Magtek ExpressCard 2000 Hardware Service Manual page 55

3 - Preventive Maintenance Procedure (EC2000)
Figure 3-10 - Using Inspection Mirror to Check Tine / Hammer Alignment (TOP VIEW FROM FRONT)
Figure 3-11 - Bad Embosser Wheel Alignment (Figure 3-10 MAGNIFIED)
6) If any cones are broken or bent, replace the characters in the same location if possible. If replacement
is not feasible, cut off the top and bottom tines using the diagonal side cutters, remove the character
from the tines, and install it to another set of tines, and re-map the character to another tine after
preventive maintenance is complete and the device is powered on (see section 5.22 How to Remove /
Re-install Embosser Fonts and section 2.9.4 How to Use the Character Mapping Page).
7) Check the embosser wheel alignment by standing in front of the device and looking straight down at
the embosser. Use an inspection mirror as shown in Figure 3-10 so you can see the cone on the
bottom of the current character and the hole in the embosser hammer. Figure 3-11 shows a cone and
hole that are not properly aligned.
8) Check embossed character heights using the steps in section 6.6 How to Calibrate the Embosser,
and adjust them if necessary to account for normal wear. Pay special attention to any characters you
have replaced or re-mapped.
9) Note the position of the top and bottom knuckles in case they move during the following steps.
10) Add 2 drops of Teflon lubricant to the left and right sides of the shaft that holds the top embosser
knuckle, between the sides of the knuckle and the rocker arm.
ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual
Page 55 of 356 (D99875607-91)