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Fargo HDP5000

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0% found this document useful (0 votes)

88 views137 pages

Fargo HDP5000

Uploaded by

Rashad Mammadov

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

15370 Barranca Parkway

Irvine, CA 92618

FARGO®
HDP®5000 (2013) & HDP®ii Plus
SERVICE MANUAL

Use this service manual for HDP5000 Card Printer part number 089600 to 089900 with serial
number cut in B3080651. HDPii Plus Card Printer part number 089382 with serial number
B3160607.

PLT-01656, Rev 1.0

HID GLOBAL CONFIDENTIAL AND/OR PROPRIETARY INFORMATION. This document contains confidential and/or proprietary information,
which may not be duplicated, published, disseminated or disclosed, or used for any purpose, without the written consent of HID Global
Corporation. If you are an unintended recipient of this information or are unwilling to accept the above restrictions, please immediately return
this document to HID Global Corporation, 15370 Barranca Pkwy, Irvine, CA 92618-3106..
HDP 5000 ( 2013) – HDPii PLUS Card Printer Service Manual PLT-01656 rev 1.0

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. You assume all liability reasonable to your use or
misuse of the Direct-to-Card Printer. HID Global Corporation assumes no liability whatsoever for damages of
any kind, including without limitation incidental, special or consequential damages. 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 and the HID logo 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.
Revision History
The revision number for this document will be updated to reflect changes, corrections, updates and
enhancements to this document.

Revision Control Date Document Title

Number

Revision 1.0 October 2013 HDP5000 ( 2013) & HDPii PLUS High Definition Card
Printer/Encoder Service Manual
VERIFY THE PRINTER PART NUMBER TO USE THIS
SERVICE MANUAL.

Use this service manual for HDP5000 Card Printer part

number 089600 to 089900 with serial number cut in
B3080651.
HDPii Plus Card Printer part number 089382 with serial
number B3160607.
**********************************************
If your HDP5000 Card Printer shows part number
089000 – 089555
Or HDPii (not PLUS) Card Printer then ref er to service
manual part number L000951.
Updated parts used for the HDP 5000 (2013) contain
parts that are NOT backwards compatible with the older
HDP printers.

October 2013 Page 2

HD GLOBAL CONFIDENTIAL AND/OR PROPRIETARY INFORMATION. This document contains confidential and/or proprietary information, which may not be
duplicated, published, disseminated or disclosed, or used for any purpose, without the written consent of HID Global Corporation. If you are an unintended recipient
of this information or are unwilling to accept the above restrictions, please immediately return this document to HID Global Corporation, 15370 Barranca Pkwy, Irvine,
CA 92618-3106..
HDP 5000 ( 2013) – HDPii PLUS Card Printer Service Manual PLT-01656 rev 1.0

Contacts

North America Europe, Middle East and Africa

15370 Barranca Parkway Phoenix Road

Irvine, CA 92618 Haverhill, Suffolk CB9 7AE
USA England
Phone: 800 237 7769 Phone: +44 1440 714 850
Fax: 949 732 2120 Fax: +44 1440 714 840
Tech Support: 866 607 7339, #6, M-F 7am-6pm CST Tech Support: +44 1440 711 822 M-F 9am – 5pm GMT
Asia Pacific Brazil

19/F 625 King’s Road Av Guido Caloi 1985 Prédio 18

North Point, Island East São Paulo – SP
Hong Kong CEP : 05802-140
Phone: 852 3160 9800 Phone: 55 11 5514-7100
Fax: 852 3160 4809 Fax: 55 11 5514-7109
Tech Support 852 3160 4895 M-F 9am – 6pm GMT +8 Tech Support: 55 11 5514-7110 M-F 9am – 6pm ATC
[Link]

October 2013 Page 3

Table of Contents
HDP5000 & HDPii Plus Parts Replacement _________________________________________________ 6
Safety Messages (review carefully) ________________________________________________________________ 7
Cover Replacement Procedures ___________________________________________________________________ 8
Reviewing the Sequence (used) To Avoid Damage _________________________________________________ 8
Reviewing the HDP Printer Covers______________________________________________________________ 9
Replacing the Front Door Assembly ____________________________________________________________ 10
Replacing the Back Cover Assembly ___________________________________________________________ 11
Replacing the Output Side Upgrade Cover _______________________________________________________ 12
Replacing the Output Side Cover ______________________________________________________________ 13
Replacing the Top Cover_____________________________________________________________________ 14
Replacing the Bezel Front Cover ______________________________________________________________ 15
Replacing the Magnetic Cover ________________________________________________________________ 16
Removing the Baseplate _____________________________________________________________________ 17
Board Replacement Procedures __________________________________________________________________ 18
Replacing the HDP5000 (2013) Magnetic Head Assembly __________________________________________ 18
Replacing the LCD Board Assembly ___________________________________________________________ 19
Replacing the Main Board Assembly ___________________________________________________________ 20
Replacing the USB/Ethernet Board Assembly ____________________________________________________ 21
Replacing the RFID Board Assembly A000365 ___________________________________________________ 23
Card Path and Roller Replacement Procedures ______________________________________________________ 25
Replacing the Card Path Assembly _____________________________________________________________ 25
HDP5000 (2013) & HDPii Plus D910721 _____________________________________________________ 25
Replacing the Card Rollers, Cleaning Roller/gear _________________________________________________ 27
Replacing the Card Rollers ___________________________________________________________________ 29
Replacing the Platen Card Roller ______________________________________________________________ 33
Replacing the Print Platen Roller ______________________________________________________________ 35
HDP5000 (2013) & HDPii Plus D910109 ____________________________________________________ 35
Motor Replacement Procedures __________________________________________________________________ 38
Replacing the Drive Train Stepper Motor Assembly _______________________________________________ 38
Replacing the Card Feed Motor/Roller Assembly _________________________________________________ 41
Replacing the Film Supply Motor (D910723), Ribbon Supply Motor (D910725), or RFID Board (A000365) ___ 43
Replacing the Headlift Motor (D910052) and Headlift Sensor (D910216) ______________________________ 49
Replacing the Lamination Mechanism (D910704) (Transfer Arm) ____________________________________ 56
Replacing the Lamination Mechanism Lam Cam Motor (D910072) ___________________________________ 57
Replacing the Lamination Mechanism Lam Cam Sensor (D910216) ___________________________________ 59
Sensor Replacement ___________________________________________________________________________ 60
Replacing the Card Path Sensor (D910217) ______________________________________________________ 60
Replacing the Ribbon Sensor (D910556) ________________________________________________________ 63
HDP Printhead Assembly Kit (086091) Replacement Guide ___________________________________________ 69
HDP Mainboard Cable Connection _______________________________________________________________ 73
Reviewing the HDP Printer Main Board connections _______________________________________________ 73
Reviewing the HDP Printer Main Board connections _______________________________________________ 74
HDP5000 Flipper Module Replacement Procedures __________________________________________________ 75
Flipper Module Cover Removal Procedures ______________________________________________________ 75
Replacing the Flipper Back Access Assembly (D910847-01) ________________________________________ 76
Replacing the Output Side Cover (D910823-01) and Input Side Covers (D910846-01) ____________________ 77
Replacing the Top Cover (D910848-01) _________________________________________________________ 78
Replacing the Flipper Front Cover (D910845-01) _________________________________________________ 79
Replacing the Flipper Module Gears (D860280) and (810266) _______________________________________ 80

October 2013 Page 4

Replacing the Flipper Table Assembly (D900205) _________________________________________________ 82

Replacing the Output Roller Assembly (D910404) ________________________________________________ 83
Replacing the Flipper Output Roller (D900123) ___________________________________________________ 84
Replacing the Flipper Sensor bundle (D900249) __________________________________________________ 85
Replacing the Flipper Motor (D900523; contains E000062 and 820524)________________________________ 86
Replacing the Card Feed Motor (D900524; contains E000062 and D900208) ____________________________ 87
Replacing the Flipper Main Board (A000394) ____________________________________________________ 88
Replacing the Accessory Board (A000451) ______________________________________________________ 89
HDP5000 Lamination Module Replacement Procedures ______________________________________________ 90
Lamination Module Cover Removal Procedures __________________________________________________ 91
Replacing the Back Access Assembly (D910821-01)_______________________________________________ 91
Replacing the Output Side Cover (D910823-01) and Input Side Covers (D910846-01) ____________________ 92
Replacing the Output Side Upgrade Cover (D910828) ______________________________________________ 93
Replacing the Top Cover (D920337) ___________________________________________________________ 94
Replacing the Front Bezel Door (D920341) and Belt (F000427) ______________________________________ 95
Replacing the Card Input Sensor (A000462) _____________________________________________________ 98
Replacing the Film Mark Sensor (D920155) Upper and Lower ______________________________________ 100
Replacing the Lamination Module Main Board (A000435) _________________________________________ 104
Replacing the Stepper Motor Assembly (D920030) and Belt (F000428) _______________________________ 106
Replacing the Upper and Lower Take-up Motor (D920118) ________________________________________ 108
Replacing the RFID Board for the Rewind Motors (A000365-01); Printer Mount _______________________ 111
Replacing the RFID Board for the Rewind Motors (A000365-01); Front Door Mount ____________________ 113
Replacing the Rewind Motor (D900406) Gear (D920170) ____________________________________________ 117
Replacing the Lamination Head (D920022) and (D920023) ________________________________________ 119
Replacing the Lamination Head (D920022) and (D920023) ________________________________________ 119
Replacing the Card Transport Drive Gears (810266), Main Pulleys (D850190) and Belt (220082) __________ 121
Replacing the Gear (D860280) and Pulley (D841202) _____________________________________________ 124
Replacing the Upper Card Path Rollers (D920013 and D920018) ____________________________________ 126
Replacing the Card Rollers (D920119 and D920119-01 and D920015) ________________________________ 129
HDP5000 Mainboard Cable Connection __________________________________________________________ 131
Reviewing the Lamination Module Main Board connections (Feed and Lower Sensing Cables) ____________ 131
Reviewing the Lamination Module Main Board Connections (Upper Sensing Cables for Dual Sided Laminator)
________________________________________________________________________________________ 132
Reviewing the Lamination Module Main Board Connections (Lower Lam Head Cables) __________________ 133
Reviewing the Lamination Module Mainboard connections (Upper Lam Head Cables) ___________________ 134
Reviewing the Lamination Module Main Board Connections (Lower Head Lift Motor Cables) _____________ 135
Reviewing the Lamination Module Mainboard connections – Upper Head Lift Motor Cables ______________ 136
Appendix A: Engineer Drawings ____________________________________________________________ 137

October 2013 Page 5

HDP5000 & HDPii Plus Parts Replacement

The purpose of this section is to provide the User with specific replacement procedures for the Card
Printer. Please see the next page to review standard precautions (to take) while performing these
replacement procedures.

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

Danger: Wear proper eye protection to perform the procedures in this section.

2 Be sure to reverse the disassembly steps to reassemble the Card Printer.

3 NOTE: Print out the Advanced Setting Card for future reference. If the main board or
the printhead is replaced these numbers will need to be added back into the
Advanced Settings Options within the driver. From the front display select OPTIONS
to MENU to TESTS. Print out the Printer Setting and the Laminator Settings keep for
future use.

October 2013 Page 6

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).
 To prevent personal injury, refer to the following safety messages before
performing an operation preceded by this symbol.
 To prevent personal injury, always remove the power cord prior to
performing repair procedures, unless otherwise specified.
 To prevent personal injury, make sure only authorized service personnel
perform these procedures.

Caution: This device is electrostatically sensitive. It can be damaged if exposed to

static electricity discharges.
Information that raises potential electrostatic safety issues is indicated by a
warning symbol (as shown to the left).
 To prevent equipment or media damage, refer to the following safety
messages before performing an operation preceded by this symbol.
 To prevent equipment or media damage, observe all established
Electrostatic Discharge (ESD) procedures while handling cables in or near the
Circuit Board and Printhead Assemblies.
 To prevent equipment or media damage, always wear an appropriate
personal grounding device (e.g., a high quality wrist strap grounded to avoid
potential damage).
 To prevent equipment or media damage, always remove the Ribbon and
Cards from the Printer before making any repairs, unless otherwise specified.
 To prevent equipment or media damage, remove jewelry as well as
thoroughly clean hands to remove oil and debris before working on the Printer.

October 2013 Page 7

Cover Replacement Procedures

Important: These procedures can only be performed by authorized service personnel.
The HDP Printer now uses fewer screws to attach parts, such as, Covers and Sensors.
 Many of the parts use a simply snapped into place. Most Sensors and Rollers SNAP in and out
to attach.
 Caution: When replacing the Covers or any parts, do NOT pinch any wires.

Caution: Please be careful not to force any of the snapping parts as they could break with
too much pressure.

Reviewing the Sequence (used) To Avoid Damage

The Covers must be removed in this sequence (order) to avoid damage to these parts.

HDP5000 (2013)
1. Front Door (D910811-01)
2. Back Cover (D910821-01)
3. Input Side Cover (D910822-01)
4. Output Side Upgrade Cover (D910828-01)
5. Output Side Cover (D910823-01)
6. Top Cover (D910825-01)
7. Full Assembly Front Cover with Cable and LCD ( D910702-01)

HDPii PLUS Flipper Module

1. Front Door (D910811-01)
2. Back Cover (D910821-01)
3. Input Side Cover (D910846-01)
4. Output Side Cover (D910850-01)
5. Top Cover (D910860-01)
6. Front Cover ( D910862-01)

October 2013 Page 8

Reviewing the HDP Printer Covers

October 2013 Page 9

Replacing the Front Door Assembly

HDP5000 (2013) & HDPii Plus D910811-01
Tools needed:
Estimated Repair Time: 5 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.

2 Remove the Ribbon, Film and Card Cartridges.

3 a. Open the Cover

b. Flex the Front Cover Assembly from the center bottom to release the two (2) side pins
from the Frame.

4 Reverse the instructions to re-assemble.

October 2013 Page 10

Replacing the Back Cover Assembly

HDP5000 (2013) & HDPii Plus D910821-01
Tools needed: 10 Torx and small flathead screwdrivers;
Estimated Repair Time: 5 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.

2 Remove the Ribbon, Film and Card Cartridges.

3 Remove the screw at the base of the Back Cover Assembly

Use a small screwdriver to pry the center tab slot to release the Cover.
Bend out and down to remove from the lower tab slots.

4 Reverse the instructions to re-assemble. (Note: First insert the tabs located at the bottom
edge of the Cover.)

October 2013 Page 11

Replacing the Output Side Upgrade Cover

HDP5000 (2013) & HDPii Plus D910828-01
Tools needed: 10 Torx screwdriver
Estimated Repair Time: 1 minute
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.

2 Remove the Ribbon, Film and Card Cartridges.

3 Use a small flathead screwdriver to release the one end. Pry the rest of the cover off.

4 Reverse the instructions to re-assemble.

Leave it off for Upgraded Printers to access the port.

October 2013 Page 12

Replacing the Output Side Cover

HDP5000 (2013) & HDPii Plus D910823-01

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 5 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.

2 Remove the Ribbon, Film and Card Cartridges.

3 Turn the Printer over and loosen the three (3) screw at the base of the Cover.

4 Remove the Output Cover Assembly by pulling it out and off.

5 Reverse the instructions to re-assemble.

(Note: First insert the tabs located at the upper edge of the Cover.)

October 2013 Page 13

Replacing the Top Cover

HDP5000 (2013) & HDPii Plus D910706-01

Tools needed:
Estimated Repair 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.

2 a. Remove the Ribbon, Film and Card Cartridges.

b. Remove the Input Side Cover (D910822-01) and Output Side Cover (D910823-01) first.
c. Remove the Top Cover Assembly by pulling it up and off.
d. Starting with the input side, grasp the two (2) sections from underneath. Then pull out
and up to release the small tabs that hold this Cover to the Frame. See display A.
e. Lift the Top Cover Assembly off from the Output side.

3 Reverse the instructions to re-assemble. (Note: Start with the input side to latch the tabs,
and then snap down on the output side to attach it.)

October 2013 Page 14

Replacing the Bezel Front Cover

HDP5000 (2013) D910702-01, HDPii Plus D910702-03)
Tools needed:
Estimated Repair Time: 10 minute
Important: This procedure can only be performed by authorized
service personnel.
This part contains the OLED Display board, front door, and cables.

Step Procedure

Caution: Power off the Printer by unplugging the power cord from the
Printer.

2 a. Remove the Ribbon, Film and Card Cartridges.

b. Remove all of the Covers to access this Bezel Front Cover.
c. Remove the Magnetic Cover (D910827-01).

3 Gently pull off the Frame.

Caution: Do not tilt it. Pull the Frame straight out from the Frame.

4 Disconnect LCD cable.

(Note: The Cable routing extends within the Front Frame.)

5 Reverse the instructions to re-assemble.

(Note: Line up the cover and then snap the Frame into place.)

October 2013 Page 15

Replacing the Magnetic Cover

HDP5000 (2013) D910827-01

 Tools needed: 10 Torx screwdriver

 Estimated Repair Time: 5 minutes
Important: This procedure can only be performed by authorized
service personnel.
This part is contained in the Front Trim Cover.

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 a. Remove the screw from the Magnetic Cover (F000177). See the photo above.
b. Remove the Magnetic Cover Assembly.
c. Replace it.

3 Reverse the instructions to re-assemble.

October 2013 Page 16

Removing the Baseplate

HDP5000 (2013) & HDPii Plus D910372

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 minutes

Preparation: Remove all Covers. See

Important: This procedure can only be
performed by authorized service personnel.
 This procedure is used when replacing
the Main Board.

Step Procedure

Caution: Power off the Printer by unplugging the power cord from the Printer.

2 Remove the two (2) screws from the Front of the Printer body.
Turn the Printer on its front and remove the three (3) Torx screws from the bottom center of
the Printer base.

3 Remove the wire connections. (Note: Ensure each wire is labeled correctly.) Tilt base back
to access the wires.

Caution: Do not allow any part of the metal Printer body to touch the Main
Board.

4 Gently ease the Baseplate off of the Printer body from the Motor side of the Printer.

October 2013 Page 17

Board Replacement Procedures

Replacing the HDP5000 (2013) Magnetic Head Assembly
(089201; Module Kit)
Tools needed: Torx screwdriver
Estimated Repair Time: 5 minutes
Important: This procedure can only be performed by authorized
service personnel.
Board and Magnetic head are one piece assembly

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 a. Remove the screw (F000177) from the Magnetic Cover (D910827-01).

b. Remove the Magnetic Cover Assembly.

3 a. Pull out the Magnetic Head and Board Assembly.

b. Install new Magnetic Head and Board

4 Reverse the instructions to re-assemble.

October 2013 Page 18

Replacing the LCD Board Assembly

HDP5000 (2013) & HDPii Plus A910820
Tools needed: Torx screwdriver
Estimated Repair Time: 10 minutes
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.

2 Remove the Bezel Front Cover (D910702-01).

3 Detach the wire to the Cover Switch at P2 and the Data Ribbon cable at P1 from the OLED
Board

4 Unclip the OLED Board Assembly from the Front Panel Assembly.
See display A.

5 Replace the OLED Board Assembly

6 Reverse the instructions to re-assemble.

Display A

October 2013 Page 19

Replacing the Main Board Assembly

**SPECIAL NOTE ON MAINBOARD PART NUMBERS
HDP5000 (2013) Serial number B3080651 and AFTER will use mainboard part number PCA-00013
HDPii PLUS serial number B3160607 and AFTER will use mainboard part number PCA-00014
The main board is NOT backwards compatible so checking the Printer serial number cut in is
essential to order the correct mainboard.

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 30 minutes
Preparation: Remove all Covers
Mainboard is located on the Baseplate. See Remove
Printer from base procedure.
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. Do
not allow any part of the metal Printer body to touch the Main Board.

2 The Main Board Assembly is located underneath the Printer assemble. (Note: The Main
Board contains the power connection port and the accessory connection port (Flipper
Module).)
 Remove all Covers.
 Remove the Printer from the base. See Removing Printer from base procedure.

3 Remove Ethernet Board if applicable. See Replacing the USB/Ethernet Board Assembly
(A910551).

4 Reverse the instructions to re-assemble.

October 2013 Page 20

Replacing the USB/Ethernet Board Assembly

HDP5000 (2013) & HDPii Plus A910551

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 minutes

Preparation: Remove all Covers.

Important: This procedure can only be performed by
authorized service personnel.
A910551 connects to the Mainboard.

Step Procedure

Caution: Power off the Printer by unplugging the power cord from the Printer.
Note: The USB/Ethernet Board Assembly (A910551) is used for the communication port of
the USB and Ethernet.

2 The USB/Ethernet Board is located vertically and connected to the main Printer Board at
location JP9.
 Do not remove the Main Board Assembly for this procedure.

3 a. Remove the Back Cover.

b. Remove the Output Side Cover.

4 Hold the Board at an angle and insert the NOTCH (A) into the slot of the metal base Frame
on the USB port side of the Main Board Assembly.
See Display A on the next page.

5 Carefully Insert the connector tab (B) into the slot on the Main Board Assembly. The
location is JP9 ETH/USB. (Note: The locking arm located towards the rear must be
released if the Board is installed or removed.)
See Display B in this section.

6 Reverse the instructions to re-assemble.

October 2013 Page 21

Installing the USB/Ethernet Board Assembly (A910551) (continued)

Display A – See Procedural Step 4 in this procedure.

Display B –

October 2013 Page 22

Replacing the RFID Board Assembly A000365

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 30 minutes
Preparation: Remove all Covers.
Remove Printer from base to access this part.
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.

2 Remove the appropriate Supply Motor. See instructions above

3 The complete Printer body must be removed from the Baseplate to allow clearance to
remove the RFID Board.
a. Remove the two (2) screws from the Front of the Printer body.
b. Turn the Printer on its front and remove the three (3) Torx screws from the bottom
center of the Printer base. Life Printer body from base. See Display A within this
procedure.

October 2013 Page 23

Replacing the RFID Board Assembly (A000365)

Step Procedure

4 Replace the RFID PCB Board (A000365) by sliding into place under the holding tabs. See
Display A

5 Reverse the instructions to re-assemble.

Display A: See Step 4 in this procedure.

October 2013 Page 24

Card Path and Roller Replacement Procedures

Replacing the Card Path Assembly
HDP5000 (2013) & HDPii Plus D910721
Tools needed: Torx screwdriver
Estimated Repair Time: 20 minutes
Preparation: Remove all 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.
Important: Card path removal makes parts removal easier. Relates to other procedures.

2 Remove the two (2) screws from the card path. (Note: One screw is located at the back
next to the Card Feed Motor Assembly (D910074). One screw is located at the back
opposite side.)

October 2013 Page 25

Step Procedure

3 Gently slide the Card Path Assembly (D910721) and slide out from the back side.

4 Detach the wire connections. (Note: Leave the other wires attached to the assemblies in
this upper section- JP1 cable stays on the card path assembly)

5 Reverse the instructions to re-assemble.

October 2013 Page 26

Replacing the Card Rollers, Cleaning Roller/gear

HDP5000 (2013) & HDPii Plus Card Roller D910064 and Cleaning Roller Idler D910107
Tools needed: Torx screwdriver - small flathead screwdriver
Estimated Repair Time: 30 minutes
Preparation: Remove all 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.

2 Remove the Card Path Sensor. See Replacing the Card Path Sensor.

3 Remove the Roller D910107 by snapping it out from the Frame. Turn card path over to
access this Roller. See Display A in this section.

4 Replace the Roller (D910107) and reassemble (if not changing the D910064 Roller).

5 a. Remove the Roller (D910107) to access the Roller (D910064).

b. Remove the Main Gear D910110 next to the Roller to clear access for removal.
See Display B.
c. Remove the Roller D910064 by snapping it out from the Frame. See Display C.
d. Leave the Gear attached to the Roller Shaft and gently work this out from the
Frame. It is snapped into place.

6 Replace the Card Sensor by snapping into place. (Note: The tabs will click when the
Sensor is properly installed.)

7 Reverse the instructions to re-assemble.

Replacing the Card Rollers, Cleaning Roller/gear (D910064) and Cleaning Roller Idler

October 2013 Page 27

(D910107) (continued)

Display A: Relates to Roller (D910107). Push down and out to unlock the Shaft from the Frame. See
Step 3 in this procedure.

Display B: You should remove this Gear to clear access for Roller removal, which snaps on and off
easily. See Step 5 in this procedure.

Display C: Relates to Roller (D910064). Push down and out to unlock the Shaft from the Frame.
Leave the Gear attached to the Roller Shaft. See Step 5.

October 2013 Page 28

Replacing the Card Rollers

HDP5000 (2013) & HDPii Plus D910062, D910455 and D910065

Tools needed: Torx screwdriver

Estimated Repair Time: 30 minute
Preparation: Remove all 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.
Important: Card Path removal makes parts removal easier.

October 2013 Page 29

Step Procedure

2 Remove the two (2) large Gears (D910448 and D910112) to access the Rollers. (Note:
These Gears are attached with an E-Clip and a C-Clip.)

3 Remove three (3) Main Plastic Gears (D910110) to access the Roller (D910062)
(Note: These are snap-on Gears.)

October 2013 Page 30

Step Procedure

4 a. Unsnap the Roller Shaft (D910062) from the Frame and slide it out.
b. Leave the Gear on the Shaft.

5 Remove the Roller (D910065) according to Steps 1 to 4 (above). (Note: The Gear remains
on the Shaft.)

6 To remove the Card Roller (D910455) located in the center of the Card Path, remove the
two (2) Gears (D910110)

7 Move the Roller on the Shaft up and out through the hole provided.

October 2013 Page 31

Step Procedure

8 The Card Idler Roller (D910295) can fall out when the Roller is removed.

9 Reverse the instructions to re-assemble.

October 2013 Page 32

Replacing the Platen Card Roller

HDP5000 (2013) & HDPii Plus D910101

Tools needed: Torx screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove all Covers.
Important: This procedure can only be performed by
authorized service personnel.
Located in the Card Path

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.
Important: Card path removal makes parts removal easier. Relates to other procedures.

2 Remove the large Gear D910485 and D910112 to access the Rollers. These Gears are
attached with an E-Clip and a C-Clip.

October 2013 Page 33

Step Procedure

3 Remove the E-Clips (140062) on both sides of the Platen Roller D910101

4 Remove the Bearing (760343) from the Platen shaft.

5 Remove the Platen Roller by sliding the long shaft up and out from the back of the card
path.

6 Reverse the instructions to re-assemble.

October 2013 Page 34

Replacing the Print Platen Roller

HDP5000 (2013) & HDPii Plus D910109

Tools needed: Torx screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove all Covers.
Important: This procedure can only be performed by
authorized service personnel.

Located in the Mechanism within the

Printhead Bracket

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.
Important: Card path removal makes parts removal easier. Relates to other procedures.

2 Remove the Printhead Assembly. See Printhead Replacement Procedures.

3 Remove the Stepper Motor. See Replacing the Print Stepper Motor (D910727) and/or the
Print Stepper Motor Belts (F000093-2 used) and/or the Print Motor Stepper Gear
(D840888).

October 2013 Page 35

Step Procedure

4 Hold the Pulley (D840889) on the Shaft and lift up and to the left to remove the Roller.

5 Install the new roller

6 Refer to this procedure for washer placement.

7 Fit the Shaft end into the hole provided. Notice the flat side of the bushing goes to the flat
side of the Frame. (Note: There is a small notch on the bushing to indicate the flat side.
This notch faces to the right.

October 2013 Page 36

Step Procedure

8 Replace the Pulley (D840889) as needed

9 Reverse the instructions to re-assemble.

October 2013 Page 37

Motor Replacement Procedures

Replacing the Drive Train Stepper Motor Assembly
HDP5000 (2013) & HDPii Plus D910729
Tools needed: Torx screwdriver
Estimated Repair Time: 20 minutes
Preparation: Remove all Covers.
Important: This procedure can only be performed by authorized service
personnel.
Located in the Card Path The Card Path does not need to be removed for this procedure.

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove all of the Covers.

3 Remove the three (3) screws from the Stepper Motor (D910729).

outer view
(continued next page)

October 2013 Page 38

Inner view

4 Unplug the Motor Cable (D910742) from the side of the Motor.

5 Slide out the Fan (D910212) to allow for room to remove the Motor.

October 2013 Page 39

Step Procedure

6 Replace with the new motor.

7 Secure with 3 screws then bias the motor to the left, and then tighten the screws.

8 Reverse the instructions to re-assemble.

October 2013 Page 40

Replacing the Card Feed Motor/Roller Assembly

HDP5000 (2013) & HDPii Plus D910074
Tools needed: Torx screwdriver
Estimated Repair Time: 30 minutes
Preparation: Remove all Covers.
Remove the Card Path Assembly. See Replacing the Card
Path Assembly (D910721).
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.

2 Remove the two (2) screws from the Card Feed Motor and Roller (D910074).

October 2013 Page 41

Replacing the Card Feed Motor/Roller Assembly (D910074) (continued)

Step Procedure

3 Unplug the cable from the Motor.

4 Pull out the Motor with the Roller (D910074).

5 Reverse the instructions to re-assemble.

 Insert the Shaft end into the hole provided. (Note: The Motor and screws will only fit one
way.)
 Replace the cable.

October 2013 Page 42

Replacing the Film Supply Motor (D910723), Ribbon Supply Motor

(D910725), or RFID Board (A000365)
HDP5000 (2013) & HDPii Plus
Tools needed: 10 Torx screwdriver
Estimated Repair Time: 30 minutes each
Preparation: Remove all Covers.
For RFID replacement, remove the Printer from the
base. See the Removing the Baseplate procedure.
Important: This procedure can only be performed
by authorized service personnel.

D910725

D910723

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.
This procedure is used to replace the RFID Boards (A000365). The same procedure is
used for both Supply Motors (D910723 and D910725).

October 2013 Page 43

Step Procedure

2 Supply & Take-up Motors & RFID Board

3 SUPPLY MOTORS
To remove Film Supply Motor (D910723) or the Ribbon Supply Motor (D910725).
Disconnect the Motor/Fan cable Assembly (D910741) from the motor

Leave the black plastic Encoder wheel collar on the Film Supply Motor.

October 2013 Page 44

Step Procedure

4 Remove the three (3) screws (F000463) that hold the Supply Motor to the Frame.

Film Supply Motor Ribbon Supply Motor

5 Pull out the Supply Motor.

6 Replace it with the new Film Supply Motor (D910723 or Ribbon Supply Motor (D910725).
Line up the screw holes. (Note: The Motor will only fit in one way.)

October 2013 Page 45

Step Procedure

7 After replacing the supply motor tighten the screws in this order shown.

Film Supply Motor Ribbon Supply Motor

TAKE UP MOTOR

1 TAKE UP MOTORS
To remove Film Take up Motor (D910726) or the Ribbon Take up Motor (D910724).
Disconnect the Motor/Fan cable Assembly (D910741) from the motor

Film Take up Motor Ribbon Take up Motor

Leave the black plastic Encoder wheel collar on the Film Supply Motor.

October 2013 Page 46

Step Procedure

2 Remove the four (4) screws (F000463) that hold the Take up Motor to the Frame.

Film Take up Motor Ribbon Take up Motor

3 Pull out the Take up Motor.

4 Replace it with the new Film Take up Motor (D910726) or Ribbon Take up Motor
(D910724).
Line up the screw holes. (Note: The Motor will only fit in one way.)

5 After replacing the Take up motor tighten the screws in this order shown.

Film Take up Motor Ribbon Take up Motor

October 2013 Page 47

Step Procedure

RFID Replacement

1 RFID Replacement
Remove the complete Printer body from the Baseplate to allow clearance to remove the
RFID Board.
See the Removing the Baseplate procedure.

2 To replace the RFID board; remove the appropriate Supply Motor according to the
instruction above.

3 Disconnect the cable (D910209) from the RFID Board.

Slide out the Board.

4 Replace the RFID PCB Board (A000365).

5 Reverse the instructions to re-assemble.

October 2013 Page 48

Replacing the Headlift Motor (D910052) and Headlift Sensor (D910216)

Tools needed: Torx screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove all 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.

2 Detach the Sensor wire (D910216) from the top of the Headlift Motor (D910052).

3 Remove the one (1) screw (F000177) that holds the Mount to the Frame. (Note: The Mount
is flush with the Frame when properly fitted.)

October 2013 Page 49

Step Procedure

4 Pull out the Motor. Press the locking tab located on the right side of the Motor IN to release
the Motor.

5 a. Disconnect the Headlift Sensor from the Harness.

b. Leave the Sensor (D910216) in the Mount (if not replacing it).

6 If you need to replace the Sensor use a small flathead screwdriver to release the Sensor.
Move the flag from out of the Sensor area to clear the Sensor.
a. Slide the Sensor out from the tabs.
b. Replace it with the new Sensor and click it back into place.

October 2013 Page 50

Step Procedure

7 Replace the Headlift Motor. Ensure the Shaft tab fits in to the hole provided in the Frame.
(Note: The top spine of the Shaft faces up. The point of the Shaft must fit into the Frame
hole provided.)

8 Reverse the instructions to re-assemble.

Caution: Do not pinch the wires. Note how wires are feed through.

9 Routing wires

October 2013 Page 51

Replacing the Print Stepper Motor (D910727) and/or the Print Stepper Motor Belts
(F000093; 2 belts) and/or the Print Motor Stepper Pulley (D840888)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove all 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.

2 Detach the Sensor wire from the Print Stepper Motor (D910727).

October 2013 Page 52

Step Procedure

3 Remove the three (3) screws that hold the Motor (D910727) to the Frame.

4 Roll the Motor (D910727 in a downward angle CCW to release the Print Stepper Motor Belt
(F000093) from the Pulley.

5 a. Check the Belts and Pulley for excessive wear.

b. Replace the Belt (F000093) or the Pulley (D840888).

6 a. If replacing the Gear, remove the clip (140063) that attaches the Gear to the Shaft.
b. Replace it with the new Gear (D840888).
c. Replace the clip on the Shaft.

October 2013 Page 53

Replacing the Print Stepper Motor (D910727) and/or the Print Stepper Motor Belts
(F000093- 2 used) and/or the Print Motor Stepper Pulley (D840888)

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 When replacing the motor first attach the Belt to pulley first then roll the Motor up to set
Into place.

October 2013 Page 54

Step Procedure

9 This stepper Motor Mount provides a self adjusting feature.

a. Keep the three (3) screws loose while holding the Mount Frame.
b. Allow the Belts to self-adjust. Then tighten the screws.

10 Reverse the instructions to re-assemble.

October 2013 Page 55

Replacing the Lamination Mechanism (D910704) (Transfer Arm)

Only the Motor and Sensor is field replaceable. For any other parts please replace complete
assembly.

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 minute
Preparation: Remove all 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.
Important: Card path removal makes parts removal easier. Relates to other procedures.

2 This procedure is used to replace the Motor (D910072) and the Lift Sensor (D910216).
a. Remove the three (3) screws that attach the lamination mechanism (D910704) to the

3 Turn printer over to remove the one (1) screw at the baseplate

4 Unplug the Sensor wire and the heater wire from the Main Board Assembly.

5 Reverse the instructions to re-assemble.

October 2013 Page 56

Replacing the Lamination Mechanism Lam Cam Motor (D910072)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove all 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.
Important: Card path removal makes parts removal easier. Relates to other procedures.

2 This procedure is used to replace the Motor (D910072) and the Lift Sensor (D910216)
Unplug the Sensor wire from the top of the Motor.

October 2013 Page 57

Step Procedure

3 Remove the three (3) screws that attach the Motor to the Transfer Arm frame.

4 Be careful of the Sensor when removing and replacing the Motor Cam.
 Move the Cam to the side to clear the Sensor.

5 Replace the Motor (D910072).

6 Reverse the instructions to re-assemble.

October 2013 Page 58

Replacing the Lamination Mechanism Lam Cam Sensor (D910216)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 minute
Preparation: Remove all 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.
Important: Card path removal makes parts removal easier. Relates to other procedures.

2 This procedure is used to replace the Motor (D910072) and the Lift Sensor (D910216).
 Unplug the Sensor wire from wire Harness.

3 Remove the two (2) screws that attach the Sensor to the Lamination Mechanism Frame.

4 Replace the Sensor (D910216).

5 Reverse the instructions to re-assemble.

October 2013 Page 59

Sensor Replacement
Replacing the Card Path Sensor (D910217)

Tools needed: small flathead screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove all Covers.
Important: This procedure can only be performed by
authorized service personnel.
Located in the Card Path (D910721)

Step Procedure

1
Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove the Card Path to access the sensor.

#Replacing the Card Path Assembly

October 2013 Page 60

Step Procedure

3 Disconnect the sensor cable (D910742)

4
Caution: The Card Path Sensor is clipped in. Be careful. Do not to force
this Sensor to come loose.
 Use a small flathead screwdriver to gently pry the two (2) tabs that hold this
Sensor in place.
 Slide the Sensor out.

Indicates the two (2) tabs that hold the Sensor in place. Be careful not to damage
the Sensor in the process.

5 Note the screwdriver leverage needed to hold the tab back away from the Sensor.
You would need to loosen two (2) tabs.

October 2013 Page 61

Replacing the Card Path Sensor (D910217) (continued)

Step Procedure

6 Replace the Card Sensor by snapping into place. (Note: The tabs will click when the
Sensor is properly installed.)

7 Reverse the instructions to re-assemble.

Wire routing.

Note: Verify Sensor is seated in place, not touching the Cleaning Roller.

October 2013 Page 62

Replacing the Ribbon Sensor (D910556)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 30 minutes
Preparation: Remove the Covers.
Important: This procedure can only be
performed by authorized service personnel.
Located on the Mechanism.

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove the Covers.

3 Remove the base plate with the Mainboard attached

Remove the 3 screws that hold the base plate to the printer frame.

Plus the 2 screws of the bottom front frame.

NOTE: While the procedure can be done with the base plate in place it may offer better
access if removed entirely).

October 2013 Page 63

Step Procedure

4 Remove the Communication board.

5 Remove the Print (Platen) Stepper Motor.

3 screws hold the motor to the frame.
NOTE: When replacing the motor it is self tensioning.

See Replacing the Print Stepper Motor (D910727) and/or the Print Stepper Motor Belts
(F000093; 2 belts) and/or the Print Motor Stepper Pulley (D840888)

October 2013 Page 64

Step Procedure

6 Remove the Printhead Cam (Headlift) Motor.

7 Remove the Printhead assembly.

See HDP5000 Printhead Assembly Kit (086091) Replacement Guide

8 Remove the Print Platen Roller.

October 2013 Page 65

See Replacing the Print Platen Roller (D910109)

Step Procedure

9 Shift the transfer roller assembly over to the side. There are 3 screws that secure this. It is
not necessary to remove the complete assembly.

10 Remove the wires from the various parts to gain clearance. The wires are held together
with white plastic clip holders.

October 2013 Page 66

Step Procedure

11 Remove the metal bracket from the frame. There are 4 screws that secure this to the
frame.

12 Locate the Ribbon Sensor location and remove the old one.

October 2013 Page 67

Step Procedure

13 To install the new sensor, position the new sensor in the same location and push down to
click it into place. NOTE: The white wire connector is to the outside.

14 Feed the sensor cable into the Bracket frame slot.

15 Reassembly all parts using reverse assembly process.

Be careful not to pinch any wires.
Plug the new sensor to the mainboard location JP11.

16 Procedure is now completed.

October 2013 Page 68

HDP Printhead Assembly Kit (086091) Replacement Guide

Tools needed: 10 Torx screwdriver, small flathead screwdriver
Estimated Repair Time: 20 minutes
Important:
 This procedure can only be performed by authorized service
personnel.
 The Printhead will come with the cable harness attached.

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove the Ribbon Cartridge (D910022).

3 a. Remove the Back Cover (D910821-01).

b. Remove the screw at the base of the Back Cover Assembly.
c. Use a small screwdriver to pry the center tab slot to release the Cover.
d. Bend out and down to remove from the lower tab slots.

October 2013 Page 69

HDP Printhead Replacement Guide (continued)

Step Procedure

4 a. Remove the Headlift Motor (D910052).

b. 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.)

5 Remove the ground strap of the Printhead.

6 Unplug the Printhead cable from the Main Board.

7 Carefully lift out the complete Printhead Assembly.

8 a. Replace the complete Printhead Assembly.

b. Replace the Printhead cable and ground strap.
c. Replace the Headlift Motor (D910052).

Caution: When replacing the Printhead Assembly, ensure that the Printhead
surface does not get scratched by any other Printer parts.

October 2013 Page 70

HDP Printhead Replacement Guide (continued)

Step Procedure

9 Fit the Frame Mount pin into the slot, provided within the Printer Frame. (Important: It
must click down solidly into the exact hole, as shown below.)
Display – Frame Mount Pin (Step 9)

Display – Print Platen Roller Slot and Frame Mount Pin (Step 9)

October 2013 Page 71

HDP Printhead Assembly Replacement Guide (continued)

Step Procedure

10 Note how the Print Platen Roller Slot would fit properly onto the Roller bushing, as shown
from the back side (below).

11 You have completed this procedure.

October 2013 Page 72

HDP Mainboard Cable Connection

Reviewing the HDP Printer Main Board connections

October 2013 Page 73

Reviewing the HDP Printer Main Board connections

October 2013 Page 74

HDP5000 Flipper Module Replacement Procedures

Flipper Module Cover Removal Procedures
Use this procedure for the replacements of all parts. All Covers must be removed to access the parts
within the module.
 The HDP5000 Printer now uses fewer screws to attach parts such as the Covers and Sensors.
Many of the parts are simply snapped.
 Be careful not to force any of the snapping parts as they could break with too much pressure.
Most of the Sensors and the Rollers simply SNAP IN and OUT for attachment.

October 2013 Page 75

Replacing the Flipper Back Access Assembly (D910847-01)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 5 minutes
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.

2 a. Use a flat screwdriver to gently pry the Access Cover out from the top slot.
b. Fold it down to open it.
c. Release the tab from the slot on the bottom Frame.

3 Reverse the instructions to re-assemble.

October 2013 Page 76

Replacing the Output Side Cover (D910823-01) and Input Side Covers
(D910846-01)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 5 minutes
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.

2 Remove the Back Cover first.

3 Turn the Flipper Module over and loosen the two (2) Torx screws, located on the base plate.

4 Lift it up from the bottom to release the top tabs on both sides.

5 Reverse the instructions to re-assemble.

October 2013 Page 77

Replacing the Top Cover (D910848-01)

Tools needed:
Estimated Repair Time: 5 minutes
Important: This procedure can only be performed by
authorized service personnel.

Top Door D910849-01

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 a. Remove the Back Cover.

b. Remove the two (2) Side Covers.

3 Lift off the Top Cover (D910848-01). (Note: Leave the Top Door attached.)

4 Reverse the instructions to re-assemble.

October 2013 Page 78

Replacing the Flipper Front Cover (D910845-01)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 5 minutes
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.

2 a. Remove the Back Cover.

b. Remove the two (2) Side Covers.

3 Lift off the Top Cover. (Note: Leave the Top Door attached.)

4 Loosen the two (2) screws on both sides of the Front Cover.

5 Lift the Front Cover off from the Frame.

6 Reverse the instructions to re-assemble.

October 2013 Page 79

Replacing the Flipper Module Gears (D860280) and (810266)

Idler Pulley Tools needed: 10 Torx screwdriver

(D900241)
Estimated Repair Time: 30 minutes
Main Pulley
Preparation: Remove the Covers.
(D850190)
Remove the Card Feed Motor.
Pulley (D900287)
Remove the Main Board.
Card Transport drive
Gear (810266) Important: This procedure can only be performed by authorized service
personnel.
Gear (D860280)
Belt (220082)

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove all the Covers.

3 Remove the Card Feed Motor (D900524). See Replacing the Card Feed Motor (D900524;
contains E000062 and D900208) .

4 Remove the Main Board. See Replacing the Flipper Main Board (A000394).

5 Use the above procedures in Steps 1 to 4 to make the printer ready for all Gear and Belt
replacements. Reverse assembly after each procedure.

6 Remove the one (1) screw that holds each of the Idler Pulley (D900241) to the Frame.
(Note: Replace it with the new Gear or Gears.)

7 To replace the Belt (220082) only, the upper Idler Pulley (D900241) needs to be removed.
(Note: Replace it with the new Belt.)

8 To replace the Pulley (D900287), remove the lower Idler pulley (D900241) and Belt
(220082). (Note: Loosen the set screw in the pulley to remove it.)
 The neck of the Gear goes up when replaced.

October 2013 Page 80

Replacing any of the Flipper Module Gears (Continued)

Step Procedure

9 To replace the Main Pulley (D850190), follow Steps 1 to 6. (Note: Remove the lower Idler
Pulley to allow clearance for removal of Main Pulley.)
 Replace it with the new pulley (D850190). This pulley has an inner rib that must be
carefully replaced by tilting the flat side in first the press in the pulley to the Shaft.

10 To replace the Gear (D860280), follow Steps 1 to 7. (Note: The Lower Idler Pulley
(D900241), the Belt (220082), the Pulley (D900287) and the Stepper Motor must be
removed to access the Gear (D860280).)
 Remove the E-Clip from the Gear (D860280) Shaft. Replace it with the new Gear. (Note:
The neck of the Gear (D860280) goes in.)

11 To replace the Card Transport Drive Gear (810266), follow Steps 1 to 9.

 Remove the Gear. Replace it with the new Gear. (Note: The neck of the Gear goes out.)

12 To replace the Main Pulley (D850190), follow Steps 1 to 6. Pull up on the pulley. Replace it
with the new pulley.

October 2013 Page 81

Replacing the Flipper Table Assembly (D900205)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 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.

2 Remove all the Covers.

3 Remove the pulleys and Gears. See Replacing the Flipper Module Gears.

4 Remove the Card Feed Motor. See Replacing the Card Feed Motor (D900524; contains
E000062 and D900208).

5 Remove the Flipper Table Sensor. See Replacing the Flipper Sensor bundle (D900249)

6 Remove both E-Clip s for both sides of the Shaft.

7 a. Remove the brass bushing form the Motor side.

b. Leave the brass bushing on the Sensor side in place.

8 Replace it with New Flipper Table assembly.

9 Reverse the instructions to re-assemble.

October 2013 Page 82

Replacing the Output Roller Assembly (D910404)

Tools needed:
Estimated Repair 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.

2 Remove all the Covers.

4 Unwind the Flipper Sensor Bundle Cable from the top of the Output Roller Assembly.

5 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.

October 2013 Page 83

Replacing the Flipper Output Roller (D900123)

Tools needed:
Estimated Repair 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.

2 Remove all the Covers.

3 a. Remove the Output Roller Assembly (D910404). (Note: The Output Roller
Assembly (D910404) clips into the two (2) slots on either side of the Frame.)
b. Gently pull from the Sensor Side Frame just enough for the assembly to be pulled
out from its slots.

4 a. Remove the Lower Idler Pulley (D900241), the Belt (220082) and the Main Pulley
(D850190).
b. Remove the Pulley and Gear. See Replacing the Flipper Module Gears.

5 Remove the E-Clip from the Sensor side of the Flipper Table Shaft and the bushing
(220082)

6 Remove the E-Clip from the Motor side and the bushing.

7 Remove the Output Roller Assembly (D910404) from the Motor side.

8 Reverse the instructions to re-assemble.

October 2013 Page 84

Replacing the Flipper Sensor bundle (D900249)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 15 minutes
Preparation: Remove the Covers.
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. All three
Sensors must be replaced at the same time if one Sensor is
damaged.
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.

2 Remove all the Covers.

3 Disconnect the wire bundle from the J3 connection.

4 a. Unwind the wire bundle to reach the Sensors.

b. Unclip the wires from the holder Mounts.

5 Remove the two (2) screws that hold each Sensor to the Frame.

6 Observe where each Sensor goes. (Note: Each wire is labeled for placement.)

7 Replace the Sensor bundle.

8 Reverse the instructions to re-assemble.

October 2013 Page 85

Replacing the Flipper Motor (D900523; contains E000062 and 820524)

Tools needed: 10 Torx screwdriver

Estimated Repair 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.

2 Remove all the Covers.

3 Disconnect the cable (D900251) from the top of the Stepper Motor.

4 Remove three (3) screws from the Motor to the Frame.

5 Replace the Motor.

6 Connect the cable to Motor (top).

7 Reverse the instructions to re-assemble.

October 2013 Page 86

Replacing the Card Feed Motor (D900524; contains E000062 and D900208)

Tools needed: 10 Torx screwdriver

Estimated Repair 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.

2 Remove all the Covers.

3 Disconnect the cable (D900251) from the bottom of the Stepper Drive Motor.

4 Remove the Main Board.

5 Remove the two (2) screws that hold the Motor base to the Frame.

6 Replace the Motor Bracket.

7 Reconnect the wires at the Motor (bottom).

8 Reverse the instructions to re-assemble.

October 2013 Page 87

Replacing the Flipper Main Board (A000394)

Tools needed: 10 Torx screwdriver

Estimated Repair 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.

2 Remove all the Covers.

3 Disconnect the cable (D900251) from the Board at J9.

4 Disconnect the cable (D900249) from the Board at J3.

5 Disconnect the Ribbon cable (D900214) from the Main Board at J1.

6 Disconnect the Ribbon cable (D900215) from the Main Board at J2.

7 Remove the Main Board by pulling from the four (4) corners out. (Note: No screws hold the
Board. Four (4) pressure tabs hold the Board.)

Caution: Be careful not to break the Board.

8 Replace the Main Board.

9 Reconnect the cables.

10 Reverse the instructions to re-assemble.

October 2013 Page 88

Replacing the Accessory Board (A000451)

Tools needed:
Estimated Repair 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.

2 Remove all the Covers from the Flipper Module.

3 Disconnect the cables from the Main Board and from the Accessory Board.

4 Use a long Torx screwdriver to remove the four (4) screws that attach the Board to the
base plate. Work from the top of the Flipper Table.

5 Replace it with the new Accessory Board (A000451)

6 Reconnect the cables.

7 Reverse the instructions to re-assemble.

October 2013 Page 89

HDP5000 Lamination Module Replacement 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.

October 2013 Page 90

Lamination Module Cover Removal Procedures

Replacing the Back Access Assembly (D910821-01)

Tools needed:
Estimated Repair Time: 5 minutes
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.

2 a. Remove 2 (one) screw from the bottom of the Rear Cover.

b. Using a flat screwdriver and from the top slot, gently pry the access Cover out.
c. Fold it down to open.
d. Release the tab from the slot on the bottom Frame.

3 Reverse the instructions to re-assemble.

 Insert the bottom tabs first.

October 2013 Page 91

Replacing the Output Side Cover (D910823-01) and Input Side Covers
(D910846-01)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 5 minutes
Important: This procedure can only be
performed by authorized service
personnel.

Output Input

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove the Back Cover first.

3 Turn the Lamination Module over and loosen the three (3) torx screws, located on the
Baseplate of each Side Cover.

4 Lift it up from the bottom to release the top tabs on both sides.
 The top Cover can be removed along with the side Covers all in one piece.

5 Reverse the instructions to re-assemble.

October 2013 Page 92

Replacing the Output Side Upgrade Cover (D910828)

Tools needed:
Estimated Repair Time: 5 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.
Remove the Ribbon, film and card cartridges.

2 Gently pry the Cover (D910828) from the center top edge while simultaneously pulling at the
center of the bottom edge.

3 Reverse the instructions to re-assemble. Leave off for Upgraded Printers to access the port.

October 2013 Page 93

Replacing the Top Cover (D920337)

Tools needed:
Estimated Repair Time: 5 minutes
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.

2 Remove the Back Cover first, then the two (2) Side Covers. The top Cover can be removed
along with the side Covers all in one piece.

3 Lift off the Top Cover. Leave the Reject door attached.

4 Reverse the instructions to re-assemble.

October 2013 Page 94

Replacing the Front Bezel Door (D920341) and Belt (F000427)

Tools needed:
Estimated Repair Time: 15 minutes
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.

2 Remove the Back Cover first, then remove the two (2) Side Covers.

3 Lift off the Top Cover.

4 Unplug the Front RFID cable from the board location

5 a. Open the Front Door and remove the two (2) screws (F000171) from the bottom of the
front panel.
b. Unsnap the front Bezel door from the frame.
See Display A

6 See Displays B and C to show the belt configuration (F000427).

7 Reverse the instructions to re-assemble.

October 2013 Page 95

Replacing the Front Bezel Door (D920341) and Belt (F000427) (cont.)

Display A: See Step 5 in this procedure.

Display C: See Step 6 in this procedure.

October 2013 Page 96

Replacing the Front Bezel Door (D920341) and Belt (F000427) (cont.)

Display C: See Step 6 in this procedure.

October 2013 Page 97

Replacing the Card Input Sensor (A000462)

Tools needed: Needle Nose Pliers

Estimated Repair Time: 25 minutes
Preparation: Remove the Covers.
Important: This procedure can only be performed by
authorized service personnel.
A000462 is located on Centerplate Input D920026

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove all the Covers. See Lamination Module Cover Removal Procedures

3 Disconnect the Card Input Sensor Cable (D920149) from the Main Board at J5.

4 Remove the metal Roller (D920137) by snapping it up and out from the side Frame peg
hole on the rear side.

5 Use a small flathead screwdriver to unsnap the Sensor from the Frame. See the Display
on the next page.

6 a. Replace the Sensor and reconnect the wire at J5.

b. Replace the cable as needed.

7 Reverse the instructions to re-assemble.

October 2013 Page 98

Replacing the Card Input Sensor (A000462) (continued)

Display: See Step 5 in this procedure.

October 2013 Page 99

Replacing the Film Mark Sensor (D920155) Upper and Lower

Tools needed: Needle Nose Pliers

Estimated Repair Time: 25 minutes
Preparation: Remove the Covers.
Important: This procedure can only be performed by authorized service
personnel.
D920155 is located on the Center Plate Exit D920027

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove all the Covers. See Lamination Module Cover Removal Procedures .

3 Disconnect the cable (D920155) from the Main Board at location J26 for the lower Sensor
and J27 for the upper Sensor.

4 Remove the Upper and Lower Take-Up Motors for clearance to access the Sensors. See
Replacing the Take-up Motor (D920118).

5 For the Upper Sensor remove the metal Roller (D920137) by snapping it up and out from
the front side Frame peg hole. (Note: Use needle nose pliers to grab the Sensor/cable
and pull it out.)
See Display A within this 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 (D920137) by sliding out.
b. Loosen the Sensor cable, grab the Sensor/cable and pull it out.

October 2013 Page 100

Replacing the Film Sensor (D920155) Upper and Lower (continued)

Step Procedure

7 Replace Sensors. (Note: The Sensor Board slides into the Frame holding tabs. Ensure
that the wires feed over the Roller.)
a. See Displays B, C, and D within this procedure for wire routing.

8 Reconnect the wire at the Main Board.

9 Reverse the instructions to re-assemble.

Display A: See Step 5 within this procedure.

Display B: See Step 7 within this procedure.

October 2013 Page 101

Display C: See Step 7 within this procedure.

October 2013 Page 102

Replacing the Film Sensor (D920155) Upper and Lower (continued)

Display D (Top Sensor removal): Grip the blue/green wires with needle nose pliers or small flat
screwdriver. See Step 7 within this procedure.

October 2013 Page 103

Replacing the Lamination Module Main Board (A000435)

Tools needed: Torx screwdriver

Estimated Repair Time: 30 minutes
Preparation: Remove the Covers.
Important: This procedure can only be performed by
authorized service personnel.
A000435 is located on the baseplate.

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove all the Covers. See Lamination Module Cover Removal Procedures
(Note: You do not need to remove the printer body to access the Main Board.)

3 a. Disconnect the cables from the Main Board.

b. Ensure all cables are labeled for reconnecting. Refer to the Cable/Board placement at
the end of this section.

4 Remove the three (3) torx screws (F000169) that hold to Board to the base.
 See Display A within this procedure.

5 Replace it with the new Main Board.

6 Reconnect the cables. Refer to the Cable/Board placement at the end of this section.

7 Reverse the instructions to re-assemble.

October 2013 Page 104

Replacing the Lamination Module Main Board (A000435)

Display A: See Step 4 in this procedure.

October 2013 Page 105

Replacing the Stepper Motor Assembly (D920030) and Belt (F000428)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 25 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.

2 Remove all the Covers. See Lamination Module Cover Removal Procedures .

3 Disconnect the Stepper Motor cable (D900032).

4 Remove the four (4) Torx screws (F000169) that attach the Motor to the Frame.

5 Remove the Belt (F000428) from the Motor.

 Replace as needed.

6 The self adjusting Spring (F000332) will fall out. (Note: This will be replaced when the new
Motor is installed.)

7 Install the new Motor. Loosely install the four (4) screws. Work the Belt (F000428) back onto
the Motor Shaft.

8 a. Insert the self adjusting Spring (F000332) into the hole (provided from the front).
b. Tighten the four (4) screws (F000169). Allow the self-adjusting Spring to hold the Motor
in place.
See Display A within this procedure.

9 Reverse the instructions to re-assemble.

October 2013 Page 106

Replacing the Stepper Motor Assembly (D920030) and Belt (F000428) (continued)

Display A-1: See Step 8 in this procedure.

Display A-2: See Step 8 in this procedure.

October 2013 Page 107

Replacing the Upper and Lower Take-up Motor (D920118)

Tools needed:
Estimated Repair Time: 25 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. The Single Laminator uses one (1) Motor. The
Dual Laminator uses two (2) Motors. Both Motors use cable
D920153.

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove all the Covers. See Lamination Module Cover Removal Procedures

3 Disconnect the cable (D920153) from the top of the Motor.

4 Hold the Motor in one hand and the Shaft in the other. Push it in and turn the Motor to
release it from the Frame.
 The (lower) Motor for the SINGLE Lamination is removed by turning it clock-wise to
release it and counter clock-wise to replace it. Refer to Display A in this procedure.
 The (upper) Motor for the DUAL Lamination Module is removed by turning it counter
clock-wise to release and clock-wise to replace it. Refer to Display B in this procedure.

5  Display C shows the cutout area to place the Motor (into) before turning it to lock it in
place. See the display page in this procedure.
 Display D shows wire routing configuration. See the display page in this procedure.

Caution: Do not pinch the wires.

October 2013 Page 108

Replacing the Take-up Motor (D920118) (continued)

Display A (Lower Motor): See Step 4 in this procedure.

Display B (Upper Motor): See Step 4 in this procedure.

October 2013 Page 109

Replacing the Take-up Motor (D920118) (continued)

Display C: See Step 5 in this procedure.

Display D: See Step 5 in this procedure.

October 2013 Page 110

Replacing the RFID Board for the Rewind Motors (A000365-01); Printer
Mount

Tools needed: Torx screwdriver

Estimated Repair 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.
The Single Laminator uses the top RFID Board that is mounted
to the printer body.
The Dual Laminator uses the bottom RFID Board and is located
within the Front Cover.
Printer Mount

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

Remove the Covers. See Lamination Module Cover Removal Procedures

2 Remove the Ribbon Rewind Motor, the Gear (D920170) and Encoder Wheel (810492) See
Replacing the Rewind Motor (D900406).

3 Disconnect the cable from the RFID Board.

4 Remove the two (2) screws (F000177) from the RFID Board. (Note: Slide the Board out from
the Frame.) See Display A in this procedure.

5 Replace it with the new RFID Board. (Note: This Board will slide into slots on the left side.)

6 Reconnect the cables. (Note: The top Board connects to J19. The bottom Board connects to
J20.)

7 Replace the Ribbon Rewind Motor. Reverse the instructions to re-assemble. Refer to Display
A below.

October 2013 Page 111

Replacing the RFID Board for the Rewind Motors (A000365-01)

Display A: See Step 4 in this procedure.

October 2013 Page 112

Replacing the RFID Board for the Rewind Motors (A000365-01); Front Door
Mount

Tools needed: Torx screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove the Covers. Remove the Rewind Motor.
 The same part number is used for both the Single and Dual
Lamination Modules.
 The Single Laminator uses the top RFID Board that is
mounted to the printer body.
 The Dual Laminator uses the bottom RFID Board and is
located within the Front Cover.
Important: This procedure can only be performed by
authorized service personnel.
Front Door Mount

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove the Covers. See Lamination Module Cover Removal Procedures

3 Remove the Rewind Motor. See Replacing the Rewind Motor (D900406) Gear (D920170)

4 Fish the upper RFID cable out through the hole in the front bezel. See Display A.

5 Plug the RFID cable into an RFID antenna board (A000365) then insert the board into an
RFID cover and snap it into place. See Display B.

6 Snap the RFID cover onto the mounts on the front door and press the RFID cable into the
cable channel. See Display C.

October 2013 Page 113

Replacing the RFID Board for the Rewind Motors (A000365-01) (continued)

Display A: See Step 2 in this procedure.

October 2013 Page 114

Replacing the RFID Board for the Rewind Motors (A000365-01) (continued)

Display B: See Step 3 in this procedure.

October 2013 Page 115

Replacing the RFID Board for the Rewind Motors (A000365-01) (continued)

Display B: See Step 4 in this procedure.

October 2013 Page 116

Replacing the Rewind Motor (D900406) Gear (D920170)

Tools needed: Small flathead screwdriver; a hook tool for

O-Ring.
Estimated Repair Time: 30 minutes
Preparation: Remove the Covers
Important: This procedure can only be performed by
authorized service personnel.
The same Rewind Motor is used for both Single and Dual
Lamination Modules. The Single Laminator uses one (1)
Rewind Motor. The Dual Laminator uses two (2) Rewind
Motors.

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove the Covers. See Lamination Module Cover Removal Procedures

3 Disconnect the cable (D920147) from the top of the Motor.

4 Disconnect the wire bundle from the holding clip. (Note: Observe how the wires are
routed.)

5 Disconnect the Encoder Sensor cable (D920147) from the Encoder Sensor Board
(A000126). (Note: This cable is located toward the bottom of the Rewind Mount.)
Unsnap the Encoder Sensor (A000126) from the Rewind Motor Frame. (Note: This will
make it easier for reassembly.)
 See the display on the next page.

6 Unclip the Rewind Mount from the top. (Note: The top tab must be lifted slightly to release
the Motor Frame.)
Be careful NOT to bend the metal Encoder wheel. (Note: The Encoder Sensor must clear
the Encoder Wheel when removing it.)
 See the display on the next page.

October 2013 Page 117

Step Procedure

7 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.
c. Replace the Sensor by (1) inserting the tab into one of the two (2) holes on the Sensor
and by (2) snapping it onto the 2nd tab.

October 2013 Page 118

Replacing the Lamination Head (D920022) and (D920023)

Tools needed: Torx screwdriver-

Estimated Repair 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.
 The Single Laminator uses one (1) Lamination
Head (D920023).
The Dual Laminator uses two (2) Lamination Head
(D920022 and D920023).

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove all Cover. See Lamination Module Cover Removal Procedures

3 Disconnect the cable from the Motor (top). See the display on the next page.

4 Disconnect the wires from the Main Board. See the display on the next page.

5 Reverse the instructions to re-assemble. (Note: The wires are routed in a specific way
around the pegs, provided on the Frame.)

October 2013 Page 119

Replacing the Lamination Head (D920022) and (D920023)

Display A: See Steps 3 and 4 in this procedure.

October 2013 Page 120

Replacing the Card Transport Drive Gears (810266), Main Pulleys

(D850190) and Belt (220082)

Tools needed: 10 Torx screwdriver- Retaining Ring

Removal Tool
Estimated Repair Time: 25 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.

Remove the Covers. See Lamination Module Cover Removal Procedures

2 Remove retaining ring from the Shaft.

3 Remove the old Gear and replace it with the new Gear.

4 Replace the Belt as needed.

5 Note the position of the Belt guide. Orient the input roller shaft and the three feed roller shafts
so the flat on the end of the shaft is facing right. (Note: Orientation of each shaft is critical so
they must all be oriented identically.)
 See Displays A and B on the next page.

6 Reverse the instructions to re-assemble. Refer to Display C below.

October 2013 Page 121

Replacing the Card Transport Drive Gears (810266), Main Pulleys (D850190) and Belt
(220082)

Display A: See Step 5 in this procedure.

Display B: See Step 5 in this procedure.

October 2013 Page 122

Replacing the Card Transport Drive Gears (810266), Main Pulleys (D850190) and Belt
(220082)

Display C: See Step 6 in this procedure.

October 2013 Page 123

Replacing the Gear (D860280) and Pulley (D841202)

Tools needed: 10 Torx screwdriver and E-Clip
Removal tool
Estimated Repair Time: 25 minutes
Preparation: Remove the Covers.
Remove the Gears and Belt.
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.

2 Remove the Covers. See Lamination Module Cover Removal Procedures

3 Remove Pulley (810266 and D850190) and Belt (220082) from the LEFT side above the
Rewind Motor. See Replacing the Card Transport Drive Gears (810266), Main Pulleys
(D850190) and Belt (220082).
Release the Top tab on Rewind Motor for clearance.
 Remove the retaining clip from the Gear (D841202).
 See Displays A and B on the next page.

4 Loosen the four (4) screws on the Stepper Motor to release the Stepper Motor Belt
(F000428). Remove the Belt.

5 a. Remove the E-Clip from the Gear and/or Pulley Shaft.

b. Replace it with the new Gear and/or Pulley. Note the position of the Gear placement.

6 Reverse the instructions to re-assemble. See Replacing the Stepper Motor Assembly
D920030 and Belt F000428 for the Stepper Motor adjustment.

October 2013 Page 124

Replacing the Gear (D860280) and Pulley (D841202)

Display A: See Step 3 in this procedure.

Display B: See Step 3 in this procedure.

October 2013 Page 125

Replacing the Upper Card Path Rollers (D920013 and D920018)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove the Covers.
Important: This procedure can only be performed
by authorized service personnel.
These are located on the CenterPlate Input and Exit
D920013 (shown above) All Rollers are held in place with Springs. Use a
small screwdriver for removal.

D920018 (shown above)

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove the Covers. See Lamination Module Cover Removal Procedures

3 Use a small flathead screwdriver to push in the Spring on one side of the Roller (to release
it from the tabs).

4 If necessary, remove the Take-Up Motor to access the middle Roller (D920018). See
Replacing the Take-up Motor (D900086).
 Do not lose the Output Spring Bushing.

5 See Display A for D920013 roller placement.

See Display B for D920018 roller placement.

6 Reverse the instructions to re-assemble.

October 2013 Page 126

Replacing the Upper Card Path Rollers (D920013 and D920018) (cont.)

Display A : See Step 5 in this procedure.

October 2013 Page 127

Replacing the Upper Card Path Rollers (D920013 and D920018) (cont.)

Display B: See Step 5 in this procedure.

October 2013 Page 128

Replacing the Card Rollers (D920119 and D920119-01 and D920015)

Tools needed: 10 Torx screwdriver

Estimated Repair Time: 20 minutes
Preparation: Remove the Covers. Important: This
D920119 ( card feed) procedure can only be performed by authorized service
personnel.

D920015 ( input)

D920119-01 ( 2 used)

Step Procedure

Caution: Turn OFF the Printer and unplug the power cord from the Printer.

2 Remove the Covers. See Lamination Module Cover Removal Procedures

3 Prepare the printer by removing the Gears (810266 and D850190). See Replacing the
Card Transport Drive Gears (810266), Main Pulleys (D850190) and Belt (220082).

4 Remove the Shaft Bushing (D900046)

 Turn it counter-clockwise to remove it. (Note: Use a flathead screwdriver to release
the tab.)

October 2013 Page 129

Replacing the Card Rollers (D920119 and D920015)

Step Procedure

5 Pull the Roller out from the copper bushing and replace it with the new Roller.

6 Observe the order of the parts removed. See Displays A and B within this procedure.

7 Reverse the instructions to re-assemble.

Display A: D920119 (below); See Step 6 in this procedure.

Display B: D920015 (below) ; See Step 6 in this procedure.

October 2013 Page 130

HDP5000 Mainboard Cable Connection

Reviewing the Lamination Module Main Board connections (Feed and
Lower Sensing Cables)

October 2013 Page 131

Reviewing the Lamination Module Main Board Connections (Upper

Sensing Cables for Dual Sided Laminator)

October 2013 Page 132

Reviewing the Lamination Module Main Board Connections (Lower Lam

Head Cables)

October 2013 Page 133

Reviewing the Lamination Module Mainboard connections (Upper Lam

Head Cables)

October 2013 Page 134

Reviewing the Lamination Module Main Board Connections (Lower Head

Lift Motor Cables)

October 2013 Page 135

Reviewing the Lamination Module Mainboard connections – Upper Head

Lift Motor Cables

October 2013 Page 136

Appendix A: Engineer Drawings

October 2013 Page 137

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