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Fargo HDP8500 Service Manual

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FARGO

HDP8500 Card Printer

SERVICE MANUAL

PLT-01583, 1.1

November 2013

15370 Barranca Parkway

Irvine, CA 92618

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Summary of HDP8500

Page 2: Liability Statement
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 2 liability statement do not attempt to operate or repair the direct-to-card printer without adequate training. Any use, operation, or repair in violation of this user guide is at your own risk. ...
Page 3
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 3 contacts north america europe, middle east and africa 15370 barranca parkway irvine, ca 92618 usa phone: 800 237 7769 fax: 949 732 2120 tech support: 866 607 7339, #6, m-f 7am-6pm cst phoenix r...
Page 4
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 4 hdp8500 parts replacement ....................................................................................................... 6 safety messages (review carefully) .............................
Page 5
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 5 flipper table remove/replace procedures ................................................................................. 87 remove/replace the output roller assembly (d910404) ...................
Page 6: Hdp8500 Parts Replacement
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 6 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 precaut...
Page 7
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 7 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 th...
Page 8
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 8 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 re...
Page 9
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 9 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 d94...
Page 11
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 11 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....
Page 12
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 12 step procedure 5 remove the cover open sensor cable. (a000125). * when replacing the rear cover do not tighten this screw at this step. 6 reverse the instructions to re-assemble or install a n...
Page 13
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 13 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 ...
Page 14
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 14 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 person...
Page 15
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 15 step procedure 3 remove (2) screws ( f000034) located in the inside hopper. ( philip driver) 4 remove (2) screws ( f000231) from the bottom side cover. (philip driver) 5 remove (1) screw(f0001...
Page 17
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 17 step procedure 7 there is a small tab that fits the cover under the hopper frame. 8 reverse the instructions to re-assemble or install a new cover. Tighten all the screws after the cover is co...
Page 18
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 18 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 perso...
Page 19
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 19 step procedure 4 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. 5 remove ...
Page 20
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 20 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 proced...
Page 21
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 21 step procedure 3 slide the cover hinge from the printer. 4 reverse the instructions to re-assemble or install a new door. *tighten all the screws after the cover is completely attached. 5 the ...
Page 22
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 22 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...
Page 23
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 23 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: thi...
Page 24
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 24 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 procedur...
Page 25
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 25 step procedure 3 remove the 3 screws holding the auxiliary board (a940221-10) to the frame. Unplug the power connection 140069 4 remove the ethernet/usb box. Remove two screws from the box bas...
Page 26
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 26 step procedure 6 gently pull the hoses from the printer. 7 disconnect the 2 fan cable from the fan box. 8 disconnect the mag wires from the back of the fan box. ..
Page 27
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 27 step procedure 9 disconnect the wires from the tie wrap on the fan box. 10 disconnect the ribbon cable from the d000445 board ( attached to the fan box riser) 11 remove the fan box and bracket...
Page 28
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 28 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 au...
Page 29
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 29 step procedure 3 remove 1 screw (f000178) that attaches the card path to the main chassis. 4 remove the 2 screws (f000170) that attach the card path to the power box frame..
Page 30
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 30 step procedure 5 remove 4 screws (f000192) that attach the main chassis to the card path. 6 slide the card path away from the main chassis. 7 disconnect all wire connection (or as many as are ...
Page 31
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 31 step procedure 8 when replacing the card path, align the card path to the main chassis 9 reverse the instructions to re-assemble. Refer to appendix a for cable connection diagram..
Page 32
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 32 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: th...
Page 33
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 33 step procedure 3 remove the 2 screws (f000192) from the front of the chassis. 4 disconnect the fi mag/printhead fan cable ( d940191) from the mainboard..
Page 34
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 34 step procedure 5 disconnect the film sensor and lam lift sensor cables from the transfer arm connection. 6 caution: do not damage the mainboard when removing or installing the main chassis. Ca...
Page 35
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 35 step procedure 7 when replacing the chassis line up the 3 square holes on the front frame and align the chassis into the notch on the frame. 8 reverse the instructions to re-assemble. Refer to...
Page 36: Printer Board Removal
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 36 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. Imp...
Page 37
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 37 step procedure 3 remove the 8 screws(f000170) from the mainboard. 4 remove the pcb cover ( d940133) when replacing the cover verify the flame sheild (d940267) is seated..
Page 38
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 38 step procedure 5 remove 1 screw (f000170) from the pcb station transistion board ( d940171) 6 remove 4 screws (f000170) from the pcb flip station interface & io board (d940195) 7 remove all ca...
Page 39
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 39 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 a...
Page 40
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 40 step procedure 3 remove the 3 screws holding the auxiliary board (a940221-10) to the frame. 4 when replacing the board insert the pcb into the tab of the base. 5 reverse the instructions to re...
Page 41
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 41 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 a...
Page 42
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 42 step procedure 3 lift up the cover from the usb pcb. 4 unplug the wire connection and lift up on the pcb(a910551) 5 reverse the instructions to re-assemble..
Page 43: Card Path Procedures
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 43 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 assemb...
Page 44
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 44 step procedure 4 feed wire through the hole and re connect the wire. 5 reverse the instructions to re-assemble..
Page 45
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 45 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. I...
Page 46
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 46 step procedure 3 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 sidepla...
Page 47
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 47 ensure the flat on the bearing is aligned with the flat in the sideplate hole. (continued next page) verify roller rolls freely 6 bottom roller #2 flattener roller (roller d940098 with bearing...
Page 48
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 48 step procedure 7 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 8 bot...
Page 49
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 49 verify roller rolls freely remove the gear d910112 and clip 140048 to replace the roller d940105 9 bottom roller #5 cleaning roller (d940100 with bearing d940169) ensure the flat on the bearin...
Page 50
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 50 step procedure 10 to replace top rollers. All rollers follow the same procedure. Top view 11 insert the d flat end into the grommet provided on the sideplate. Fit the bearing and the spring on...
Page 52
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 52 step procedure 12 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...
Page 53
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 53 step procedure 13 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. Remov...
Page 54
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 54 step procedure 14 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...
Page 55
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 55 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 impor...
Page 56
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 56 step procedure 5 remove the 4 screws (f000170) screws from the stepper motor. Remove the gear covering the upper right screw. ( not shown) 6 lift the motor from the frame. 7 reverse the instru...
Page 57
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 57 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: thi...
Page 58
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 58 step procedure 4 remove the gear ( d940252) and e-clip (140063) from the motor post. 5 remove 4 screws ( f000193) to release the motor from the frame. Lift motor up and out. 6 reverse the inst...
Page 59: Main Chassis Procedures
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 59 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 p...
Page 60
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 60 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. Pre...
Page 61
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 61 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/b...
Page 62
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 62 step procedure 3 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 o...
Page 63
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 63 6 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. 7 reverse the instructions to ...
Page 64
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 64 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. Suggest...
Page 65
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 65 step procedure 3 remove the 3 screws (f000177) that hold the motor (d910050) to the frame. Screws # 1 & 2 have washers ( 140040) 4 roll the motor (d910050) in a downward angle ccw to release t...
Page 66
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 66 step procedure 7 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) 8 attach belt to pulley first t...
Page 67
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 67 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...
Page 68
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 68 step procedure 3 remove 2 screws (f000191) from the mount. Lift out the mount. 4 replace if necessary reverse assembly to complete the replacement procedure. 5 cable routing shown..
Page 69
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 69 remove/replace the lamination mechanism (d940009) (transfer arm) only the motor and sensor is field replaceable. For any other parts please replace complete assembly. Tools needed: t10 torx dr...
Page 70
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 70 step procedure 4 disconnect the lam up/down motor connection 5 disconnect the heater wire 1 ((j3) and the rtd 1 (j17) from the auxiliary board (a940221-10) 6 remove the three (3) screws (f0001...
Page 71
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 71 step procedure 7 important note: tilt the roller when replacing back into the frame- do not scratch the roller. 8 verify lam cam postion when replacing the arm 9 reverse the instructions to re...
Page 72
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 72 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 asse...
Page 73
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 73 replace the 3 screws on the motor. 3 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 ...
Page 74
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 74 step procedure 4 important note: tilt the roller when replacing back into the frame- do not scratch the roller. Final position before replacing the assembly. 5 reverse the instructions to re-a...
Page 75
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 75 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 m...
Page 76: Installing The Printhead
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 76 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 personn...
Page 77
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 77 step procedure 5 unplug the rtd wire cable, heater wire cable, and interconnect cable (with small com board d940171) from the auxiliary board (a920221-10). 6 remove the 3 screws holding the au...
Page 78
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 78 step procedure 7 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 (eth...
Page 79
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 79 step procedure 10 gently pull the hoses from the printer. 11 disconnect the 2 fan cable from the fan box. 12 disconnect the mag wires from the back of the fan box. ..
Page 80
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 80 step procedure 13 disconnect the wires from the tie wrap on the fan box. 14 disconnect the ribbon cable from the d000445 board ( attached to the fan box riser) set aside the fan box and fan bo...
Page 81
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 81 step procedure 15 the printhead motor mount (d910052) is now accessible. 16 remove the printhead motor mount (d910052). Remove the one (1) screw that holds the motor mount to the frame, as sho...
Page 82
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 82 step procedure 17 remove the ground strap of the printhead. 18 unplug the printhead motor mount connectors..
Page 83
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 83 step procedure 19 lift out the printhead motor mount assembly. 20 carefully lift out the complete printhead assembly (d910515)..
Page 84
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 84 step procedure 21 complete the replacement by doing the following steps. See below for details. A. Replace the complete printhead assembly. Important note: locate the printhead resistance valu...
Page 85
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 85 23 note how the print platen roller slot would fit properly onto the roller bushing, as shown from the back side (below)..
Page 86
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 86 step procedure 24 careful when replacing the printhead motor mount (d910052) 25 replace fan box and all cables, ethernet/usb box, and auxiliary board. Replace covers in reverse assembly. You h...
Page 87
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 87 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 ...
Page 88
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 88 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: thi...
Page 89
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 89 step procedure 3 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...
Page 90
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 90 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 ...
Page 91
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 91 step procedure 3 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. 4 remove the e-clip fro...
Page 92
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 92 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 co...
Page 93
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 93 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. Import...
Page 94
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 94 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. ....
Page 95
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 95 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 ou...
Page 96
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 96 step procedure 8 reconnect the cables. See ribbon cable routing below. 9 reverse the instructions to re-assemble..
Page 97
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 97 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: ...
Page 98
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 98 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 ...
Page 99
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 99 step procedure remove covers 4 remove 6 screws from the rear cover (d940073-02). Remove 5 screws from the top cover. Lift up and off frame 5 remove 6 screws from the rear cover (d940073-02). 6...
Page 100
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 100 step procedure 7 remove 2 screws from the output cover (d940226-02). 8 lift covers off frame and set aside..
Page 101
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 101 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:...
Page 102
Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 102 step procedure 3 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 r...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 103 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: ...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 104 step procedure 3 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 ro...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 105 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 ...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 106 step procedure 3 remove the retaining ring(140062) and washer (f000450) release the spring from the tab (d940254) (continued next page).
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 107 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 4 reverse th...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 108 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...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 109 step procedure 6 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 (d92...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 110 8 reconnect the wire at the main board. 9 reverse the instructions to re-assemble..
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 111 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 perfo...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 112 step procedure 5 replace it with the new main board. 6 reconnect the cables. Refer to appendix a for cable connection diagram..
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 113 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 o...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 114 step procedure 7 the self adjusting spring (f000332) will fall out. (note: this will be replaced when the new motor is installed.) 8 install the new motor. Loosely install the four (4) screws...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 115 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 authoriz...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 116 display a (lower motor): see step 4 in this procedure. Display b (upper motor): see step 4 in this procedure..
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 118 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:...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 119 remove/replace the rewind motor (d900406) and gear (d920170) (cont.) step procedure 7 reverse the instructions to re-assemble. A. Line up the bottom of the rewind motor on the tabs. B. Snap t...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 120 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 proced...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 121 remove/replace the rfid board for the rewind motors (a000365-01) display a: see step 4 in this procedure..
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 122 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 perf...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 123 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 au...
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 124 appendix a board & wire connections mainboard (a940234) cable connection – main chassis image shown is printer main chassis wire connections to the mainboard..
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 127 mainboard (a940234) cable connection – card path film transfer fan, pick sensor, flattener up/down sensor, lam motor (d940213) d940213.
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 130 lamination board hopper full sensor connection lamination board card sensor connection.
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Hdp8500 service manual, plt-01583, 1.1 © 2013 hid global corporation/assa abloy ab. All rights reserved. 131 lamination module cable routing gather all wires together and secure with tie wrap (140069).
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