assembly

    Disconnect the printhead fan connector from the main control board. Pull the cables back through the cable guides in the transport chassis. Unhinge the swingarm by pulling each side off the hinge pins. CP60 and CP60 Plus Service Manual 6-13...

  • Page 138: Printhead Fan

    Printhead Fan There are two different sizes of fans in the printers. The thicker fan is removed from the top of the swingarm, and the thinner fan slides out from the bottom of the swingarm. To identify the fan size, look for the retaining tabs on the top side of the swingarm as shown in the right-hand picture below.

  • Page 139: Printhead Spring

    Press in on the printhead release lever and remove the printhead. Pull up firmly on the printhead spring to unhook it from the retaining pin on the swingarm latch. Remove the other end of the spring from the printhead release lever. CP60 and CP60 Plus Service Manual 6-15...

  • Page 140: Sensors

    Sensors Card Input Sensor (Without Clear Card) Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Gently press the side of a screwdriver against the tip of the sensor (removal access slot shown below) and push it out of the chassis. Only when the sensor cannot be pushed out any further is it okay to pull the sensor out with the wires.

  • Page 141: Card Input Sensor (With Clear Card)

    Make sure the sensor is fully seated. The tip of the sensor should be flush with the edge of the chassis. • Refer to the Front Wire Routing Functional Block Diagram replacement details. • Use Diagnostics to pick cards and verify that the sensor is functional. CP60 and CP60 Plus Service Manual 6-17...

  • Page 142: Swingarm Sensor

    Swingarm Sensor Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Gently press the side of a screwdriver against the mounting tab of the sensor (removal access slot shown below) and push it out of the chassis. •...

  • Page 143: Ribbon Motion Sensor

    Push against the corners of the circuit board. • Use the sensor display in Diagnostics to verify that the sensor changes state as the ribbon supply spindle is rotated. CP60 and CP60 Plus Service Manual 6-19...

  • Page 144: Ribbon Index Sensor

    Ribbon Index Sensor Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Optional: For easier access, you may choose to remove the Ribbon Guide (p. 6-42). Unplug the sensor from the main control board. Pull the sensor off the mounting post on the ribbon guide.

  • Page 145: Cam Sensor

    Make sure the sensor is fully seated. The edge of the sensor arm should be against the edge of the chassis. • Refer to the Front Wire Routing Functional Block Diagram replacement details. • Run the Printhead Cam Test in Diagnostics to verify the sensor is functional. CP60 and CP60 Plus Service Manual 6-21...

  • Page 146: Card Hopper Empty Sensor

    Card Hopper Empty Sensor The Input Hopper Empty Option has a bracket that clips onto the Card Tray. The sensor fits into the bracket and plugs into the J40 connector labeled Spare. Even though this sensor displays on the Diagnostics Sensor screen, it is used only by the printer driver API and is not reported to the driver;...

  • Page 147: Motors

    Follow-up Procedure • Refer to the Functional Block Diagram for replacement details. • Use the motor tests in Diagnostics to verify the motor is functioning properly. • Print several test cards. CP60 and CP60 Plus Service Manual 6-23...

  • Page 148: Pick Motor

    Pick Motor Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Unplug the wires from the motor. To access the motor mounting screws, it is necessary to remove the Card Hopper (p.
  • Page 149 Reconnect the wires to the motor. (The motor will turn backward if the wires are reversed.) Continue reassembling the printer. Run the Pick and Eject Card Test in Diagnostics to verify that the motor is functioning properly. CP60 and CP60 Plus Service Manual 6-25...

  • Page 150: Cam Motor

    Cam Motor Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Remove the Transport Assembly from the base (p. 6-29). Rotate the motor gear until the mounting screws are accessible through the slots.

  • Page 151: Ribbon Motor And Gear

    Using pliers, pull the gear off the motor shaft. (During replacement, make sure to line up the shaft flats.) Remove the two screws that secure the motor to the transport chassis, and remove the motor. CP60 and CP60 Plus Service Manual 6-27...
  • Page 152 Follow-up Procedure Tighten the mounting screws to 8 in-lbs. • • Connect the wires as shown below. • Make sure the wires are not routed under the motor. • Refer to the Front Wire Routing Functional Block Diagram replacement details. •...

  • Page 153: Transport Assembly

    Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly. CP60 and CP60 Plus Service Manual 6-29...
  • Page 154 Remove the front of the chassis from the base: Simultaneously pull back on the transport chassis and forward on the card hopper. The hopper can be left attached or removed. When the tabs on the chassis are clear of the openings, lift the chassis (and control board) out of the base.
  • Page 155 Verify that all cable connectors are properly seated, even if they were not disconnected. • Refer to the Front Wire Routing Functional Block Diagram replacement details. • Print several test cards to verify that the printer is functioning properly. CP60 and CP60 Plus Service Manual 6-31...

  • Page 156: Main Control Board

    Main Control Board Refer to chapter 5 of this manual for additional details on using the Diagnostics software. Backup the Printer Values With the printer powered and connected to a computer, start Diagnostics and log in as an Advanced User. From the Printer menu, select Values.
  • Page 157 (p. 6-75) from the main control board. If the printer is equipped with a smart card option, remove the Smart Card Interface Board (p. 6-81) and the two standoffs from the main control board. CP60 and CP60 Plus Service Manual 6-33...
  • Page 158 Replacement Procedure If the printer is equipped with smart card, transfer the circuit board standoffs from the old board to the new board, and replace the smart card interface board. If the printer is equipped with magnetic stripe, replace the magnetic stripe board.
  • Page 159 To change the value, press the Up or Down arrow to increment or decrement the existing value in each field. Press the Enter key to move the cursor to the next field in the value and repeat the process. CP60 and CP60 Plus Service Manual 6-35...

  • Page 160: Transport Timing Belt

    Transport Timing Belt Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Release the belt tension, and remove the transport belt. Replacement Notes Follow the belt routing shown below. If the printer is not equipped with the •...

  • Page 161: Belt Tensioner Pulley And Tension Spring

    Release the belt tension, and remove the transport belt. Lift the release tab and slide the tensioner down as far as it will go, and remove the spring. Pull the idler pulley off the tensioner. CP60 and CP60 Plus Service Manual 6-37...

  • Page 162: Drive And Idler Pulleys

    Drive and Idler Pulleys Removal Procedure Unplug the printer. Remove the Main Enclosure (p. 6-8). Release the belt tension, and remove the transport belt. Remove the idler pulleys by pulling them off their studs. Remove the drive pulleys from their shafts by squeezing the end of the shaft, and slipping the pulley off.

  • Page 163: Cleaning Rocker Assembly

    Push the rocker mount one direction and the rocker arm the other direction and pull up and out. Be careful not to lose the springs. Rocker Arm Assembly Rocker Arm Mount Spring 2x Front of Printer Sp35726s CP60 and CP60 Plus Service Manual 6-39...

  • Page 164: Front Rocker Assembly

    Front Rocker Assembly When replacing the rocker assembly, it is a good idea to replace the springs as well. Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Push the rocker assembly one direction and the rocker mounting tab in the opposite direction, and pull up on the rocker.

  • Page 165: Rear Rocker Assembly

    Unplug the printer. Remove the ribbon cartridge. Push the rocker assembly one direction and the rocker mounting tab in the opposite direction, and pull up on the rocker. Be careful not to lose the springs. CP60 and CP60 Plus Service Manual 6-41...

  • Page 166: Ribbon Guide

    Ribbon Guide Removal Procedure Unplug the printer and remove the ribbon cartridge and cleaning roller. Lift the ribbon guide out of the receivers in the transport chassis sidewalls: Simultaneously grasp the left and right sides of the ribbon guide with both hands.
  • Page 167 Route the cable through the ribbon guide as shown below. • Refer to the Front Wire Routing Functional Block Diagram • replacement details. Use the sensor display in Diagnostics to verify the sensor changes state as the • ribbon is advanced. CP60 and CP60 Plus Service Manual 6-43...

  • Page 168: Pick Roller

    Pick Roller Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). To access the pick motor mounting screws, remove the card hopper. Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly.
  • Page 169 Tighten the mounting screws to 8 in-lbs. Continue reassembling the printer. Run the Pick and Eject Card Test in Diagnostics to verify that the motor is functioning properly. CP60 and CP60 Plus Service Manual 6-45...

  • Page 170: Cleaning Drive Roller

    Cleaning Drive Roller Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure and card hopper (p. 6-8). Remove the Transport Timing Belt (p. 6-36). Remove the cleaning rocker assembly. Remove the pulley from the shaft by squeezing the end of the shaft, and slipping the pulley off.
  • Page 171 Remove the drive roller: Lift the pulley-end of the shaft up. Slide the shaft out the side. Lift the opposite end of the shaft and remove the roller. CP60 and CP60 Plus Service Manual 6-47...

  • Page 172: Front Drive Roller

    Front Drive Roller Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Lift the Ribbon Guide (p. 6-42) out and set it aside. Remove the Front Rocker Assembly (p. 6-40). Remove the Front Card Guide (p.
  • Page 173 Lift the pulley-end of the shaft, slide it out until the roller touches the sidewall, and lift the other end out of the chassis. Follow-up Procedure Print several test cards to ensure there are no transport problems. CP60 and CP60 Plus Service Manual 6-49...

  • Page 174: Rear Drive Roller

    Rear Drive Roller Removal Procedure Unplug the printer. Remove the ribbon cartridge. Remove the Main Enclosure (p. 6-8). Depending on the configuration of the printer, remove either the Rear Rocker Assembly (p. 6-41) or the Magnetic Stripe Rocker Assembly (p. 6-80). If present, partially remove the smart card contact carrier: Insert a screwdriver between the carrier and the left mounting tab.
  • Page 175 Remove the pulley from the shaft by squeezing the end of the shaft and slipping the pulley off. The pulley's flange is permanently adhered to the pulley. Do not try to remove the flange. CP60 and CP60 Plus Service Manual 6-51...
  • Page 176 Remove the drive roller: Lift the pulley-end of the shaft up. Slide the shaft out the side. (It is necessary to deform the roller slightly as it will not fully clear the opening in the bottom of the transport chassis.) Lift the opposite end of the shaft and remove the roller.

  • Page 177: Platen Roller

    Make sure the washer is between the platen roller and the transport chassis. • Put a thin film of Molykote DX grease (Part No. 807421-001) on the shaft at ® the locations shown. Print several test cards to check print quality. • CP60 and CP60 Plus Service Manual 6-53...

  • Page 178: Printhead Cam

    Printhead Cam Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Remove the Transport Assembly from the base (p. 6-29). Rotate the cam until the cam flag is clear of the sensor. Using a screwdriver, pry the flag-side of the cam out of the transport chassis.

  • Page 179: Printhead Lifter

    Grasp the rear lever of the lifter and pull up and out of the chassis. Follow-up Procedure Run the Printhead Cam Test in Diagnostics to verify that the lifters are • operating properly. CP60 and CP60 Plus Service Manual 6-55...

  • Page 180: Front Card Guide

    Front Card Guide Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Ribbon Guide (p. 6-42). Remove the Front Rocker Assembly (p. 6-40). Remove the front card guide: Remove the bias spring from the card guide. This will reduce the chance for the spring flying loose when the guide is removed.

  • Page 181: Rear Card Guide

    If present, partially remove the smart card contact carrier: Insert a screwdriver between the carrier and the left mounting tab. Twist the blade to pry the carrier out of the mounting tab. It is not necessary to fully remove the carrier. CP60 and CP60 Plus Service Manual 6-57...
  • Page 182 Remove the rear card guide: Remove the bias spring from the card guide. This will reduce the chance of the spring flying loose when the guide is removed. Pull up on the card guide. 6-58 Removal and Replacement...

  • Page 183: Static Brushes

    Before putting new static brushes on the transport, use isopropanol to clean • off the old adhesive residue from the chassis. Run the Pick and Eject Card Test in Diagnostics to verify that the pick motor is • functioning properly. CP60 and CP60 Plus Service Manual 6-59...

  • Page 184: Rfid Antenna

    RFID Antenna Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Disconnect the cable connector from the bottom of the antenna board. With the tip of your finger or a screwdriver, pull back slightly on the bottom of the circuit board, and lift the board out of the slots.

  • Page 185: Duplex Module

    Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly. CP60 and CP60 Plus Service Manual 6-61...
  • Page 186 Disconnect the interface cable from the duplex interface board. Pull back on the duplex assembly and lift it off the transport chassis. 6-62 Removal and Replacement...

  • Page 187: Duplex Entry Sensor

    Remove the Main Enclosure (p. 6-8). Disconnect the duplex interface cable from the interface board. Remove the Duplex Module (p. 6-61) from the printer. Disconnect the entry sensor connector from the interface board. CP60 and CP60 Plus Service Manual 6-63...
  • Page 188 Remove the Duplex Entry Rocker from the module (p. 6-68). Push the sensor out of the duplex chassis. Replacement Notes • When pushing the sensor into the duplex chassis, do not push against the wires or crush them. • Print a test card to verify that the duplex is functioning properly. 6-64 Removal and Replacement...

  • Page 189: Duplex Home Sensor (Without Clear Card)

    Replacement Notes When pushing the sensor into the duplex chassis, do not push against the • wires or crush them. Print a test card to verify that the duplex is functioning properly. • CP60 and CP60 Plus Service Manual 6-65...

  • Page 190: Duplex Home Sensor (With Clear Card)

    Duplex Home Sensor (With Clear Card) Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Disconnect the sensor connector from the duplex interface board. Carefully push the sensor out of the sensor bracket in the duplex chassis. Sensor Replacement Notes •...

  • Page 191: Duplex Interface Board

    Disconnect all connectors from the duplex interface board. Lift the edge of the board slightly and slide it off the retaining pins. Remove the board. Follow-up Procedure Print several test cards to ensure the duplex is operating properly. CP60 and CP60 Plus Service Manual 6-67...

  • Page 192: Duplex Entry Rocker

    Duplex Entry Rocker Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Disconnect the duplex interface cable from the interface board, and remove Duplex Module (p. 6-61) from the printer. Lift one side of the entry rocker off its pivot pin. As soon as possible, grasp the pressure spring and remove it before it gets loose.

  • Page 193: Duplex Motor

    Disconnect the duplex interface cable from the interface board. Remove the Duplex Module (p. 6-61) from the printer. Disconnect the motor connector from the interface board. Free up the cable from the retaining tabs. CP60 and CP60 Plus Service Manual 6-69...
  • Page 194 Simultaneously press in on the locking tabs, and rotate the motor to remove Replacement Notes • When inserting the motor into the duplex chassis, make sure the gears mesh properly. • Print several test cards to verify that the duplex is functioning properly. 6-70 Removal and Replacement...

  • Page 195: Magnetic Clutch/Spring Clutch/Duplex Rollers

    Disconnect the duplex interface cable from the interface board. Remove the Duplex Module (p. 6-61) from the printer. Remove the duplex motor by simultaneously pressing in on the locking tabs, and rotating the motor. Disconnect the clutch connector from the clutch. CP60 and CP60 Plus Service Manual 6-71...
  • Page 196 Rotate the flipper until the calibration pointer is pointing up. Pull the flipper assembly toward the clutch end until the pivot pin is free from the chassis. (The stabilizing tab, which was previously constrained by the motor, will bend as necessary.) Tilt the flipper assembly up and remove the whole assembly.
  • Page 197 Squeeze the ends of the spring clutch and pull it off the boss. To remove the idler rollers, spread the sidewalls of the flipper, and pull the roller out one side at a time. CP60 and CP60 Plus Service Manual 6-73...
  • Page 198 To remove the drive rollers: Spread the non-gear sidewall of the flipper and pull back on the roller. Tilt the roller shaft up and withdraw the gear through the opening in the sidewall. Replacement Notes • The magnetic clutch will not fit into the opening if it is rotated incorrectly. •...

  • Page 199: Magnetic Stripe Option

    Make sure the connectors between the two boards are aligned properly. If not, both boards could be damaged. • Using the Diagnostics in chapter 5, calibrate the magnetic stripe head as described in Start Sentinel Position. CP60 and CP60 Plus Service Manual 6-75...

  • Page 200: Magnetic Stripe Registration Sensor (Without Clear Card)

    Magnetic Stripe Registration Sensor (Without Clear Card) Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Remove the Transport Assembly from the base (p. 6-29). Remove the Magnetic Stripe Rocker Assembly (p.

  • Page 201: Magnetic Stripe Registration Sensor (With Clear Card)

    Carefully push down on the sensor from above and remove it through the bottom of the chassis, being careful not to lose the spacer. Replacement Notes • Reuse the spacer with the new sensor. • Use Diagnostics to verify that the sensor is working properly. CP60 and CP60 Plus Service Manual 6-77...

  • Page 202: Magnetic Stripe Head

    Magnetic Stripe Head Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Remove the Transport Assembly from the base (p. 6-29). Unplug the magnetic head from the magnetic stripe board. Remove the Magnetic Stripe Rocker Assembly (p.
  • Page 203 The long pin on the head points toward the front of the printer (fits only one • direction). Using the Diagnostics in chapter 5, calibrate the magnetic stripe head as • described in Start Sentinel Position. CP60 and CP60 Plus Service Manual 6-79...

  • Page 204: Magnetic Stripe Rocker Assembly

    Magnetic Stripe Rocker Assembly Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Using a screwdriver, pry the rocker's pivot pin out of the mounting tab on the chassis. Rotate the rocker clockwise, and remove it through the side of the chassis (note that the encoder is pointing straight down during removal).

  • Page 205: Smart Card Option

    Squeeze the locking tab on one standoff and lift the board up slightly. Repeat for the other standoff. Gently pry the board off the connector. Follow-up Procedure Using Diagnostics, perform the Smart Card Test Card procedure as described in chapter 5 of this manual. CP60 and CP60 Plus Service Manual 6-81...

  • Page 206: Solenoid Assembly/Solenoid Link

    Solenoid Assembly/Solenoid Link Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Using a screwdriver carefully pry out the solenoid release tab, and pull the solenoid out just slightly from the mounting pocket. •...
  • Page 207 To remove the solenoid link, rotate it 90 degrees and pull it off the rocker. Follow-up Procedure Using Diagnostics, perform the Smart Card Test Card procedure as described in chapter 5 of this manual. CP60 and CP60 Plus Service Manual 6-83...

  • Page 208: Smart Card Contact

    Smart Card Contact Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-8). Remove the Transport Assembly from the base (p. 6-29). Disconnect the interface cable from the smart card interface board. Refer to Functional Block Diagram (p.
  • Page 209 Replacement Notes • Make sure the contact is fully seated in the carrier. • Make sure the wires are not routed under the motor. Route wire out through the side of the chassis. • CP60 and CP60 Plus Service Manual 6-85...
  • Page 210 • Route the wires around the solenoid and connect it to the smart card interface board. • Using Diagnostics, perform the Smart Card Test Card procedure as described in chapter 5 of this manual. 6-86 Removal and Replacement...

  • Page 211: Contactless Smart Card Coupler

    Main Enclosure (p. 6-8). Remove the Transport Assembly from the base (p. 6-29). Use a screwdriver to press the plastic locking tabs out of the chassis. Remove the coupler bracket or plastic cover. CP60 and CP60 Plus Service Manual 6-87...
  • Page 212 Replacement Notes Snap the coupler back into the chassis using the four mounting bracket locking tabs. Orientation is important for reading the smart card. Connect the three connectors. Follow-Up Procedure Using Diagnostics, perform the Smart Card Test Card procedure as described in chapter 5 of this manual.

This manual is also suitable for:

Cp60 plus

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