MagTek EC2000 99875651 User Manual
ExpressCard 2000
Instant Issuance Card Personalization System
Preventive Maintenance Procedure
June 2014
Manual Part Number:
99875651-2.01
REGISTERED TO ISO 9001:2008
MagTek I 1710 Apollo Court I Seal Beach, CA 90740 I Phone: (562) 546-6400 I Technical Support: (888) 624-8350
www.magtek.com
Copyright © 2006 - 2014 MagTek, Inc.
Rev Number
Date
Notes
1.01
01/14/2014
Initial release derived from 99875607-2.01-DRAFT
2.01
06/27/2014
General updates to tipper heater replacement.
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.
Magensa™ is a trademark of MagTek, Inc.
MagneSafe™ is a trademark of MagTek, Inc.
ExpressCard 2000 is a trademark of MagTek, Inc.
Microsoft® and Windows® are registered trademarks of Microsoft Corporation.
All other system names and product names are the property of their respective owners.
Table 0.1 - Revisions
ExpressCard 2000| Instant Issuance Card Personalization System | Preventive Maintenance Procedure
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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 machine, 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
Caution: 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 override or “cheat” electrical or mechanical interlock devices.
DO NOT use EC2000 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 EC2000 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 EC2000 on a solid surface that can safely support the device’s weight support the weight of
the EC2000 PLUS the weight of a person leaning against the device (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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1 - Table of Contents
Table of Contents
Table of Contents ............................................................................................................................... 4
1 Required Tools, Materials, and Documents ........................................................................... 5
1.1 Required Tools ..................................................................................................................... 5
1.2 Suggested Tools .................................................................................................................. 5
1.3 Required Materials ............................................................................................................. 5
1.4 Suggested Materials ........................................................................................................... 5
1.5 Required Software and Documents ................................................................................. 5
2 Introduction ................................................................................................................................. 6
3 Preventive Maintenance Procedure ........................................................................................ 6
3.1 Prepare the Device for Preventive Maintenance ........................................................... 6
3.2 Clean the Card Path ............................................................................................................ 6
3.3 Clean All Transport Rollers ................................................................................................ 7
3.4 Update the Software ........................................................................................................... 9
3.5 Update the Firmware ........................................................................................................ 10
3.6 Service the Hopper Module ............................................................................................. 11
3.7 Service the XY Transport Module ................................................................................... 12
3.8 Power Down the Device / Cool the Tipper Heater ....................................................... 13
3.9 Clean Inside the Device .................................................................................................... 14
3.10 Clean the Card Cleaning Roller ................................................................................... 14
3.11 Clean the Image Print Head ........................................................................................ 15
3.12 Service the Embosser Module ..................................................................................... 16
3.13 Service the Electronics ................................................................................................. 17
3.14 Service the Cover ........................................................................................................... 17
4 Perform Final Tests .................................................................................................................. 18
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1 - Required Tools, Materials, and Documents
Part Number
Quantity
Description
33011008
1 ea.
ASM TOOL KIT,FIELD SERVICE,EC2000
67800019 or equiv.
1 ea.
Small USB keyboard with touchpad mouse
N/A
1 ea.
Small diagonal side cutters
N/A
1 ea.
USB thumb drive with required software and documentation
Part Number
Quantity
Description
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.
Flashlight
Part Number
Quantity
Description
97200153
1 ea.
ASM KIT,PREVENTIVE MAINTENANCE,EC2000
Part Number
Quantity
Description
33011009
1 ea.
ASM KIT,STARTER,SPARE,FIELD SERVICE,EC2000
93400047
1 ea.
PRI RIBBON, COLOR YMCKOK EV (R3314)
33070896
1 ea.
ASM RIBBON ASSY,TIP FOIL,SILVER
33070621
1 ea.
AAY ASSY,INDENT CARTRIDGE
Part Number
Quantity
Description
99875600
1 ea.
MNL USER INSTALL & OPERATION MANUAL,EC2000
99875607
1 ea.
MNL HARDWARE SERVICE MANUAL,EC2000
99875651
1 ea.
REF PROCEDURE,PREVENTIVE MAINTENANCE,EC2000
99875646
1 ea.
REF CHECKLIST,PREVENTIVE MAINTENANCE,EC2000
N/A
1 ea.
Passwords and factory defaults for the device being serviced
1 Required Tools, Materials, and Documents
1.1 Required Tools
1.2 Suggested Tools
1.3 Required Materials
1.4 Suggested Materials
1.5 Required Software and Documents
MagTek recommends loading the following required software and documents on the USB thumb drive or
service laptop before visiting the customer site.
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3 - Introduction
Part Number
Quantity
Description
VARIOUS
0 or more
EC2000 software patch .CAB files provided by MagTek Support
Services, loaded onto USB thumb drive or service laptop
2 Introduction
This document contains the preventive maintenance procedure for the ExpressCard 2000 (EC2000),
extracted from 99875607 ExpressCard 2000 Hardware Service Manual. It assumes the reader is
familiar with basic operation of the ExpressCard 2000’s user and maintenance functions, so many of the
cross-references to deeper “how-to” procedures from that manual have been removed for brevity. For
details about performing any procedure described in this document, see that manual and 99875600
ExpressCard 2000 User Installation and Operation Manual.
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 manual as-written and in
the order provided.
CAUTION: For your personal safety, and to prevent damage to the device, disconnect
power from the ExpressCard 2000 before you connect or disconnect any cable, electronic
board, or assembly.
3 Preventive Maintenance Procedure
3.1 Prepare the Device for Preventive Maintenance
Prepare the device for preventive maintenance by following these steps:
1) Offer the customer the opportunity to remove any proprietary or security-sensitive consumables from
the device, including card stock, image printer ribbons, indent cartridges, and tipper foils. Some
consumables contain negative imprints of cardholder data and must be handled securely.
2) Make sure the device is powered up and connected to the network.
3) Open the top access door.
4) Open the two side access doors.
5) Inspect the device for any items that do not belong inside the cover, and remove them (examples
include loose mechanical parts, cards, insect or animal leavings, or jewelry).
6) Inspect the mechanical parts inside the device and inside the image printer, paying special attention to
belts, cables, and plastic gears to see if there are signs of wear or damage.
3.2 Clean the Card Path
Clean the card path using a cleaning card by following these steps:
1) Obtain a cleaning card from the kit.
2) Remove the cleaning card from its package and let it dry for one minute.
3) Remove the image printer ribbon and set it aside in a secure location, or offer it to the customer for
temporary storage or secure disposal.
4) Using the touchscreen, navigate to Menu > Maintenance to open the Maintenance Menu page.
5) Press the Clean Printer… button to launch the Printer Utility page.
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