Fargo HDP8500 Service Manual
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Fargo HDP8500 Service Manual

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15370 Barranca Parkway
Irvine, CA 92618
FARGO
®
HDP8500 Card Printer
SERVICE MANUAL
PLT-01583, 1.1
November 2013
© 2013 HID Global Corporation/ASSA ABLOY AB.
All rights reserved.

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  • Page 1 15370 Barranca Parkway Irvine, CA 92618 FARGO ® HDP8500 Card Printer SERVICE MANUAL PLT-01583, 1.1 November 2013 © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 2: Liability Statement

    The Direct-to-Card Printer specifications, applications and options are subject to change at the discretion of HID Global Corporation without notice. Trademarks HID GLOBAL, HID, the HID logo, HDP and FARGO are the trademarks or registered trademarks of HID Global Corporation or its licensors in the U.S. and other countries. Trademark Acknowledgments Other trademarks and trade names may be used in this document to refer to either entities claiming the marks and names or their products.
  • Page 3 HDP8500 Service Manual, PLT-01583, 1.1 Contacts North America Europe, Middle East and Africa 15370 Barranca Parkway Phoenix Road Irvine, CA 92618 Haverhill, Suffolk CB9 7AE England Phone: 800 237 7769 Phone: +44 1440 714 850 Fax: 949 732 2120 Fax: +44 1440 714 840 Tech Support: +44 1440 711 822 M-F 9am –...

  • Page 4: Table Of Contents

    HDP8500 Service Manual, PLT-01583, 1.1 HDP8500 Parts Replacement ....................... 6 Safety Messages (review carefully) .........................7 Cover Removal / Replacement Procedures .....................8 Reviewing the HDP8500 Covers .........................9 Remove/Replace the Rear/TOP Cover Assembly (D940089) ..............11 Remove/Replace the Front Panel Cover (D940201-01) ................13 Remove/Replace the Input Cover (D940092-02) ..................
  • Page 5 HDP8500 Service Manual, PLT-01583, 1.1 Flipper Table Remove/Replace Procedures ................. 87 Remove/Replace the Output Roller Assembly (D910404) ..............88 Remove/ Replace the Table or Flip Home Sensor (D900249) ..............92 Remove/ Replace the Flipper Motor (D900523) ..................93 Remove/ Replace the Card Feed Motor (D900524) ................. 94 Remove/Replace the Flipper Main Board (A000394) ................

  • Page 6: Hdp8500 Parts Replacement

    HDP8500 Service Manual, PLT-01583, 1.1 HDP8500 Parts Replacement The purpose of this section is to provide the technician with specific replacement procedures for the Card Printer. Please see the next page to review standard precautions (to take) while performing these replacement procedures.

  • Page 7: Safety Messages (Review Carefully)

    HDP8500 Service Manual, PLT-01583, 1.1 Safety Messages (review carefully) Symbol Critical Instructions for Safety purposes Danger: Failure to follow these installation guidelines can result in death or serious injury. Information that raises potential safety issues is indicated by a warning symbol (as shown to the left).

  • Page 8: Cover Removal / Replacement Procedures

    HDP8500 Service Manual, PLT-01583, 1.1 Cover Removal / Replacement Procedures  Important: These procedures can only be performed by authorized service personnel.  Important: Make note of the wire routing when moving wires for parts replacements. Clips are provided inside the printer for wires and tie clips are used to bundle wires. Keep wires away from moving parts.

  • Page 9: Reviewing The Hdp8500 Covers

    HDP8500 Service Manual, PLT-01583, 1.1 Reviewing the HDP8500 Covers The Covers must be removed in this sequence (order) to avoid damage to these parts. Reverse order to re-assemble. 1. Top/Rear Cover D940089 2. Front Panel Cover D940201-01 3. Input Cover D940092-02 4.
  • Page 10 HDP8500 Service Manual, PLT-01583, 1.1 © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 11: Remove/Replace The Rear/Top Cover Assembly (D940089)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Rear/TOP Cover Assembly (D940089) Tools needed: T10 (Torx )Driver Estimated Time: 10 minutes Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Power off the Printer by unplugging the power cord from the Printer.
  • Page 12 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the Cover Open Sensor cable. (A000125). * When replacing the Rear Cover do not tighten this screw at this step. Reverse the instructions to re-assemble or install a new cover. *Tighten all the screws after the cover is completely attached.

  • Page 13: Remove/Replace The Front Panel Cover (D940201-01)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Front Panel Cover (D940201-01) Tools needed: Philip driver Estimated Time : 10 minutes Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Power off the Printer by unplugging the power cord from the Printer.

  • Page 14: Remove/Replace The Input Cover (D940092-02)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Input Cover (D940092-02) Tools needed: T10 Torx Driver, Philip driver Estimated Time: 10 minutes Important: This procedure can only be performed by authorized service personnel. **Remove this cover if replacing the Bezel LCD Display Assembly...
  • Page 15 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove (2) screws ( F000034) located in the inside hopper. ( Philip driver) Remove (2) screws ( F000231) from the bottom SIDE cover. (Philip driver) Remove (1) screw(F000170) from the bottom FRONT cover. (T10 driver) Note: Cable Routing.
  • Page 16 HDP8500 Service Manual, PLT-01583, 1.1 Lift OUT and UP from the bottom to clear the top frame. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 17 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure There is a small TAB that fits the cover under the hopper frame. Reverse the instructions to re-assemble or install a new cover. Tighten all the screws after the cover is completely attached.

  • Page 18: Remove/Replace The Output Cover (D940199-02)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Output Cover (D940199-02) Tools needed: T10 Torx Driver, Philip driver Estimated Time: 10 minutes Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Power off the Printer by unplugging the power cord from the Printer.
  • Page 19 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove (2) screws (F000231) from the bottom Output Trim Cover (D940202-02). (Philip Driver) * When replacing the Output Cover do not tighten this screw at this step. Remove the Output Cover. Reverse the instructions to re-assemble or install a new cover.

  • Page 20: Remove/Replace The Door Cover (D940090-01)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Door Cover (D940090-01) Tools needed: T10 Torx Driver Estimated Time: 10 minutes Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Power off the Printer by unplugging the power cord from the Printer.
  • Page 21 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Slide the Cover Hinge from the Printer. Reverse the instructions to re-assemble or install a new door. *Tighten all the screws after the cover is completely attached. The Foam Filter (D940140) may be replaced if necessary.

  • Page 22: Remove/Replace The Bezel Lcd Display (D940088-01)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Bezel LCD Display (D940088-01) Tools needed: T10 Torx Driver, Estimated Time: Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Power off the Printer by unplugging the power cord from the Printer.

  • Page 23: Remove/Replace The Cover Insert (D940204-02)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Cover Insert (D940204-02) Tools needed: T10 Torx Driver Estimated Time: 10 minutes Important: This procedure can only be performed by authorized service personnel. Note: This is where the ANDON Light Upgrade is installed.

  • Page 24: Main Printer Modules Removal

    HDP8500 Service Manual, PLT-01583, 1.1 Main Printer Modules Removal Remove the Fan Box/Bracket Assembly (D940005) Tools needed: T10 Torx Driver Estimated Time: 20 minutes Preparation: Remove Rear/Top Cover. Important: This procedure can only be performed by authorized service personnel. Note: Removing this assembly is required for many procedures.
  • Page 25 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the 3 screws holding the Auxiliary Board (A940221-10) to the frame. Unplug the power connection 140069 Remove the Ethernet/USB box. Remove two screws from the BOX base. Pull the box forward and slide to the RIGHT then OUT.
  • Page 26 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Gently pull the hoses from the Printer. Disconnect the 2 Fan Cable from the Fan Box. Disconnect the MAG wires from the back of the Fan Box. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 27 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Disconnect the wires from the tie wrap on the Fan Box. Disconnect the Ribbon Cable from the D000445 Board ( attached to the Fan Box Riser) Remove the FAN BOX and BRACKET as one piece.

  • Page 28: Remove The Card Path (D940005)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove the Card Path (D940005) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove Covers Remove the Fan Assembly Important: This procedure can only be performed by authorized service personnel. Note: Removing this assembly is required for many procedures.
  • Page 29 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove 1 screw (F000178) that attaches the Card Path to the Main Chassis. Remove the 2 screws (F000170) that attach the Card Path to the Power Box frame. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 30 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove 4 screws (F000192) that attach the Main Chassis to the Card Path. Slide the Card Path away from the Main Chassis. Disconnect all wire connection (or as many as are needed for access).
  • Page 31 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure When replacing the Card Path, align the Card Path to the Main Chassis Reverse the instructions to re-assemble. Refer to Appendix A for Cable Connection diagram. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 32: Remove The Main Printer Chassis

    HDP8500 Service Manual, PLT-01583, 1.1 Remove the Main Printer Chassis Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove covers Remove Fan Box/Bracket Assembly Remove the Card Path Assembly. Important: This procedure can only be performed by authorized service personnel.
  • Page 33 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the 2 screws (F000192) from the front of the Chassis. Disconnect the FI Mag/Printhead Fan cable ( D940191) from the Mainboard. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 34 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Disconnect the Film Sensor and Lam Lift Sensor cables from the Transfer Arm connection. Caution: Do not damage the Mainboard when removing or installing the Main Chassis. Carefully rotate the chassis up and off of the frame.
  • Page 35 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure When replacing the Chassis line up the 3 square holes on the front frame and align the chassis into the notch on the frame. Reverse the instructions to re-assemble. Refer to Appendix A for Cable Connection diagram.

  • Page 36: Printer Board Removal

    HDP8500 Service Manual, PLT-01583, 1.1 Printer Board Removal Remove the Mainboard (A940234) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove the Covers. Remove the Card Path. Remove the Main Chassis. Important: This procedure can only be performed by authorized service personnel.
  • Page 37 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the 8 screws(F000170) from the Mainboard. Remove the PCB Cover ( D940133) When replacing the cover verify the Flame Sheild (D940267) is seated. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 38 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove 1 screw (F000170) from the PCB station Transistion board ( D940171) Remove 4 screws (F000170) from the PCB Flip Station Interface & IO board (D940195) Remove all cable connections. Lift off the Mainboard from the Base.

  • Page 39: Remove/Replace The Auxiliary Board (A920221-10)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Auxiliary Board (A920221-10) Tools needed: T10 Torx Driver Estimated Time: 15 minutes Preparation: Remove Rear/Top Cover Important: This procedure can only be performed by authorized service personnel. Note: Removing this assembly is required for many procedures.
  • Page 40 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the 3 screws holding the Auxiliary Board (A940221-10) to the frame. When replacing the board insert the PCB into the tab of the base. Reverse the instructions to re-assemble. Refer to Appendix A for Cable Connection diagram.

  • Page 41: Remove/Replace The Usb Ethernet Pcb (A910551)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the USB Ethernet PCB (A910551) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove Top/Rear Covers. Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Power off the Printer by unplugging the power cord from the Printer.
  • Page 42 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Lift up the cover from the USB PCB. Unplug the wire connection and lift UP on the PCB(A910551) Reverse the instructions to re-assemble. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 43: Card Path Procedures

    HDP8500 Service Manual, PLT-01583, 1.1 Card Path Procedures Card Path Sensor (D910217) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove Rear/Top Cover. Remove the Card path. Remove Fan Box/Bracket Assembly Important: This procedure can only be performed by authorized service personnel.
  • Page 44 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Feed wire through the hole and re connect the wire. Reverse the instructions to re-assemble. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 45: Card Path - Roller Replacement Procedures

    HDP8500 Service Manual, PLT-01583, 1.1 Card Path - Roller Replacement Procedures Tools needed: 10T Torx Driver. Roto Clip A-150 Estimated Time: 60 minutes Preparation: Remove Rear/Top/Covers and Fan Box/Bracket Assembly/ Bracket. Important: This procedure can only be performed by authorized service personnel.
  • Page 46 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure TO REPLACE BOTTOM ROLLERS. Insert the D flat end into the grommet provided on the Sideplate. Fit the bearing and E Clip into the slot provided on the other side of the Sideplate.
  • Page 47 HDP8500 Service Manual, PLT-01583, 1.1 Ensure the flat on the bearing is aligned with the flat in the Sideplate hole. (continued next page) Verify roller rolls freely Bottom Roller #2 Flattener Roller (Roller D940098 with bearing D940169) Ensure the flat on the bearing is aligned with the flat in the Sideplate hole.
  • Page 48 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Bottom Roller #3 Cleaning Roller (D940100 with bearing D940169) Ensure the flat on the bearing is aligned with the flat in the Sideplate hole. Verify roller rolls freely Bottom Roller #4 Transfer Roller ( D940105) Long end goes to the LEFT side.
  • Page 49 HDP8500 Service Manual, PLT-01583, 1.1 Verify roller rolls freely Remove the gear D910112 and clip 140048 to replace the roller D940105 Bottom Roller #5 Cleaning Roller (D940100 with bearing D940169) Ensure the flat on the bearing is aligned with the flat in the Sideplate hole.
  • Page 50 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure TO REPLACE TOP ROLLERS. All Rollers follow the same procedure. Top View Insert the D flat end into the grommet provided on the Sideplate. Fit the Bearing and the SPRING on the other side of the Sideplate.
  • Page 51 HDP8500 Service Manual, PLT-01583, 1.1 Use a small tool to move the LED over the tab. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 52 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure ROLLER #1 Roller Transport Idler (D940108) with Bearing (760343) Long end goes to the LEFT side. Ensure the flat on the bearing is aligned with the flat in the Sideplate hole. Remove the gear and clip 140048 to replace the roller Verify roller rolls freely ©...
  • Page 53 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Roller #2 Cleaning Roller (D940108) with bearing (760343) Long end goes to the LEFT side. Ensure the flat on the bearing is aligned with the flat in the Sideplate hole. Remove the gear and clip 140048 to replace the roller Verify roller rolls freely ©...
  • Page 54 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Roller #3 Transport Roller (D940099) Long end goes to the LEFT side. Ensure the flat on the bearing is aligned with the flat in the Sideplate hole. Verify roller rolls freely Roller #4 Cleaning Roller (D940108) with bearing (760343) Long end goes to the LEFT side.

  • Page 55: Card Path- Stepper Motor Assembly (D940257)

    HDP8500 Service Manual, PLT-01583, 1.1 Card Path- Stepper Motor Assembly (D940257) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Fan Box/ Bracket Remove the Card Path Important: This procedure can only be performed by authorized service personnel.
  • Page 56 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the 4 screws (F000170) screws from the Stepper Motor. Remove the Gear covering the upper right screw. ( not shown) Lift the Motor from the frame. Reverse the instructions to re-assemble. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 57: Card Path- Gear Motor (D900484-01)

    HDP8500 Service Manual, PLT-01583, 1.1 Card Path- Gear Motor (D900484-01) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Fan Box/ Bracket Remove the Card Path Important: This procedure can only be performed by authorized service personnel.
  • Page 58 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the Gear ( D940252) and E-Clip (140063) from the motor post. Remove 4 screws ( F000193) to release the motor from the frame. Lift Motor up and out. Reverse the instructions to re-assemble.

  • Page 59: Main Chassis Procedures

    HDP8500 Service Manual, PLT-01583, 1.1 Main Chassis Procedures Remove/Replace the Film Supply Motor (D900484-06), Ribbon Supply Motor (D900484-07), and RFID Board (A000365) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove the Covers. Remove the Auxiliary board. Remove the Fan Box/Bracket Important: This procedure can only be performed by authorized service personnel.

  • Page 60: Remove/Replace The Film Take-Up Motor (D900484-01) And Ribbon Take-Up Motor (D900484-01)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Film Take-Up Motor (D900484-01) and Ribbon Take-Up Motor (D900484-01) Tools needed: T10 Torx Driver Estimated Time: 20 minute The same procedure is used for both Motors. Preparation: Remove the Covers. Remove the Auxiliary board.

  • Page 61: Remove/Replace The Headlift Motor (D910052) And Headlift Sensor (D910216)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Headlift Motor (D910052) and Headlift Sensor (D910216) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove the Rear/Top Covers. Remove the Fan Box/Bracket Assembly Important: This procedure can only be performed by authorized service personnel.
  • Page 62 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the one (1) screw that holds the Mount to the Frame. (Note: The Mount is flush with the Frame when properly fitted.) Pull out the Motor. Press the locking tab located on the right side of the Motor IN to release the Motor.
  • Page 63 HDP8500 Service Manual, PLT-01583, 1.1 Replace the Headlift Motor. Ensure the Shaft tab fits in to the hole provided in the Frame. Note: Turn the shaft so the FLAG is within the sensor, then insert. Reverse the instructions to re-assemble.

  • Page 64: Remove The Print Stepper Motor (D910050)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove the Print Stepper Motor (D910050) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove Covers. Remove the Fan Box/Bracket Assembly Remove the Card Path. Suggestion: Lay the printer on the front side for ease of accessing the motors.
  • Page 65 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the 3 screws (F000177) that hold the Motor (D910050) to the Frame. Screws # 1 & 2 have washers ( 140040) Roll the Motor (D910050) in a downward angle CCW to release the Print Stepper Motor Belt (F000093) from the Pulley.
  • Page 66 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Replace the two (2) Print Stepper Motor Belts (F000093-2) as needed. (Note: One of the Belts goes around the Print Platen Roller Gear (D910109) Attach Belt to pulley first then roll the Motor up to set into place.

  • Page 67: Remove The Card Path Step Mount Assembly (D940258)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove the Card Path Step Mount Assembly (D940258) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove the Covers. Remove the Card Path. Suggestion: Lay the printer on the front side for ease of accessing the motors.
  • Page 68 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove 2 screws (F000191) from the Mount. Lift out the Mount. Replace if necessary Reverse Assembly to complete the replacement procedure. Cable Routing shown. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 69: Remove/Replace The Lamination Mechanism (D940009) (Transfer Arm)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Lamination Mechanism (D940009) (Transfer Arm) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove Top/Rear Covers Remove the Fan Box/Bracket Assembly Important: This procedure can only be performed by authorized service personnel.
  • Page 70 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Disconnect the Lam Up/Down Motor Connection Disconnect the Heater Wire 1 ((J3) and the RTD 1 (J17) from the Auxiliary Board (A940221-10) Remove the three (3) screws (F000177) that attach the Transfer Arm (D940009) to the Main Chassis Frame.
  • Page 71 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure IMPORTANT NOTE: Tilt the roller when replacing back into the frame- DO NOT scratch the roller. Verify LAM CAM Postion when replacing the Arm Reverse the instructions to re-assemble. See below for the Motor (D910072) or Sensor (D910216) replacement.

  • Page 72: Remove/Replace The Transfer Arm Motor (D910072) Or Up/Down Sensor (D910216)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Transfer Arm Motor (D910072) or Up/Down Sensor (D910216) Tools needed: T10 (Torx )Driver Estimated Time: Preparation: Remove Top/Rear Covers. Remove the Fan Box/Bracket Assembly. Remove the complete Transfer Arm to access the motor and sensor.
  • Page 73 HDP8500 Service Manual, PLT-01583, 1.1 Replace the 3 screws on the Motor. Remove 2 screws (F000417) to remove and replace the Lift Sensor (D910216) Be careful of the Sensor when removing and replacing the Motor Cam. Move the Cam to the side to clear the Sensor.
  • Page 74 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure IMPORTANT NOTE: Tilt the roller when replacing back into the frame- DO NOT scratch the roller. Final position before replacing the assembly. Reverse the instructions to re-assemble. Refer to Appendix A for Cable Connection diagram.

  • Page 75: Remove/Replace The Ribbon Sensor (D910556)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Ribbon Sensor (D910556) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove the Covers. Remove the Card Path Remove the Fan Box Bracket Remove the Main Chassis Important: This procedure can only be performed by authorized service personnel.

  • Page 76: Installing The Printhead

    HDP8500 Service Manual, PLT-01583, 1.1 Installing the Printhead Kit Part Number: 088934 Tools needed: T10 (Torx )Driver Estimated Repair Time: 30 minutes Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Power off the Printer by unplugging the power cord from the Printer.
  • Page 77 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Unplug the RTD Wire Cable, Heater Wire Cable, and Interconnect Cable (with small com board D940171) from the Auxiliary Board (A920221-10). Remove the 3 screws holding the Auxiliary Board (A920221-10) to the frame.
  • Page 78 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the Ethernet/USB box. Remove two screws from the BOX base. Pull the box forward and slide to the RIGHT then OUT. Doing this will release the box from the PCB board (Ethernet/ USB Connection ) directly behind the box.
  • Page 79 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Gently pull the hoses from the Printer. Disconnect the 2 Fan Cable from the Fan Box. Disconnect the MAG wires from the back of the Fan Box. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 80 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Disconnect the wires from the tie wrap on the Fan Box. Disconnect the Ribbon Cable from the D000445 Board ( attached to the Fan Box Riser) Set aside the Fan Box and Fan Box Riser.
  • Page 81 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure The Printhead Motor Mount (D910052) is now accessible. Remove the Printhead Motor Mount (D910052). Remove the one (1) screw that holds the Motor Mount to the Frame, as shown below. (Note: The Mount should be “flush” with the Frame when properly fitted.)
  • Page 82 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the ground strap of the Printhead. Unplug the Printhead Motor Mount Connectors. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 83 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Lift out the Printhead Motor Mount assembly. Carefully lift out the complete Printhead Assembly (D910515). © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 84 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Complete the replacement by doing the following steps. See below for details. a. Replace the complete Printhead Assembly. IMPORTANT NOTE: Locate the Printhead Resistance value stamped on the printhead BEFORE installing. This VALUE is needed for step 26 b.
  • Page 85 HDP8500 Service Manual, PLT-01583, 1.1 Note how the Print Platen Roller Slot would fit properly onto the Roller bushing, as shown from the back side (below). © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 86 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Careful when replacing the Printhead Motor Mount (D910052) Replace Fan Box and all cables, Ethernet/USB Box, and Auxiliary Board. Replace Covers in reverse assembly. You have completed this procedure. Open the Driver Toolbox then Advanced Settings. Change/verify the Printhead Resistance value.

  • Page 87: Flipper Table Remove/Replace Procedures

    HDP8500 Service Manual, PLT-01583, 1.1 Flipper Table Remove/Replace Procedures In order to access the Flipper Module please remove the Rear/Top Cover, the Front Panel, and the Output Cover. Refer to the procedures for: 1. Top/Rear Cover D940089 2. Front Panel Cover D940201-01 3.

  • Page 88: Remove/Replace The Output Roller Assembly (D910404)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Output Roller Assembly (D910404) Tools needed: Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Front Panel Remove the Output Cover. Important: This procedure can only be performed by authorized service personnel.
  • Page 89 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure The Output Roller Assembly (D910404) clips into the two (2) slots on either side of the Frame. Gently pull the Assembly from the Sensor side Frame just enough for the Assembly to be pulled out from its slots.
  • Page 90 HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Flipper Output Roller (D900123) Tools needed: Philip driver, E-Clip Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Front Panel Remove the Output Cover. Important: This procedure can only be performed by authorized service personnel.
  • Page 91 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the E-Clip from the Sensor side of the Flipper Table Shaft and the bushing (760343). NOTE: the bushing has a flat side that fits into the frame. Remove the E-Clip from the Motor side and the bushing.

  • Page 92: Remove/ Replace The Table Or Flip Home Sensor (D900249)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/ Replace the Table or Flip Home Sensor (D900249) Tools needed: 10 Torx drive; Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Front Panel Remove the Output Cover. This Sensor bundle connects to J3 on the Flipper Main Board. The Sensor bundle contains three (3) optical Sensors used for the Card Input Sensor, Flipper Home Sensor and Table Sensor.

  • Page 93: Remove/ Replace The Flipper Motor (D900523)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/ Replace the Flipper Motor (D900523) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Front Panel Remove the Output Cover. Important: This procedure can only be performed by authorized service personnel.

  • Page 94: Remove/ Replace The Card Feed Motor (D900524)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/ Replace the Card Feed Motor (D900524) Tools needed: Philip screwdriver Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Front Panel Remove the Output Cover. Important: This procedure can only be performed by authorized service personnel.

  • Page 95: Remove/Replace The Flipper Main Board (A000394)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Flipper Main Board (A000394) Tools needed: T10 Torx Driver, screwdriver. Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Front Panel Remove the Output Cover Important: This procedure can only be performed by authorized service personnel.
  • Page 96 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Reconnect the cables. See Ribbon Cable routing below. Reverse the instructions to re-assemble. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 97: Remove/Replace The Accessory Board (A000451)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Accessory Board (A000451) Tools needed: T10 Driver Estimated Time: 30 minutes Preparation: Remove Rear/Top Covers. Remove the Front Panel Remove the Output Cover Important: This procedure can only be performed by authorized service personnel.

  • Page 98: Lamination Module Remove/Replace Procedures

    HDP8500 Service Manual, PLT-01583, 1.1 Lamination Module Remove/Replace Procedures Important: These procedures can only be performed by authorized service personnel. Use this procedure for the replacements of all parts. All Covers must be removed to access the parts within the lamination module. All media must be removed for these procedures.
  • Page 99 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove Covers Remove 6 screws from the Rear cover (D940073-02). Remove 5 screws from the Top cover. Lift up and off frame Remove 6 screws from the Rear cover (D940073-02). Remove 5 screws from the Front cover (D940222-01)
  • Page 100 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove 2 screws from the Output cover (D940226-02). Lift covers off frame and set aside. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 101: Remove/Replace The Cleaning Roller (D940203)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Cleaning Roller (D940203) Cleaning Output Assembly Tools needed: Needle Nose Pliers- Estimated Time: 30 minutes Preparation: Remove the Lamination Module Covers. Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Turn OFF the Printer and unplug the power cord from the Printer.
  • Page 102 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure The long end goes to the RIGHT Side. Ensure the flat on the Bearing (D940169) is aligned with the flat hole in the sideplate. Remove the gear and clip 140048 to replace the roller Reverse the instructions to re-assemble.

  • Page 103: Remove/Replace The Cleaning Roller Idler (D940102)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Cleaning Roller Idler (D940102) Cleaning Output Assembly Tools needed: E-Clip tool, Estimated Time: 30 minutes Preparation: Remove the Lamination Module Covers. Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Turn OFF the Printer and unplug the power cord from the Printer.
  • Page 104 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure The long end goes to the RIGHT Side. Ensure the flat on the Bearing (760343) is aligned with the flat hole in the sideplate. Remove the gear and clip 140048 to replace the roller Reverse the instructions to re-assemble.

  • Page 105: Remove/Replace The Roller Transport Idler (D940108)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Roller Transport Idler (D940108) Cleaning Output Assembly Tools needed: E-Clip Estimated Time: 30 minutes Preparation: Remove the Lamination Module Covers. Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Turn OFF the Printer and unplug the power cord from the Printer.
  • Page 106 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Remove the retaining ring(140062) and washer (F000450) Release the spring from the tab (D940254) (continued next page) © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 107 HDP8500 Service Manual, PLT-01583, 1.1 The long end goes to the RIGHT Side. Ensure the flat on the Bearing (760343) is aligned with the flat hole in the sideplate. Remove the gear and clip 140048 to replace the roller Reverse the instructions to re-assemble.

  • Page 108: Remove/Replace The Film Mark Sensor (D920155) Upper And Lower

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Film Mark Sensor (D920155) Upper and Lower Tools needed: Needle Nose Pliers Estimated Time: 30 minutes Preparation: Remove the Covers. Important: This procedure can only be performed by authorized service personnel. D920155 is located on the CenterPlate Exit D920027...
  • Page 109 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure To remove Lower Sensor (D920155), repeat Step 1 to 4. (Note: The second drive roller, gear, pulley needs to be removed first for easy access.) a. Remove the metal roller (D920137) by sliding out.
  • Page 110 HDP8500 Service Manual, PLT-01583, 1.1 Reconnect the wire at the Main Board. Reverse the instructions to re-assemble. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 111: Remove/Replace The Lamination Module Main Board (A940221)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Lamination Module Main Board (A940221) Tools needed: 10T Torx driver; Estimated Time: 30 minutes Preparation: Remove the Covers. Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Turn OFF the Printer and unplug the power cord from the Printer.
  • Page 112 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure Replace it with the new Main Board. Reconnect the cables. Refer to Appendix A for Cable Connection diagram. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 113: Remove/Replace The Stepper Motor Assembly (D930413) And Belt (F000428)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Stepper Motor Assembly (D930413) and Belt (F000428) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove the Covers. Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Turn OFF the Printer and unplug the power cord from the Printer.
  • Page 114 HDP8500 Service Manual, PLT-01583, 1.1 Step Procedure The self adjusting Spring (F000332) will fall out. (Note: This will be replaced when the new Motor is installed.) Install the new Motor. Loosely install the four (4) screws. Work the Belt (F000428) back onto the Motor Shaft.

  • Page 115: Remove/Replace The Upper And Lower Take-Up Motor (D920189)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Upper and Lower Take-up Motor (D920189) Tools needed: Estimated Time: 30 minutes Preparation: Remove the Covers. Important: This procedure can only be performed by authorized service personnel. The same part number is used for both the Single and Dual Lamination Modules.
  • Page 116 HDP8500 Service Manual, PLT-01583, 1.1 Display A (Lower Motor): See Step 4 in this procedure. Display B (Upper Motor): See Step 4 in this procedure. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 117 HDP8500 Service Manual, PLT-01583, 1.1 Display C: See Step 5 in this procedure. Display D: See Step 5 in this procedure. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 118: Remove/Replace The Rewind Motor (D900406) Gear (D920170)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Rewind Motor (D900406) Gear (D920170) Tools needed: Small flathead screwdriver; a hook tool for O-Ring. Estimated Time: 30 minutes Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 119 HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Rewind Motor (D900406) and Gear (D920170) (cont.) Step Procedure Reverse the instructions to re-assemble. a. Line up the bottom of the Rewind Motor on the tabs. b. Snap the top rewind Motor to the Frame into the tab provided.

  • Page 120: Remove/Replace The Rfid Board For The Rewind Motors (A000365-01); Printer Mount

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the RFID Board for the Rewind Motors (A000365-01); Printer Mount Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove the Covers. Important: This procedure can only be performed by authorized service personnel.
  • Page 121 HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the RFID Board for the Rewind Motors (A000365-01) Display A: See Step 4 in this procedure. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 122: Remove/Replace The Lamination Head (D920022) And (D920023)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Lamination Head (D920022) and (D920023) Tools needed: T10 Torx Driver Estimated Time: 30 minutes Preparation: Remove the Covers.. Important: This procedure can only be performed by authorized service personnel. This part is sold as one assembly which includes the Film LED (A000454) Head Lift Sensor (E000186) Thermocouple RTD (A000449) and the wires.

  • Page 123: Remove/Replace The Hopper Full Sensor (D940295)

    HDP8500 Service Manual, PLT-01583, 1.1 Remove/Replace the Hopper Full Sensor (D940295) Tools needed: T10 Torx Driver; Estimated Time: 15 minutes Preparation: Remove the Covers. Important: This procedure can only be performed by authorized service personnel. Step Procedure Caution: Turn OFF the Printer and unplug the power cord from the Printer.

  • Page 124: Appendix A Board & Wire Connections

    HDP8500 Service Manual, PLT-01583, 1.1 Appendix A Board & Wire Connections Mainboard (A940234) Cable Connection – Main Chassis Image shown is Printer Main Chassis wire connections to the Mainboard. © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 125: Mainboard (A940234) Cable Connection -Keypad/Led Cable (D855013)

    HDP8500 Service Manual, PLT-01583, 1.1 Mainboard (A940234) Cable Connection -Keypad/LED cable (D855013) © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 126: Mainboard (A940234) Cable Connection -Power Cable

    HDP8500 Service Manual, PLT-01583, 1.1 Mainboard (A940234) Cable Connection –Power Cable © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 127: Mainboard (A940234) Cable Connection - Card Path Film Transfer Fan, Pick Sensor, Flattener Up/Down Sensor, Lam Motor (D940213)

    HDP8500 Service Manual, PLT-01583, 1.1 Mainboard (A940234) Cable Connection – Card Path Film Transfer Fan, Pick Sensor, Flattener Up/Down Sensor, Lam Motor (D940213) D940213 © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 128: Auxiliary Board (A920221-10) Cable Connection

    HDP8500 Service Manual, PLT-01583, 1.1 Auxiliary Board (A920221-10) Cable Connection © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 129: Lamination Module Mainboard Connection

    HDP8500 Service Manual, PLT-01583, 1.1 Lamination Module Mainboard connection © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 130: Lamination Board Hopper Full Sensor Connection

    HDP8500 Service Manual, PLT-01583, 1.1 Lamination board Hopper Full Sensor connection Lamination board Card Sensor connection © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.

  • Page 131: Lamination Module Cable Routing

    HDP8500 Service Manual, PLT-01583, 1.1 Lamination Module Cable Routing Gather all wires together and secure with tie wrap (140069) © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
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