Fargo Fargo HDP8500 User manual

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

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. 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, the HID logo, HDP and FARGO are the trademarks or registered trademarks of HID
Global Corporation or its licensors in the U.S. and other countries.
Trademark Acknowledgments
Other trademarks and trade names may be used in this document to refer to either entities claiming the
marks and names or their products.
Revision History
The revision number for this document will be updated to reflect changes, corrections, updates and
enhancements to this document.
Revision Control
Number
Date
Document Title
Revision 1.1
November 2013
HDP8500 Service Manual
Corrected printhead kit part number to 088934 &
transfer arm to D940009

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Contacts
North America
Europe, Middle East and Africa
15370 Barranca Parkway
Irvine, CA 92618
USA
Phone: [phone]
Fax: [phone]
Tech Support: 866 607 7339, #6, M-F 7am-6pm CST
Phoenix Road
Haverhill, Suffolk CB9 7AE
England
Phone: [phone]
Fax: [phone]
Tech Support: [phone] M-F 9am –5pm GMT
Asia Pacific
Brazil
19/F 625 King’s Road
North Point, Island East
Hong Kong
Phone: [phone]
Fax: [phone]
Tech Support 852 3160 4895 M-F 9am –6pm GMT +8
Av Guido Caloi 1985 Prédio 18
São Paulo –SP
CEP : 05802-140
Phone: [phone]
Fax: [phone]
Tech Support: 55 11 5514-7110 M-F 9am –6pm ATC
support.hidglobal.com

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HDP8500 Parts Replacement .......................................................................................................6
Safety Messages (review carefully) .................................................................................................................7
Cover Removal / Replacement Procedures .....................................................................................................8
Reviewing the HDP8500 Covers .................................................................................................................9
Remove/Replace the Rear/TOP Cover Assembly (D940089) .................................................................. 11
Remove/Replace the Front Panel Cover (D940201-01)........................................................................... 13
Remove/Replace the Input Cover (D940092-02) ..................................................................................... 14
Remove/Replace the Output Cover (D940199-02)................................................................................... 18
Remove/Replace the Door Cover (D940090-01)....................................................................................... 20
Remove/Replace the Bezel LCD Display (D940088-01).......................................................................... 22
Remove/Replace the Cover Insert (D940204-02)..................................................................................... 23
Main Printer Modules Removal.................................................................................................................... 24
Remove the Fan Box/Bracket Assembly (D940005)................................................................................ 24
Remove the Card Path (D940005)............................................................................................................ 28
Remove the Main Printer Chassis ........................................................................................................... 32
Printer Board Removal ................................................................................................................................. 36
Remove the Mainboard (A940234)........................................................................................................... 36
Remove/Replace the Auxiliary Board (A920221-10) ............................................................................... 39
Remove/Replace the USB Ethernet PCB (A910551) .............................................................................. 41
Card Path Procedures ................................................................................................................................... 43
Card Path Sensor (D910217).................................................................................................................... 43
Card Path - Roller Replacement Procedures........................................................................................... 45
Card Path- Stepper Motor Assembly (D940257)..................................................................................... 55
Card Path- Gear Motor (D900484-01) ..................................................................................................... 57
Main Chassis Procedures.............................................................................................................................. 59
Remove/Replace the Film Supply Motor (D900484-06), Ribbon Supply Motor (D900484-07), and RFID
Board (A000365)........................................................................................................................................ 59
Remove/Replace the Film Take-Up Motor (D900484-01) and Ribbon Take-Up Motor (D900484-01). 60
Remove/Replace the Headlift Motor (D910052) and Headlift Sensor (D910216) ................................. 61
Remove the Print Stepper Motor (D910050) ........................................................................................... 64
Remove the Card Path Step Mount Assembly (D940258)...................................................................... 67
Remove/Replace the Lamination Mechanism (D940009) (Transfer Arm) ............................................ 69
Remove/Replace the Transfer Arm Motor (D910072) or Up/Down Sensor (D910216) ......................... 72
Remove/Replace the Ribbon Sensor (D910556)....................................................................................... 75
Installing the Printhead.............................................................................................................76

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Flipper Table Remove/Replace Procedures.................................................................................87
Remove/Replace the Output Roller Assembly (D910404) ...................................................................... 88
Remove/ Replace the Table or Flip Home Sensor (D900249) ................................................................. 92
Remove/ Replace the Flipper Motor (D900523) ...................................................................................... 93
Remove/ Replace the Card Feed Motor (D900524) ................................................................................. 94
Remove/Replace the Flipper Main Board (A000394).............................................................................. 95
Remove/Replace the Accessory Board (A000451).................................................................................... 97
Lamination Module Remove/Replace Procedures .......................................................................98
Remove/Replace the Cleaning Roller (D940203)................................................................................... 101
Remove/Replace the Cleaning Roller Idler (D940102) ......................................................................... 103
Cleaning Output Assembly..................................................................................................................... 103
Remove/Replace the Roller Transport Idler (D940108)........................................................................ 105
Cleaning Output Assembly..................................................................................................................... 105
Remove/Replace the Film Mark Sensor (D920155) Upper and Lower ................................................ 108
Remove/Replace the Lamination Module Main Board (A940221) ....................................................... 111
Remove/Replace the Stepper Motor Assembly (D930413) and Belt (F000428) .................................. 113
Remove/Replace the Upper and Lower Take-up Motor (D920189)...................................................... 115
Remove/Replace the Rewind Motor (D900406) Gear (D920170).......................................................... 118
Remove/Replace the RFID Board for the Rewind Motors (A000365-01); Printer Mount................... 120
Remove/Replace the Lamination Head (D920022) and (D920023)...................................................... 122
Remove/Replace the Hopper Full Sensor (D940295) ............................................................................ 123
Appendix A Board & Wire Connections..................................................................................................... 124
Mainboard (A940234) Cable Connection –Main Chassis .................................................................... 124
Mainboard (A940234) Cable Connection -Keypad/LED cable (D855013) ........................................... 125
Mainboard (A940234) Cable Connection –Power Cable....................................................................... 126
Mainboard (A940234) Cable Connection –Card Path Film Transfer Fan, Pick Sensor, Flattener
Up/Down Sensor, Lam Motor (D940213)............................................................................................... 127
Auxiliary Board (A920221-10) Cable Connection ................................................................................. 128
Lamination Module Mainboard connection........................................................................................... 129
Lamination board Hopper Full Sensor connection ............................................................................... 130
Lamination board Card Sensor connection ........................................................................................... 130
Lamination Module Cable Routing ........................................................................................................ 131

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HDP8500 Parts Replacement
The purpose of this section is to provide the technician with specific replacement procedures for the
Card Printer. Please see the next page to review standard precautions (to take) while performing these
replacement procedures.
Step
Procedure
1
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
Reverse assembly steps to reassemble the Card Printer.
3
Make note of how the wires are routed through the printer. There are tie clips to hold the wires
in place.
4
An electric screw driver is handy for removing the screws.
5
Suggestion: Lay the printer on the front side for ease of accessing some parts.
6
Important: These procedures can only be performed by authorized service personnel.
7
NOTE: Print out the Advanced Setting Card for future reference.
If the main board or the printhead is replaced or if an EPROM error is displayed these
numbers will need to be added back into the Advanced Settings Options within the
driver.
From the LCD display select the TOOLS icon then select the DIAGNOSTIC icon. Find
the SELF TEST –PRINTER SETTINGS CARDS. Print out the Printer Setting and the
Laminator Settings keep for future use.

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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, take jewelry off of fingers and hands,
as well as thoroughly clean hands to remove oil and debris before working on
the Printer.

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Cover Removal / Replacement Procedures
Important: These procedures can only be performed by authorized service personnel.
Important: Make note of the wire routing when moving wires for parts replacements. Clips are
provided inside the printer for wires and tie clips are used to bundle wires. Keep wires away from
moving parts.
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.
Suggestion: Lay the printer on the front side for ease of accessing the parts.
SAFETY CONCERNS:
Safety glasses must be worn
ESD CONCERNS:
ESD precautions are necessary when handling electronic assemblies

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Reviewing the HDP8500 Covers
The Covers must be removed in this sequence (order) to avoid damage to these parts.
Reverse order to re-assemble.
1. Top/Rear Cover D940089
2. Front Panel Cover D940201-01
3. Input Cover D940092-02
4. Output Cover D940199-02

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Remove/Replace the Rear/TOP Cover Assembly (D940089)
Tools needed: T10 (Torx )Driver
Estimated Time: 10 minutes
Important: This procedure can only be performed by authorized service
personnel.
Step
Procedure
1
Caution: Power off the Printer by unplugging the power cord from the Printer.
2
Remove the (8) screws (F000170) from the back side of the cover.
* When replacing the Rear Cover do not tighten this screw at this step.
3
Remove the (5) screws (F000190) from the top of the rear cover.
* When replacing the Rear Cover do not tighten this screw at this step.
4
Lift the cover up and back from the printer.

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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 new cover.
*Tighten all the screws after the cover is completely attached.

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Remove/Replace the Front Panel Cover (D940201-01)
Tools needed: Philip driver
Estimated Time : 10 minutes
Important: This procedure can only be performed by authorized service
personnel.
Step
Procedure
1
Caution: Power off the Printer by unplugging the power cord from the Printer.
2
Remove the (9) screws (F000231) from the front cover panel
(D940201-01)
3
Remove the 2 Door Centering Guides (D940292) from the Input Cover in order to have
clearance.
Lift up the Front Cover Panel and off of the frame.
4
Reverse the instructions to re-assemble or install a new cover. Start all 9 screws first, and then
tighten all 9 screws down.

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Remove/Replace the Input Cover (D940092-02)
Tools needed: T10 Torx Driver, Philip driver
Estimated Time: 10 minutes
Important: This procedure can only be performed by authorized
service personnel.
**Remove this cover if replacing the Bezel LCD Display Assembly
(D940088-01)
Step
Procedure
1
Caution: Power off the Printer by unplugging the power cord from the Printer.
2
Remove (1) screw (F000190) from the bottom BACK cover. (T10 driver)

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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(F000170) from the bottom FRONT cover. (T10 driver)
Note: Cable Routing. Do not pinch cable.
(continued next page)

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6
Lift OUT and UP from the bottom to clear the top frame.

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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 completely attached.

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Remove/Replace the Output Cover (D940199-02)
Tools needed: T10 Torx Driver, Philip driver
Estimated Time: 10 minutes
Important: This procedure can only be performed by authorized service
personnel.
Step
Procedure
1
Caution: Power off the Printer by unplugging the power cord from the Printer.
2
Remove (1) screw (F000170) from the bottom BACK cover. (T10 driver)
* When replacing the Output Cover do not tighten this screw at this step.
3
Remove (1) screw (F000170) from the bottom FRONT cover. (T10 driver)
* When replacing the Output Cover do not tighten this screw at this step.

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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 the Output Cover.
6
Reverse the instructions to re-assemble or install a new cover.
*Tighten all the screws after the cover is completely attached.

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Remove/Replace the Door Cover (D940090-01)
Tools needed: T10 Torx Driver
Estimated Time: 10 minutes
Important: This procedure can only be performed by authorized service
personnel.
Step
Procedure
1
Caution: Power off the Printer by unplugging the power cord from the Printer.
2
Remove the (2) screws (F000170) from the left and right side hinges.
* When replacing the Door do not tighten this screw at this step.