Magtek ExpressCard 1000 User manual

MagTek I 1710 Apollo Court I Seal Beach, CA 90740 I Phone: (562) 546-6400 I Technical Support: (888) 624-8350

www.magtek.com

ExpressCard 2000 /

ExpressCard 3000

Instant Issuance Card Personalization System

Hardware Service Manual

February 2020

Document Number:

D99875607-91

REGISTERED TO ISO 9001:2015

ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual

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Printed in the United States of America

INFORMATION IN THIS PUBLICATION IS SUBJECT TO CHANGE WITHOUT NOTICE AND

MAY CONTAIN TECHNICAL INACCURACIES OR GRAPHICAL DISCREPANCIES. CHANGES

OR IMPROVEMENTS MADE TO THIS PRODUCT WILL BE UPDATED IN THE NEXT

PUBLICATION RELEASE. NO PART OF THIS DOCUMENT MAY BE REPRODUCED OR

TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, FOR

ANY PURPOSE, WITHOUT THE EXPRESS WRITTEN PERMISSION OF MAGTEK, INC.

MagTek® is a registered trademark of MagTek, Inc.

MagnePrint® is a registered trademark of MagTek, Inc.

MagneSafe® is a registered trademark of MagTek, Inc.

Magensa™ is a trademark of MagTek, Inc.

ExpressCard 2000 and ExpressCard 3000™ are trademarks of MagTek, Inc.

AAMVA™ is a trademark of AAMVA.

American Express® is a registered trademark of American Express Marketing & Development Corp.

ANSI®, the ANSI logo, and numerous other identifiers containing "ANSI" are registered trademarks,

service marks, and accreditation marks of the American National Standards Institute (ANSI).

EMVCo™ and EMV™ are trademarks of EMVCo and its licensors.

ISO® is a registered trademark of the International Organization for Standardization.

MasterCard® is a registered trademark and PayPass™ and Tap & Go™ are trademarks of MasterCard

International Incorporated.

Microsoft® and Windows® are registered trademarks of Microsoft Corporation.

UL™ and the UL logo are trademarks of UL LLC.

Visa® and Visa payWave® are registered trademarks of Visa International Service Association.

TiltWatch® is a registered trademark of ShockWatch, Inc.

TrueType® is a trademark of Apple Inc., registered in the United States and other countries.

All other system names and product names are the property of their respective owners.

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Table 0.1 - Revisions

Rev Number

Date

Notes

1.01

Dec 11, 2013

Initial release derived from 99875357-6.01, 33099078-2.01,

99875617-1.01, MagTek Support Services videos

2.01

Jan 14, 2014

Add removal / replacement for tipper heater, hopper module,

exit transport module, exit ramp and tipper module, MLB,

power controller, embedded PC, power supply, MSR,

touchscreen. Update some figures with improved renderings.

Add orientation to cardinal directions. Incorporate warnings

and re-order to support tipper cooling time. Re-order

Replacement and Adjustments chapters for more logical cross-

references. Improve cover removal/re-install instructions. Add

time estimates for replacements. Make terminology and order

of steps more consistent. Start section for troubleshooting

service-only issues. Add introduction to embosser alignment.

Update cleaning photos. Add sensor diagram. Improve content

about security of consumables. Fix image printer replacement

structure. Add details about top deck plate keys / slots.

3.01

May 5, 2014

Fix minor formatting issues; add step to move hopper shuttle

before removing side access doors; add advisory to not pinch

wires when removing left side access door.

4.01

Jun 27, 2014

Update troubleshooting information about uneven tipping;

general updates to tipper heater replacement.

50

Aug 15, 2014

Make parking hopper shuttle a standard part of preparation for

preventive maintenance and removal/replacement.

60

Feb 13, 2015

General cleanup and clarity enhancements; simplify embosser

replacement; modify power supply replacement to not tip

device; add AC filter remove/re-install; add Ethernet jack

remove/re-install; add right side cover replacement; add hopper

transport flex cable replacement; add section about retrieving

dropped hardware; fix MCP button name in hopper transport

cleaning per Support; fix cable orientation in embedded PC

replacement; general cleanup

61

Apr 10, 2015

Update hex wrench sizes for embosser replacement.

70

May 1, 2015

Update section 5.21 and section 1 to provide unboxing and re-

packaging steps for embosser module; update section 6.6 to add

information about calibrating embossed character relief height;

miscellaneous clarifications.

80

Oct 30, 2015

Add section 5.6 to support complete replacement of top access

door right latch per customer request; minor update to embosser

photos in section 5.21 and section 6.6.1.

81

Apr 8, 2016

Add steps to lubricate and test embosser hammer pin and

knuckle during preventive maintenance (section 3.12); fix ToC

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Rev Number

Date

Notes

82

Oct 21, 2016

Add section 5.13 How to Remove / Re-install the Image

Printer Top Door Cover based on content from new

D998200131

83

Mar 20, 2017

Update and streamline section 5.8 based on design changes;

misc. clarifications and corrections

84

Nov 6, 2017

Update section 3.5 to specify updating firmware if MagTek

Support Services has supplied a .CAB file; Update section 3.15

to specify direct handoff of consumables; Retrofit standardized

Caution, Warning, Notice tables throughout

90

Jan 17, 2020

Throughout, add separate EC3000 procedures where they differ

substantially from EC2000, including 4 Preventive

Maintenance Procedure (EC3000), section 5.17 How to

Remove / Re-Install the Image Print Head (EC2000 with

ECP2, EC3000), section 5.14 How to Remove / Re-install the

Image Printer Module (EC2000 with ECP2, EC3000); Add

section 5.12 How to Remove / Re-install the Image Print

Head migrated from Installation and Operation Manual;

Remove Aligning Embossed Characters with Printed

Characters (deprecated feature); 6.5.2 fix decrease vs. increase

of values; Migrate tools/materials information to individual

procedures; Add new summary checklist at top of each

procedure; Update tipper heater instructions section 5.27; Add

combined tipper / exit procedure section 5.24 and do

corresponding rewrites to individual modules in sections 5.25

and 5.23 and tipper calibration in section 6.8.1; Add diagnosis

section 7.1.3; Misc. clarifications and corrections.

91

Feb 20, 2020

Re-order section 5 replacement procedure subsections to be

consistent with order of card movement through device; Section

5.20 add standard tools and materials subsection; Section 5.22

add standard remove / re-install subsection; Section 5.30 add

standard remove subsection; Sections 5.30 and 7.1, incorporate

MLB handling content from technical bulletin D998200325;

Add section 5.16; Add checklists to sections 5.8, 5.19, 5.21;

Misc. clarifications and corrections.

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SAFETY

This product has been evaluated by multiple safety certification agencies, including

Underwriters Laboratories (UL) and the United States Federal Communications

Commission (FCC Class A and Class B), and is designed to protect both the user and the

device. This document is written specifically to work in conjunction with these safety and

integrity features to protect the user and the device. It is very important to follow all

steps in the product documentation carefully, in the order in which they are described,

and at the recommended times. Failure to do so could result in personal injury, and / or

cause damage to the device, and / or void the product warranty.

The information within this manual has been prepared for use by trained professional

service personnel and is not intended for general use. To maintain the safety and integrity

of the device, follow the procedures described in this manual carefully.

For your personal safety and to prevent damage to the device, disconnect power from the

device before you connect or disconnect any cable, electronic board, or assembly.

SAFETY REQUIREMENTS

Never do any of the following:

 DO NOT use a ground adapter plug to connect equipment to a power socket-outlet that lacks a

ground connection terminal.

 DO NOT attempt any maintenance function that is not specifically described in this manual or in

other ExpressCard 2000 instructional documents published by MagTek.

 DO NOT remove any of the covers or guards that are fastened with screws. There are no user-

serviceable areas within these covers.

 DO NOT override or “cheat” electrical or mechanical interlock devices.

 DO NOT use ExpressCard supplies or cleaning materials for other than their intended purposes.

 DO NOT operate the equipment if you or anyone else have noticed unusual noises or odors.

Consider the following before operating the ExpressCard 2000:

 Connect the ExpressCard to a properly grounded AC power socket-outlet. If in doubt, have the

socket-outlet checked by a qualified electrician. Improper connection of the device’s grounding

conductor creates a risk of electric shock.

 Place the ExpressCard on a solid surface that can safely support the device’s weight plus the weight

of a person leaning against it (such as a service technician).

 Be careful when moving or relocating the device. Use proper lifting techniques.

Use materials and supplies specifically designed for MagTek devices. Using unsuitable

materials may result in poor performance, and in some cases may be hazardous.

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Table of Contents

Safety .................................................................................................................................................................. 5

Table of Contents .............................................................................................................................................. 6

1 Required Tools, Materials, and Documents ....................................................................................... 13

1.1 Required Tools ................................................................................................................................ 13

1.2 Suggested Tools ............................................................................................................................. 13

1.3 Required Materials ......................................................................................................................... 14

1.4 Suggested Materials ...................................................................................................................... 14

1.5 Required Software and Documents ............................................................................................ 15

2 Introduction ............................................................................................................................................. 16

2.1 Recommended Preparation for Service Appointments ........................................................... 17

2.2 Important Safety Information ...................................................................................................... 18

2.3 How to Handle ESD-Sensitive Parts ............................................................................................. 19

2.4 Introduction to ExpressCard Components .................................................................................. 20

2.5 Device Specifications ..................................................................................................................... 21

2.6 About Installation & Operation .................................................................................................... 21

2.7 How to Open the Top Access Door .............................................................................................. 21

2.8 How to Safely Move Transports By Hand .................................................................................... 22

2.8.1 XY Transport Carriage............................................................................................................ 22

2.8.2 Hopper Transport Shuttle ..................................................................................................... 23

2.9 How to Use Maintenance Functions On the Touchscreen ........................................................ 24

2.9.1 How to Use the MCP Commands Page .............................................................................. 25

2.9.2 How to Use the Sensor Utility Page ..................................................................................... 27

2.9.3 How to Use the Embosser Utility Page................................................................................ 31

2.9.3.1 About the Embosser Utility Page ................................................................................. 31

2.9.3.2 How to Move the Embosser Wheel ............................................................................. 31

2.9.3.3 How to Move the Embosser Cams (Hammers) ......................................................... 32

2.9.3.4 How to Change the Embosser Character Depth and Dwell Time ........................... 32

2.9.4 How to Use the Character Mapping Page .......................................................................... 34

3 Preventive Maintenance Procedure (EC2000) ................................................................................... 36

3.1 Prepare the Device for Preventive Maintenance ....................................................................... 38

3.2 Clean the Card Path ....................................................................................................................... 38

3.3 Clean All Transport Rollers ........................................................................................................... 38

3.4 Update the Software ...................................................................................................................... 41

3.5 Update the Firmware ..................................................................................................................... 42

3.5.1 Check Firmware Revision Numbers .................................................................................... 42

3.5.2 Update the Main Logic Board (Controller) Firmware ........................................................ 43

3.5.3 Update the Image Printer Firmware ................................................................................... 45

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3.6 Service the Hopper Module ........................................................................................................... 46

3.7 Service the XY Transport Module ................................................................................................. 47

3.8 Service the Exit Transport Module ............................................................................................... 50

3.9 Cool the Tipper Heater / Power Down the Device..................................................................... 50

3.10 Clean Inside the Device ............................................................................................................. 51

3.11 Service the Image Printer Module ........................................................................................... 52

3.12 Service the Embosser Module .................................................................................................. 53

3.12.1 About Servicing the Embosser Module ............................................................................... 53

3.12.2 How to Service the Embosser Module ................................................................................ 54

3.13 Service the Electronics .............................................................................................................. 58

3.14 Service the Cover ........................................................................................................................ 58

3.15 Perform Final Tests .................................................................................................................... 58

4 Preventive Maintenance Procedure (EC3000) ................................................................................... 59

4.1 Prepare the Device for Preventive Maintenance ....................................................................... 61

4.2 Deep Clean the Image Printer ...................................................................................................... 61

4.3 Clean Transport Rollers ................................................................................................................. 61

4.4 Update the Software ...................................................................................................................... 62

4.5 Update the Firmware ..................................................................................................................... 63

4.5.1 Check Firmware Revision Numbers .................................................................................... 63

4.5.2 Update the Main Logic Board (Controller) Firmware ........................................................ 64

4.5.3 Update the Image Printer Firmware ................................................................................... 66

4.6 Service the Hopper Module ........................................................................................................... 67

4.7 Service the XY Transport Module ................................................................................................. 67

4.8 Service the Exit Transport Module ............................................................................................... 67

4.9 Cool the Tipper Heater / Power Down the Device..................................................................... 67

4.10 Clean Inside the Device ............................................................................................................. 68

4.11 Service the Image Printer Module ........................................................................................... 68

4.12 Service the Embosser Module .................................................................................................. 69

4.12.1 About Servicing the Embosser Module ............................................................................... 69

4.12.2 How to Service the Embosser Module ................................................................................ 70

4.13 Service the Electronics .............................................................................................................. 74

4.14 Service the Cover ........................................................................................................................ 74

4.15 Perform Final Tests .................................................................................................................... 74

5 Removal and Re-installation................................................................................................................. 75

5.1 How to Prepare the Device for Removing / Re-installing Modules ........................................ 75

5.2 How to Retrieve Dropped Screws and Other Hardware ........................................................... 76

5.3 How to Remove / Re-install the Cover ........................................................................................ 77

5.3.1 Tools, Materials, and Documents ........................................................................................ 78

5.3.2 Remove.................................................................................................................................... 79

5.3.3 Re-install .................................................................................................................................. 86

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5.4 How to Remove / Re-install the Right Side Cover .................................................................... 91

5.4.1 Tools, Materials, and Documents ........................................................................................ 91

5.4.2 Remove.................................................................................................................................... 92

5.4.3 Re-install .................................................................................................................................. 93

5.5 How to Remove / Re-install the Top Access Door .................................................................... 94

5.5.1 Tools, Materials, and Documents ........................................................................................ 95

5.5.2 Remove.................................................................................................................................... 96

5.5.3 Re-install .................................................................................................................................. 98

5.6 How to Remove / Re-install the Top Access Door Right Latch ............................................... 99

5.6.1 Tools, Materials, and Documents ...................................................................................... 100

5.6.2 Remove.................................................................................................................................. 101

5.6.3 Re-install ................................................................................................................................ 104

5.7 How to Remove / Re-install the Side Access Doors ............................................................... 106

5.7.1 Tools, Materials, and Documents ...................................................................................... 106

5.7.2 Remove.................................................................................................................................. 107

5.7.3 Re-install ................................................................................................................................ 108

5.8 How to Remove / Re-install the Hopper Module ..................................................................... 109

5.8.1 Tools, Materials, and Documents ...................................................................................... 111

5.8.2 Remove.................................................................................................................................. 112

5.8.3 Re-install ................................................................................................................................ 124

5.9 How to Remove / Re-install the Hopper Module Flex Cable ................................................. 144

5.9.1 Tools, Materials, and Documents ...................................................................................... 144

5.9.2 Remove.................................................................................................................................. 145

5.9.3 Re-install ................................................................................................................................ 150

5.10 How to Remove / Re-install the Image Printer Module (EC2000 with ECP1) ................ 155

5.10.1 Tools, Materials, and Documents ...................................................................................... 156

5.10.2 Remove.................................................................................................................................. 157

5.10.3 Re-install ................................................................................................................................ 160

5.11 How to Remove / Re-install the Image Printer Card Cleaning Roller (EC2000 with ECP1)

162

5.12 How to Remove / Re-install the Image Print Head (EC2000 with ECP1) ....................... 163

5.13 How to Remove / Re-install the Image Printer Top Door Cover (EC2000 with ECP1) .. 166

5.13.1 Tools, Materials, and Documents ...................................................................................... 166

5.13.2 Remove.................................................................................................................................. 167

5.13.3 Re-install ................................................................................................................................ 170

5.14 How to Remove / Re-install the Image Printer Module (EC2000 with ECP2, EC3000)174

5.14.1 Tools, Materials, and Documents ...................................................................................... 175

5.14.2 Remove.................................................................................................................................. 176

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5.14.3 Re-install ................................................................................................................................ 181

5.15 How to Upgrade the Image Printer Module from ECP1 to ECP2 ...................................... 188

5.16 How to Remove / Re-install the Image Printer Card Cleaning Roller (EC2000 with ECP2,

EC3000) 189

5.17 How to Remove / Re-Install the Image Print Head (EC2000 with ECP2, EC3000) ....... 190

5.17.1 Tools, Materials, and Documents ...................................................................................... 191

5.17.2 Remove.................................................................................................................................. 192

5.17.3 Re-install ................................................................................................................................ 195

5.18 How to Remove / Re-install the Image Printer Top Door Cover (EC3000) ..................... 197

5.19 How to Remove / Re-install the XY Transport Module ....................................................... 198

5.19.1 Tools, Materials, and Documents ...................................................................................... 200

5.19.2 Remove.................................................................................................................................. 201

5.19.3 Re-install ................................................................................................................................ 205

5.20 How to Remove / Re-install the XY Transport Ribbon Cable ............................................ 207

5.20.1 Tools, Materials, and Documents ...................................................................................... 208

5.20.2 Remove.................................................................................................................................. 209

5.20.3 Re-install ................................................................................................................................ 211

5.21 How to Remove / Re-install the Embosser Module ............................................................ 214

5.21.1 Tools, Materials, and Documents ...................................................................................... 215

5.21.2 Unpack ................................................................................................................................... 216

5.21.3 Remove.................................................................................................................................. 218

5.21.4 Re-install ................................................................................................................................ 221

5.21.5 Pack ....................................................................................................................................... 224

5.22 How to Remove / Re-install Embosser Fonts ...................................................................... 226

5.22.1 Tools, Materials, and Documents ...................................................................................... 226

5.22.2 Remove and Re-install ........................................................................................................ 227

5.23 How to Remove / Re-install the Exit Transport Module ..................................................... 228

5.23.1 Tools, Materials, and Documents ...................................................................................... 230

5.23.2 Remove.................................................................................................................................. 231

5.23.3 Re-install ................................................................................................................................ 234

5.24 How to Remove / Re-install the Combined Tipper Module / Exit Transport Module .... 236

5.24.1 Tools, Materials, and Documents ...................................................................................... 238

5.24.2 Remove.................................................................................................................................. 239

5.24.3 Re-install ................................................................................................................................ 244

5.25 How to Remove / Re-install the Tipper Module .................................................................. 249

5.25.1 Tools, Materials, and Documents ...................................................................................... 251

5.25.2 Remove.................................................................................................................................. 252

5.25.3 Re-install ................................................................................................................................ 258

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5.26 How to Upgrade the Tipper Module from 4:1 Model to 1:1 Model ................................... 261

5.27 How to Remove / Re-install the Tipper Heater.................................................................... 262

5.27.1 Tools, Materials, and Documents ...................................................................................... 263

5.27.2 Remove.................................................................................................................................. 264

5.27.3 Re-install ................................................................................................................................ 269

5.28 How to Remove / Re-install the Embedded PC................................................................... 273

5.28.1 Tools, Materials, and Documents ...................................................................................... 274

5.28.2 Remove.................................................................................................................................. 275

5.28.3 Re-install ................................................................................................................................ 279

5.29 How to Remove / Re-install the Embedded PC Solid State Drive (SSD) ......................... 281

5.29.1 Tools, Materials, and Documents ...................................................................................... 281

5.29.2 Remove.................................................................................................................................. 282

5.29.3 Re-install ................................................................................................................................ 283

5.30 How to Remove / Re-install the Main Logic Board (MLB) ................................................. 284

5.30.1 Tools, Materials, and Documents ...................................................................................... 284

5.30.2 Remove.................................................................................................................................. 285

5.30.3 Re-install ................................................................................................................................ 287

5.31 How to Remove / Re-install the Power Controller and Backplane .................................. 288

5.31.1 Tools, Materials, and Documents ...................................................................................... 289

5.31.2 Remove.................................................................................................................................. 290

5.31.3 Re-install ................................................................................................................................ 294

5.32 How to Remove / Re-install the AC Filter (Power Supply Jack) ........................................ 296

5.32.1 Tools, Materials, and Documents ...................................................................................... 297

5.32.2 Remove.................................................................................................................................. 298

5.32.3 Re-install ................................................................................................................................ 301

5.33 How to Remove / Re-install the Power Supply ................................................................... 302

5.33.1 Tools, Materials, and Documents ...................................................................................... 303

5.33.2 Remove.................................................................................................................................. 304

5.33.3 Re-install ................................................................................................................................ 308

5.34 How to Remove / Re-install the Ethernet Jack ................................................................... 309

5.34.1 Tools, Materials, and Documents ...................................................................................... 309

5.34.2 Remove.................................................................................................................................. 310

5.34.3 Re-install ................................................................................................................................ 313

5.35 How to Remove / Re-install the Magnetic Stripe Reader (MSR) Module ....................... 314

5.35.1 Tools, Materials, and Documents ...................................................................................... 314

5.35.2 Remove.................................................................................................................................. 315

5.35.3 Re-install ................................................................................................................................ 316

5.36 How to Remove / Re-install the Touchscreen ..................................................................... 317

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5.36.1 Tools, Materials, and Documents ...................................................................................... 317

5.36.2 Remove.................................................................................................................................. 318

5.36.3 Re-install ................................................................................................................................ 319

6 Adjustments .......................................................................................................................................... 320

6.1 How to Calibrate the Touchscreen ............................................................................................. 320

6.2 How to Calibrate the Hopper Transport Module ...................................................................... 323

6.2.1 How to Calibrate Hopper Transport Home to Printer Handoff ...................................... 323

6.2.2 How to Calibrate Hopper Transport Manual Feed Slot to Printer Handoff .................. 324

6.3 How to Calibrate the Image Printer Module ............................................................................ 325

6.3.1 About Calibrating the Image Printer ................................................................................. 325

6.3.2 How to Set Ribbon and Driver Settings ............................................................................ 325

6.3.3 How to Calibrate Image Alignment ................................................................................... 329

6.4 How to Minimize Image Printer Margins .................................................................................. 330

6.5 How to Calibrate the XY Transport Module .............................................................................. 332

6.5.1 About Calibrating the XY Transport ................................................................................... 332

6.5.2 How to Calibrate Printer to XY Transport Handoff .......................................................... 332

6.5.3 How to Calibrate XY Transport to Exit Transport Handoff .............................................. 334

6.6 How to Calibrate the Embosser Module ................................................................................... 335

6.6.1 About Embosser Calibration ............................................................................................... 335

6.6.2 Check Knuckle Position ...................................................................................................... 336

6.6.3 Calibrate the Embosser Wheel Home Position ............................................................... 337

6.6.4 Set Embossed Character Height Using Software ............................................................ 339

6.6.5 Calibrate Embossed Character Relief Height and Card Flatness ................................. 340

6.7 How to Calibrate the Indenter Module ...................................................................................... 342

6.7.1 About Calibrating the Indenter Module ............................................................................ 342

6.7.2 How to Calibrate the Rear Indent Cartridge Positions ................................................... 342

6.7.3 How to Calibrate the Front Indent Cartridge Positions .................................................. 345

6.8 How to Calibrate the Tipper Module .......................................................................................... 346

6.8.1 Set Correct Calibrated Temperature ................................................................................. 346

6.8.2 Set Tipper Fan Delay to 0 ................................................................................................... 347

6.8.3 Align Card Position In Tipper .............................................................................................. 347

6.8.4 Calibrate Tip Angle (Pressure) ........................................................................................... 348

6.8.5 Calibrate Dwell Time ........................................................................................................... 348

6.8.6 Calibrate Foil Cool Time ...................................................................................................... 349

7 Diagnosis................................................................................................................................................ 350

7.1 Known Symptoms and Possible Causes .................................................................................. 351

7.1.1 Error message “Card jam at roller station” ...................................................................... 351

7.1.2 Hopper shuttle does not move ........................................................................................... 351

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7.1.3 Card Does Not Exit Image Printer Correctly ..................................................................... 351

7.1.4 Uneven Tipping ..................................................................................................................... 351

7.1.5 Error message “Eject Bin Full” ........................................................................................... 351

7.1.6 Error Message “Unable to Start the MTECJobServer” / Error Message “Error Opening

Controller” .............................................................................................................................................. 351

7.1.7 Main Logic Board Diagnostics and Troubleshooting ...................................................... 352

Appendix A Technical Support ................................................................................................................ 353

Appendix B Glossary ................................................................................................................................. 354

Appendix C Key Loading .......................................................................................................................... 356

1 - Required Tools, Materials, and Documents

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1 Required Tools, Materials, and Documents

The tools and materials required for each procedure are listed in the procedure introductions, and in many

cases are included in the box with the replacement kit.

Additional tools, materials, documents, and software may be required (or helpful / suggested) depending

on the situation, and are listed in the subsections below as guidance for putting together a general-purpose

toolkit, a documentation and software set, and a reserve cache of materials, to bring to every service

appointment.

1.1 Required Tools

Part Number

Quantity

Description

N/A

1 ea.

Any tools specified in each procedure you will perform

N/A

1 ea.

Device top cover key

67800019 or equiv.

1 ea.

Small USB keyboard with touchpad mouse (if calibrating)

N/A

1 ea.

ESD grounding wrist strap

N/A

1 ea.

ESD mat and/or ESD bags

N/A

1 ea.

USB thumb drive with required software and documentation

N/A

1 ea.

Thin-tipped permanent marker

1.2 Suggested Tools

Part Number

Quantity

Description

33011008

1 ea.

ASM TOOL KIT, FIELD SERVICE, EC2000, EC3000

N/A

1 ea.

Laptop with available Ethernet port

22350302 or equiv.

1 ea.

10 ft. Ethernet cable (COM ETHERNET CAT5E BLK 10')

N/A

1 ea.

Pen or pencil

N/A

1 ea.

Paper and clipboard

N/A

1 ea.

Flashlight

N/A

1 ea.

Digital camera or smartphone with camera

N/A

1 ea.

Needle nose pliers

N/A

1 ea.

Hemostat pliers

N/A

1 ea.

Scissors

N/A

1 ea.

Box cutter

N/A

1 ea.

Cable tie tool with adjustable tension

N/A

1 ea.

Multimeter

N/A

1 ea.

Flex Phillips screwdriver OR

Electric screwdriver with flex extension

1 - Required Tools, Materials, and Documents

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1.3 Required Materials

Part Number

Quantity

Description

97200153

1 ea.

ASSEMBLY, KIT, PREVENTIVE MAINTENANCE, EC2000,

EC3000

N/A

1 ea.

Any replacement kits specified in the work order. For a list of kits,

see D99875730 LIST, REPLACEMENT KITS, EC2000, EC3000

N/A

3 ea.

Cloth, clean and lint-free

1.4 Suggested Materials

Part Number

Quantity

Description

33011009

1 ea.

ASSEMBLY, FIELD SERVICE KIT, SPARE PARTS STARTER,

EC2000, EC3000

93400047

1 ea.

PRINTER ACCESSORY, RIBBON, COLOR OVERLAY BLACK

YMCKOK, 200 PRINTS, EC2000

1000002070

1 ea.

PRINTER ACCESSORY, RIBBON, COLOR OVERLAY YMCKO,

200 PRINTS, EC500P, EC3000

33070896

1 ea.

PRINTER ACCESSORY, TIPPER FOIL ROLL, SILVER, EC2000,

EC3000

33070621

1 ea.

ASSEMBLY, REAR INDENT CARTRIDGE, BLACK, EC2000,

EC3000

N/A

Ball

Poster putty, tape, or other adhesive to hold screws on screwdrivers /

hex drivers during removal and insertion

1 - Required Tools, Materials, and Documents

ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual

Page 15 of 356 (D99875607-91)

1.5 Required Software and Documents

MagTek recommends loading the following required software and documents on a USB thumb drive or

service laptop before visiting the customer site.

Part Number

Quantity

Description

D99875600

1 ea.

INSTALLATION AND OPERATION MANUAL, EC2000

D998200281

1 ea.

INSTALLATION AND OPERATION MANUAL, EC3000

D99875607

1 ea.

HARDWARE SERVICE MANUAL, EC2000, EC3000

D99875651

1 ea.

PROCEDURE, PREVENTIVE MAINTENANCE, EC2000

D99875646

1 ea.

CHECKLIST, PREVENTIVE MAINTENANCE, EC2000

D998200294

1 ea.

PROCEDURE, PREVENTIVE MAINTENANCE, EC3000

D998200295

1 ea.

CHECKLIST, PREVENTIVE MAINTENANCE, EC3000

N/A

1 ea.

EC2000 reference image (C:\ from a working EC2000), loaded onto

USB thumb drive or service laptop

N/A

1 ea.

EC3000 reference image (C:\ from a working EC3000), loaded onto

USB thumb drive or service laptop

N/A

1 ea.

Set of passwords for the device being serviced

N/A

1 ea.

Factory defaults for the device being serviced

VARIOUS

0 or more

ExpressCard software patch .CAB files or other supporting files

provided by MagTek Support Services, loaded onto USB thumb drive

or service laptop

2 - Introduction

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Page 16 of 356 (D99875607-91)

2 Introduction

This document provides detailed information about maintaining ExpressCard devices (EC2000 and

EC3000). It is part of the ExpressCard Service Library, which includes:

 D99875600 ExpressCard 2000 Installation and Operation Manual

 D998200281 ExpressCard 3000 Installation and Operation Manual

 D99875607 ExpressCard 2000 / ExpressCard 3000 Hardware Service Manual

 D99875730 ExpressCard 2000 / ExpressCard 3000 Replacement Kit List

Documents in the service library reference each other frequently and are designed to be used together.

2 - Introduction

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Page 17 of 356 (D99875607-91)

2.1 Recommended Preparation for Service Appointments

Before visiting a customer for a service appointment, MagTek recommends you do the following:

1) Review the documentation. For example:

a) D99875600 ExpressCard 2000 Installation and Operation Manual and D998200281

ExpressCard 3000 Installation and Operation Manual, which contain important information

about the device, including Introduction to ExpressCard Features, Introduction to

ExpressCard Components, Operation, Maintenance, and Troubleshooting.

b) Section 2 Introduction, especially section 2.2 Important Safety Information and section 2.3

How to Handle ESD-Sensitive Parts.

c) All sections relevant to the service you will be performing. Depending on the service order, it

may include section 3 Preventive Maintenance, section 7 Diagnosis, section 6 Adjustments,

and section 5 Removal and Re-installation.

2) Gather and test/inspect all tools, materials, and documents, using section 1 Required Tools,

Materials, and Documents and the procedures for any replacements you are performing as a guide.

If you are performing replacements, also gather and inspect available replacement parts.

3) If you need special instructions or information, such as the administrator password for the device(s)

you will be servicing, contact MagTek Support Services for assistance.

4) Copy software and documents you will need to a USB thumb drive.

5) Print any supporting documents you want to have available in hardcopy form.

6) Print a copy of the preventive maintenance checklist for the device you will be servicing:

a) D99875646 EC2000 Preventive Maintenance Checklist

b) D998200295 EC3000 Preventive Maintenance Checklist

7) Test the field service laptop to make sure its browser and network connection are functional.

2 - Introduction

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Page 18 of 356 (D99875607-91)

2.2 Important Safety Information

The information in this document is intended for use by trained professional service

personnel only. It is not intended for general use. To maintain the safety and integrity of

the device, it is important to follow the procedures laid out in this document as-written

and in the order provided.

For your personal safety, and to prevent damage to the device, disconnect power from the

ExpressCard device before you connect or disconnect any cable, electronic board, or

assembly.

2 - Introduction

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Page 19 of 356 (D99875607-91)

2.3 How to Handle ESD-Sensitive Parts

To prevent electrostatic discharge (ESD) damage to electronic parts, follow the

instructions below:

 Keep ESD-sensitive parts in their original shipping containers until you are ready to

install them.

 When handling ESD sensitive parts, prevent static discharge by moving around as

little as possible. Static charges are produced by rubbing together clothing, carpets,

furniture, etc.

 Wear an ESD wrist strap connected to a metal part on the device’s chassis, such as the

base plate. This will discharge static electricity from your body.

 Hold ESD-sensitive parts by their edges or their mounting trays. Do not touch their

pins or circuitry.

 Do not place an ESD-sensitive part on the device or on a metal table; put it in an ESD

bag or on an ESD mat.

 Use extra caution when working under climate conditions that increase the potential

for ESD, such as cold weather or low humidity.

2 - Introduction

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Page 20 of 356 (D99875607-91)

2.4 Introduction to ExpressCard Components

For an introduction to identifying EC2000 components, see D99875600 EC2000 Installation and

Operation Manual. For an introduction to identifying EC3000 components, see D998200281 EC3000

Installation and Operation Manual.

This manual uses the words “Front,” “Rear,” “Left,” and “Right” to describe where to find various parts

of the device. These terms assume the reader is standing in front of the device facing the touchscreen,

and are shown in Figure 2-1. During service, it is normal to move around the device to get easier access

to parts. In the same way, many of the photos and drawings in this manual show the device from different

angles that make key “landmarks” visible. In these cases, the caption will generally state the direction the

figure can be seen from (for example, “FRONT RIGHT VIEW”).

Figure 2-1 – Front/Rear/Left/Right Definition (TOP VIEW)

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