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Fargo DTC1000Me Service Manual

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15370 Barranca Parkway
Irvine, CA 92618-2215
USA
FARGO
© 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
®
DTC1000Me-DTC1250e-DTC4250e-DTC4500e

Card Printer Service Manual

PLT-01543 Rev 1.0
November 2013

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Table of Contents

   Also See for Fargo DTC1000Me

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   Summary of Contents for Fargo DTC1000Me

  • Page 1: Fargo ® Dtc1000me-dtc1250e-dtc4250e-dtc4500e

    15370 Barranca Parkway Irvine, CA 92618-2215 ® FARGO DTC1000Me-DTC1250e-DTC4250e-DTC4500e Card Printer Service Manual PLT-01543 Rev 1.0 November 2013 © 2013 HID Global Corporation/ASSA ABLOY AB. All rights reserved.
  • Page 2 M-F 9am – 6pm ATC (FR 8:30 - 17:00) support.hidglobal.com www.hidglobal.com HID GLOBAL, HID, the HID logo, DTC and FARGO are the trademarks or registered trademarks of HID Global Corporation, or its licensors, in the U.S. and other countries. November 2013...
  • Page 3: Table Of Contents

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 ® FARGO DTC1000Me-DTC1250e-DTC4250e-DTC4500e ................1 Card Printer Service Manual ........................1 Introduction ..............................5 Safety Messages (review carefully) ......................6 Tools need for DTC Card Printer repair- replacement procedures ................7 Cover Removal Procedures ........................8 Remove/Replace Printer Covers DTC 1000Me- 1250e Single Side ................
  • Page 4 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Appendix C ............................... 127 Lamination Module Mainboard connections ....................... 127 Upper Sensing Cables ............................127 Feed & Lower Sensing Cables ..........................128 Upper Lam Head Cables ............................129 Lower Lam Head Cables ............................130 Lower Motor Cables ...............................
  • Page 5: Introduction

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Introduction The service manual serves to inform the technician about the DTC Card Printer & Dual-Sided Printing Module & Lamination Module parts replacement procedures. Important: These procedures can only be performed by authorized service personnel.
  • Page 6: Safety Messages (review Carefully)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Safety Messages (review carefully) The purpose of this section is to provide the User with specific replacement procedures for the Card Printer. Please review standard precautions (to take) while performing these replacement procedures.
  • Page 7: Tools Need For Dtc Card Printer Repair- Replacement Procedures

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Tools need for DTC Card Printer repair- replacement procedures T10 Torx screwdriver E Clip tool Small flathead screwdriver Needle Nose Pliers (NOTE: HID Global offers a kit that contains many of the tools needed to repair the printers.
  • Page 8: Cover Removal Procedures

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Cover Removal Procedures Remove/Replace Printer Covers DTC 1000Me- 1250e Single Side Tools needed: T10 Torx screwdriver Estimated Repair Time: 15 minutes Preparation: Important: This procedure can only be performed by authorized service personnel.
  • Page 9 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the 2 screws (F000178) that hold the side covers to the frame. Remove both side covers. The input and output hoppers are attached to the side covers. Remove the 2 screws on the bottom right and left side to remove the inner back cover.
  • Page 10: Dtc Flipper Short Dual-sided Printing Module Removal

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 DTC Flipper SHORT Dual-Sided Printing Module Removal Complete Short Flipper Assembly D930010-04 DTC1250e Dual side D930010-06 DTC4250e & 4500e Short Flipper Tools needed: T10 Torx screwdriver DTC4250e DTC1250e Dual Estimated Repair Time: 15 minutes...
  • Page 11 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Top Cover first in order to access the Flipper Module screw attachment. From the back of the printer locate and remove the 2 screws and washers. Remove the Top Cover.
  • Page 12 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove one (1) screw (F000178) that attaches the Flipper Module to the Printer. Detach the cable from J23 on the mainboard. November 2013...
  • Page 13 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Tilt the Flipper Module back to release the 3 tabs from the bottom of the printer; NOTE: Your printer may or may not have screws holding the Module to the Printer depending on the serial number.
  • Page 14: Dtc1250e Dual - Dtc4250e Single Printer Cover Removal

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 DTC1250e DUAL - DTC4250e Single Printer Cover Removal (NOTE: Use this procedure for removing the covers of the DTC1250e DUAL & DTC4250e printer cover AFTER the Dual-Sided Printing Module has been removed.)
  • Page 15 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Caution: Turn OFF the Printer and unplug the power cord from the Printer. From the back of the printer locate and remove the 2 screws and washers. Remove the Top Cover.
  • Page 16 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure To Remove the Display: With the Top Cover removed, unsnap the display by pivoting from the top DOWN to release the bottom tabs. Remove the ribbon cable from the mainboard.
  • Page 17 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Input Hopper by tilting back and away from the frame. There are tabs at the bottom that hold the hopper to the frame. Remove the screw that holds the Output Cover in place.
  • Page 18 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the outer back cover by releasing the tabs on the right and left side. Tilt cover down to release the bottom tabs. November 2013...
  • Page 19 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the 2 screws on the bottom right and left side to remove the inner back cover. Right Side Left Side Lift UP the bottom of this cover to release the upper tabs that hold the cover to the frame.
  • Page 20: Dtc4500e Single Side Printer Cover Removal

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 DTC4500e Single Side Printer Cover Removal Tools needed: T10 Torx screwdriver Estimated Repair Time: 15 minutes Preparation: Important: This procedure can only be performed by authorized service personnel. Top Cover D930181-01 Display Cover/PCB/cable...
  • Page 21 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure From the back of the printer locate and remove the 2 screws and washers. Remove the Top Cover. Unsnap the release tabs located on the back of the printer. Lift the Top Cover from the front edge and tilt up and back.
  • Page 22 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure NOTE: In some cases you may need to remove the Display. Unsnap the display by pivoting from the top DOWN to release the bottom tabs. Remove the ribbon cable from the mainboard.
  • Page 23 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove 2 screws (F000178) from the bottom of the Printer. Release the cable connection. Remove the Input Hopper by tilting back and away from the frame. There are tabs at the bottom that hold the hopper to the frame.
  • Page 24 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Tilt down and remove the Output Cover. Remove the Back Cover. Remove the 2 screws and washers. Release for 2 tabs at the front and tilt back to release. November 2013...
  • Page 25 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Lift UP the bottom of this cover to release the upper tab locks that hold the cover to the frame. Reverse assembly instructions for replacing the covers. November 2013...
  • Page 26: Dtc4500e Lamination Module Cover Removal

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 DTC4500e Lamination Module Cover Removal NOTE: Remove the Lamination Module prior to removing the printer covers if repairing the PRINTER. The Lamination Module does not need to be removed in order to repair the Lamination Module (unless replacing the Lamination Mainboard).
  • Page 27 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Lift up the Top Cover (D930294-01) to unsnap it from the module. Open from front door. Unsnap to loosen the 2 side tabs located on either side of the Lam Input Cover (D930290-01) (It is not necessary to remove the Lam Input assembly to remove this front plate.)
  • Page 28 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Open the Flipper Door. Remove the 2 screws (F000178) from the left side. Picture shows door removed, but not necessary for Lamination cover removal. Remove 1 screw (F000178) from the blue retainer clip (D930077).
  • Page 29 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Unsnap the Lam Back Cover (D930293-02) panel from the bottom and lift up to remove. Make NOTE: of the latches holding these together when replacing it. Remove the Front Lam Door Cover (D930291-01) by flexing the door IN, release the top and bottom pins holding the door to the frame.
  • Page 30: Complete Lamination Module Removal

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Complete Lamination Module Removal If the Lamination Module needs to be removed from the printer completely then turn the printer over and unscrew the 2 screws that attach the Lamination Module to the printer.
  • Page 31 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Set the printer upright and move to the edge of the table. Unclip the tabs from below and move the module outward. This will release the PCB connection within the door.
  • Page 32: Parts Replacement- Printer

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Parts Replacement- Printer Remove/Replace the Mainboard Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel. DTC1000Me...
  • Page 33 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Slide board out from the corner posts Install new board and reconnect all wires. Wires are labeled for location connection. Procedure is complete. November 2013...
  • Page 34: Remove/replace The Display Assembly (mdp-00093 Dtc4250e/4500e)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Display Assembly (MDP-00093 DTC4250e/4500e) (MDP-00059 DTC1250e) Contains Cover, PCB, LCD Buttons and Cable The same procedure is used for either orientation of the LCD Display. Tools needed: T10 Torx screwdriver...
  • Page 35 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Install completed assembly. Do not pinch the cable when replacing. Pull cable taught when replacing. Procedure is complete. November 2013...
  • Page 36: Remove/replace The Stepper Motor D930027, Stepper Belt F000424, Pulley D900430

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Stepper Motor D930027, Stepper Belt F000424, Pulley D900430 Tools needed: T10 Torx screwdriver E CLIP tool Estimated Repair Time: 30 min Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 37 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the 3 screws that hold the Motor/Mount to the printer frame. (Make NOTE: of where the 2 screw/washers go and the one machine screw. Remove the printhead cable for more clearance) The motor is attached to a plastic mounting frame.
  • Page 38 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure If replacing the Pulley D900430 remove the E CLIP (140063). Replace with new Pulley. Re-install the E-clip. Replace the new Motor to the mount frame. Make sure Spring (F000332) gets put back into proper place...
  • Page 39 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure This Stepper Motor Mount provides a self tensioning feature. Keep the four (4) screws loose while holding the Mount Frame. Allow the spring to self-tension, then tighten the four (4) screws.
  • Page 40 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Fit the Mount behind the tab on the printers side plate frame. This locks the mount in place. Secure the stepper drive assembly with 2 screws (F000171) with 2 washers (140040), and one screw (F000178) at the specific locations shown.
  • Page 41 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Plug motor cable back in. Replace the Printhead cable if it was removed in step 4. Procedure is complete. November 2013...
  • Page 42: Remove/replace The Mag Roller (d930122)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Mag Roller (D930122) Tools needed: Small flat screwdriver, T10 Torx screwdriver Estimated Repair Time: 20 min Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 43 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Mag Roller Gear (D930361) by pulling out. Release the tabs that Remove the Ribbon Deflector Plate (D930129) to access the Mag Roller. hold the plate in place. Pull the Mag Roller out from the front side of the printer.
  • Page 44 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Replace with the new roller. Install the Mag Roller from the back to hold the roller in place. Make sure roller sits in front tab (hidden) in front sideplate. Make sure tabs line up and snap into place. Wiggle in place.
  • Page 45: Remove/replace The Output Roller (d930123) Pinch Roller-spring (d920013-f000338)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Output Roller (D930123) Pinch Roller-spring (D920013-F000338) Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 46 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Flip printer on front remove Output Roller (D930123) Pull straight up and out Replace with new roller and replace the gear onto the roller. Procedure completed. Pinch Roller and Spring Remove the output roller first ( as stated above) and then remove the Pinch Roller Use a small flathead screwdriver to release the spring (F000338) and the Pinch Roller (D920013).
  • Page 47: Remove/replace The Platen Roller (d930120) & Pulley/gear (d900429)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Platen Roller (D930120) & Pulley/Gear (D900429) Tools needed: T10 Torx screwdriver Estimated Repair Time: 45 min Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 48 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Turn the twist lock Bushing-Twist Lock (D930178) counter clockwise to unlock and lift up. It is not necessary to remove the surrounding gears. Remove the Platen Cam (D930135). Rotate cam clockwise to remove. Pull off of the Platen Roller Shaft.
  • Page 49 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the print head assembly if better access is needed. See Printhead removal procedure Replacing the DTC Printhead. Move the lever up to clear the Platen Roller (D930120) Replace with new roller.
  • Page 50: Remove/replace The Lift Pinch Roller Assembly (d930137) Pinch Lift Bracket (d930136)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Lift Pinch Roller Assembly (D930137) Pinch Lift Bracket (D930136) Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 Min D930137 Preparation: . Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 51 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Rotate the Lift Bracket (D930136) with the spring (D930266) upwards to disengage the hinge. Lift out the Pinch Roller Bracket (D930137). NOTE: Verify orientation when re installing. Replace with new Platen Roller.
  • Page 52 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure To reinstall the Pinch Roller Assembly: a. Verify orientation of the Pinch Roller Assembly b. Connect the spring to the bracket. Continued next page c. Insert the Bracket tabs into the holes provided in the sideplate frame.
  • Page 53 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 d. Tilt the spring upward and fit in to the slot provided. Some force is needed to snap the spring and tabs in place. e. Click the Bracket into the frame. f. Snap the Roller Bracket tabs to the Lift Bracket.
  • Page 54 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 g. Procedure is complete. November 2013...
  • Page 55: Remove/replace The Cleaning Roller (d930121), Input Feed Lever (d930132)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Cleaning Roller (D930121), Input Feed Lever (D930132), Input Lever Gear (D930164) Tools needed: T10 Torx screwdriver Estimated Repair Time: 30 min D930121 Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 56 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure NOTE: This step is used for the DTC 1250e, 1000Me, 4250e. Remove the Cleaning Roller Gear (D930361) Remove the stepper motor assembly and belt (D930028) Remove the pulley (e-clip) and washers.
  • Page 57 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure From the front of the printer release the cleaning roller from the peg by pushing all the way back and dropping the roller. NOTE: Do not hold the roller by the rubber but only from the plastic shaft. The rubber can move out of position on the shaft and cause a print quality issue.
  • Page 58: Remove/replace Supply Spindle Rfid Motor

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace Supply Spindle RFID Motor Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min 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 59 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Slide the Supply Spindle DOWN To release. Slide the Motor UP to install. NOTE: You do not need to remove the gears or the Stepper Motor for this procedure. NOTE: If ribbon wrinkle occurs after replacing the motor, move the motor assembly DOWN slightly in the frame.
  • Page 60: Remove/replace Ribbon Take-up Motor (d930014)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace Ribbon Take-Up Motor (D930014) Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min Preparation: Remove the Covers Important: This procedure can only be performed by D930014 authorized service personnel. Step Procedure Caution: Turn OFF the Printer and unplug the power cord from the Printer.
  • Page 61 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the wire connection (D930600) harness from the top of the Take-Up Motor. Replace the complete assembly Motor. Reconnect wires. Procedure is complete. November 2013...
  • Page 62: Remove/replace Encoder Sensor (a930514) For Rfid Supply Spindle

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace Encoder Sensor (A930514) for RFID Supply Spindle NOTE: For any other parts (motor/ encoder wheel) REPLACE COMPLETE ASSEMBLY (D930015). Tools needed: Torx screwdriver and flat head screwdriver Estimated Repair Time: 30 min...
  • Page 63 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Damper Cap (F000487) Use a thin flathead screwdriver to loosen one side. The cap will pop off. NOTE: Replace the Damper Cap by lining up the shaft first then snap the Damper Cap back on.
  • Page 64 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the supply cover (D930116) by pulling up from the open end. This will unlatch the tabs holding the cover to the frame. This allows for access to the sensor.
  • Page 65 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the sensor. Use a thin flat blade screwdriver to unlatch the tabs holding the sensor to the frame. Press the new sensor into the assembly; make sure the encoder wheel is in between the sensor.
  • Page 66: Remove/replace The Pcb Board (a000365-01)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the PCB board (A000365-01) Step Procedure Remove Supply Spindle-RFID assembly. See procedure above (D930015). Un-snap the PCB from the frame. The PCB with the HOLES is set under the corner tabs.
  • Page 67: Remove/replace Ribbon Sensor (d930016)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace Ribbon Sensor (D930016) Tools needed: T10 Torx screwdriver Estimated Repair Time: 30 min Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel. Ribbon Sensor Cable only D930608...
  • Page 68 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the screw F000178 & washer 140040 from the Stepper Motor assembly. This is done from the front of the printer. NOTE: DTC1250e/4250e will have 2 screws holding the Supply. DTC4500e has only one screw holding the supply.
  • Page 69 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the cleaning roller Gear (D930361) to access the Ribbon Sensor. From the front of the printer: Pinch the tabs to help remove the sensor from the frame. PUSH the Ribbon Sensor back to release the tabs and remove the sensor.
  • Page 70 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Replace with the new sensor. Push the sensor back in using the tabs to snap the sensor in place. This is done from the rear sideplate of the printer near the gears.
  • Page 71: Remove/replace Card Path/cover Sensor (d930613)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace Card Path/Cover Sensor (D930613) Tools needed: T10 Torx screwdriver Estimated Repair Time: 30 min 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 72 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Replace with the new sensor. Line up the sensor and push down to snap it in place UNDER the small tab. Route the cable on the right side of the frame as shown in the picture below.
  • Page 73: Parts Replacement - Dual-sided Printing Module

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Parts Replacement - Dual-Sided Printing Module D930010-04 (Short Module) used for DTC1250e Flipper complete assembly D930010-06 (Short Module) used for DTC4250e & 4500e Flipper complete assembly MDP-00104 (Tall Module) used for DTC4500e Flipper complete assembly IMPORTANT NOTE: The Flipper Table should be level when the Printer is powered up.
  • Page 74: Remove/replace The Flipper Cover

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Flipper Cover Tools needed: T10 Torx screwdriver Estimated Repair Time: 15 min Preparation: Remove the top cover of the Printer and Dual-Sided Printing Module from the Printer Important: This procedure can only be performed by authorized service personnel.
  • Page 75 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Dual-Sided Printing Module Top Cover. Grasp the cover from the open end and tilt forward to unlatch the front tabs. Remove the Flipper Base Cover: Turn the module over and use a T10 Torx screwdriver to remove the 2 screws of the bottom plate.
  • Page 76 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure The module is now ready to replace any of the following parts: Flipper Table with gear and rollers (D930611) Stepper Motor (E001192) with Gear connects to J5 Stepper Motor (E001192) Cable (D930610)
  • Page 77: Remove/replace The Flipper Table (d930011)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Flipper Table (D930011) Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min 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 78 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Lead Screw Assembly by pushing UP and pulling OUT from the bottom at an angle. Short Lead Screw D930155 Tall Lead Screw D930176 November 2013...
  • Page 79 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the one screw that holds the Flipper Table to the Bracket Table Mount Remove the Flipper Table. Reverse assembly to install new Flipper Table. Verify Lead Screw and Lead Pin is set correctly. Also see step 8 for spring and washer placement.
  • Page 80 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Verify the Lead Screw Assembly has the washer and spring in the correct position. Replace the twist lock. November 2013...
  • Page 81: Remove/replace The Flipper Feed Roller (d930149), Pinch Roller D920013 & F000338)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Flipper Feed Roller (D930149), Pinch Roller D920013 & F000338) Pinch Roller Gears (D30165 & D930166) Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 minutes Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 82 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Flipper Table from the Base Bracket by pinching the 2 side tabs inward to release the table from the base. Card Feed Roller (D930149) - Replace with the new Roller. Line up the roller and the tab slots and push together.
  • Page 83 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Pinch Roller (D920013) Insert spring into the roller and line up one end at a time. Gear (D930165 –D930166) placement shown below for pivot bracket. Verify the assembly is fully snapped together if these are replaced.
  • Page 84: Remove/replace The Flipper Assembly Stepper Motor - E001192

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Flipper Assembly Stepper Motor – E001192 Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 85: Remove/replace The Headlift Sensor/cable- D900113

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Headlift Sensor/Cable- D900113 Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min 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 86: Remove/replace The Ir Sensors D930609 (short) D930614 (tall)

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the IR Sensors D930609 (short) D930614 (tall) Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min Preparation: Remove the Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 87: Remove/replace The Pcb Output Controller -a930503

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the PCB Output Controller -A930503 Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min 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 88: Parts Replacement- Lamination Module

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Parts Replacement- Lamination Module Remove/Replace the Lamination Module Mainboard Tools needed: T10 Torx screwdriver Estimated Repair Time: 20 min Preparation: Remove the Lamination Module Covers Important: This procedure can only be performed by authorized service personnel.
  • Page 89 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove all the wire connections. Tilt the mainboard up to access the wires. Wires are labeled with the numbered location for easy replacement. (Refer to Appendix B for wire/board locations) Replace with the new mainboard using reverse assembly.
  • Page 90: Remove/replace The Lamination Head Assembly

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Lamination Head Assembly Upper Assembly (D920022) & Lower Assembly (D920023) Tools needed: T10 Torx screwdriver Estimated Repair Time: 35 min Preparation: Remove the Lamination Module Covers. Remove the mainboard to access the wire removal procedure.
  • Page 91 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Retaining Ring (140048) and Platen Drive Gear ( 810265) Remove the 3 screws (F000182) that hold the assembly to the frame. Upper Module Lower Module November 2013...
  • Page 92 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure With the Mainboard loosened and tilted back the wire connections are now accessible. Locate the Lamination Head Assembly wire connections. Remove these wires from the mainboard. Location of Upper Lam Head Cables...
  • Page 93 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 NOTE: Ensure there is cable slack between the lam head and the upper wire clip to allow free movement of the lam head. Do not pinch any wires. Make NOTE: of how the wires are routed. LOWER ASSEMBLY...
  • Page 94 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 NOTE: Ensure there is cable slack between the lam head and the lower wire clip to allow free movement of the lam head. Do not pinch any wires. November 2013...
  • Page 95: Remove/replace The Lamination Module Rollers

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Lamination Module Rollers Roller- Feed High Cof (D920119-01) Roller- Input Flipside (D920218) Roller- Input (D920015) Tools needed: T10 Torx screwdriver Estimated Repair Time: 30 min Preparation: Remove the Lamination Module Covers.
  • Page 96 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure To replace D920218, Input Flipside Roller Remove the 3 screws (F000463) from the Stepper Motor Assembly. NOTE: Wire Routing Remove the retaining ring (140048) gear ( 810266) , white spacer ( F000156) and gear...
  • Page 97 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Unlock the shaft bushing (D900046) by twisting it counter clock wise. (TIP: Lift UP on the tab to unlock the pin underneath the tab.) Replace with the new roller (D920218).
  • Page 98 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the 3 screws (F000463) from the Stepper Motor Assembly in order to remove the roller on the right. November 2013...
  • Page 99 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure RIGHT ROLLER: Remove the retaining ring (140048) and Gear (8180266). Remove the Shaft Bushing. (D900046) Unlock the shaft bushing (D900046) by turning it counter clock wise. (TIP: Lift UP on the tab to unlock the pin underneath the tab.) Pull out the roller (D920119-01).
  • Page 100 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Replacing the Rollers (continued) To replace D920119-01, High COF Feed Roller (Left Roller) Remove the Lower Rewind Assembly to access the Left roller (D920119-01). Remove/Replace the Rewind Motor Assembly RFID Board A000365-01 LEFT ROLLER: Remove the retaining ring ( 140048) Remove the pulley (D850190).
  • Page 101 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the next retaining ring (140048). Remove the gear (810266). Remove the wave washer (130951). NOTE: Orientation of wave washer- concave side down when replacing. November 2013...
  • Page 102 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Shaft Bushing. (D900046) Unlock the shaft bushing (D900046) by turning it counter clock wise. (TIP: Lift UP on the tab to unlock the pin underneath the tab.) Remove the roller ( D920119-01) C-10 Replace with the new roller (D920119-01).
  • Page 103 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure C-11 Reverse assembly to complete the roller replacement. A new belt (220082) may be replaced if necessary. C-12 TIP: Orient the flat side of the shaft facing RIGHT on both rollers when replacing the pulley.
  • Page 104 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Replacing the Rollers (continued) To replace D920015, Input Feed Roller. Remove the Rewind Motor to access the roller. Remove/Replace the Rewind Motor Assembly Remove the retaining ring (140048) Remove the pulley. ( D850190) Pull up with the belt attached.
  • Page 105 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the Shaft Bushing. (D900046) Unlock the shaft bushing (D900046) by turning it counter clock wise. (TIP: Lift UP on the tab to unlock the pin underneath the tab.) Remove the Roller (D920015) Replace with the new roller (D920015).
  • Page 106 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure TIP: Orient the flat side of the shaft facing RIGHT on both rollers when replacing the pulley. Shows order of parts when replacing. November 2013...
  • Page 107: Remove/replace The Rewind Motor Assembly Rfid Board A000365-01

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Remove/Replace the Rewind Motor Assembly RFID Board A000365-01 Encoder Sensor A000126 Tools needed: T10 Torx screwdriver Estimated Repair Time: 30 min Preparation: Remove the Lamination Module Covers. Important: This procedure can only be performed by authorized service personnel.
  • Page 108 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure The Rewind Mount assembly (D900406) is attached at the bottom then snapped at the top. Unsnap the top of the assembly then pivot the assembly to the LEFT to release the encoder sensor from the encoder wheel.
  • Page 109 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Verify the Encoder Wheel is positioned properly between the Encoder Sensor. November 2013...
  • Page 110 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Replace the RFID PCB (A000365-01) Remove the Rewind Assembly as described above. Remove the Retaining Ring (140048) Gear (D920170) Remove the Encoder Wheel (810492) 2 screws hold the PCB (A000365-01) Slide the RFID PCB to the right.
  • Page 111: Replacing The Dtc Printhead

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Appendix A Replacing the DTC Printhead The guide serves to instruct the user about replacing the Printhead. This procedure can only be performed by authorized service personnel. Caution: Turn OFF the Printer and unplug the power cord from the Printer.
  • Page 112: Dtc Printhead Procedure

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 DTC Printhead procedure The guide serves to instruct the user about replacing the Printhead. This procedure can only be performed by authorized service personnel. Caution: Turn OFF the Printer and unplug the power cord from the Printer.
  • Page 113 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Use a flathead screwdriver to lift the cover from the frame. VERY IMPORTANT STEP Turn the gear clockwise until the Push Rod is in the DOWN position. (in relation to the printer base)
  • Page 114 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure correct position wrong position Pull the 2 tabs IN and pull UP to loosen the Printhead assembly. Hold UP until you can push the white rod to the right. Do not pull up until the push rod has been moved.
  • Page 115 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Unlock the push-rod by moving it from the left to the right side of the tab. November 2013...
  • Page 116 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure The printhead assembly can now be pulled up and out from the frame. The back side of Printhead assembly shown has been removed from the printer. November 2013...
  • Page 117 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Grasp the printhead mount and rotate to release the printhead from the main assembly. November 2013...
  • Page 118 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Remove the cable (D930602). Be careful not to damage the pins. Remove the Torx screw (F000170) and release the ground cable. Leave the wires in the main assembly. Before installing the new Printhead make NOTE: of the R=xxxx value. This number will be used after the Printhead is installed and ready to make the final adjustment.
  • Page 119 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Replace with the new printhead. Install the printhead assembly holes into the tabs and tilt to snap the printhead assembly into place. Verify the printhead is secure in the mount.
  • Page 120 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure VERY IMPORTANT STEP Reinstall the printhead mount assembly into the printer. Line up the Printhead assembly. IMPORTANT NOTE: Verify the white Push Rod is to the right of the assembly before reinserting.
  • Page 121 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Advanced Adjustment procedure Open the Toolbox to access Advanced Settings tab from the printer driver. Use the R=xxxx number from step 11. Add this number to the CURRENT box and click OK to save OR proceed to the TOF, EOF or LOF adjustments below.
  • Page 122 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure Adjust the Image Darkness, Print Top of Form (TOF), Print End of Form (EOF), Print Left of Form (LOF) as needed by increasing or decreasing the CURRENT setting numbers. NOTE: Refer to the Advances Settings section in the User Guide..
  • Page 123 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Step Procedure To adjust IMAGE DARKNESS: Increase the number to darken the image density or decrease the number to lighten the image density. Procedure is now complete. November 2013...
  • Page 124: Printer Mainboard Connections

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Appendix B Printer Mainboard connections J2-J4-J7-J12 Printhead Harness Cable (D930616) Printhead, Lift Stepper & Sensor, Fan November 2013...
  • Page 125 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Motor Harness Cable (D930600) Stepper Motor, Ribbon Supply, Ribbon Take-up RFID Cable (D930603) Encoder Cable (D930605) November 2013...
  • Page 126 DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 J10 (D930608) Ribbon Sensor Cable J11 (D930613) Card Path Cable November 2013...
  • Page 127: Lamination Module Mainboard Connections

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Appendix C Lamination Module Mainboard connections Upper Sensing Cables November 2013...
  • Page 128: Feed & Lower Sensing Cables

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Feed & Lower Sensing Cables November 2013...
  • Page 129: Upper Lam Head Cables

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Upper Lam Head Cables November 2013...
  • Page 130: Lower Lam Head Cables

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Lower Lam Head Cables November 2013...
  • Page 131: Lower Motor Cables

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Lower Motor Cables November 2013...
  • Page 132: Upper Rfid And Ribbon Cable

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Upper RFID and Ribbon Cable November 2013...
  • Page 133: Engineering Drawings

    DTC1000Me-1250e-4250e-4500e Card Printer Service Manual PLT-01543 rev 1.0 Appendix D Engineering Drawings November 2013...
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  • Ajay Jan 18, 2019 05:50:
    How to remove ribbon take up motor.