8.Ilustrated Parts.pdf part of Datacard Datacard 150i 0.Index Service manual.pdf, MANUAL SERVICE text manual preview

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Chapter 8: Illustrated Parts
The 150i Card Personalization System operates as a standalone card embosser. This chapter provides information on assembly and subassembly part numbers for the 150i embosser.
Introduction 8-3 General 8-3 Parts Lists for Base Assembly 8-3
Base System without Topper (596660-102) 8-3 Base Assembly (555099-002) 8-4 Top Cover Assembly (555120-002, FRU is 555120-008) 8-5 Right Door Assembly (556277-001), Rev E 8-5 Back Side Panel Assembly (555098-002) 8-5 Null Modem Cable, DSub,9P-M-F (596813-001) 8-6 Output Door Assembly (556788-001) 8-6

Illustrated Cabinet Parts 8-7 Input/Output Assembly (556787-051), Rev Y 8-8
Input/Output Assembly Parts (596662-002) 8-8 Output Stacker Plate Assembly Parts (596696-001), Rev E 8-9 Illustrated Input/Output Assembly 8-10

Card Transport Assembly 8-11
Card Transport Assembly FRU Parts (556787-050) 8-11 Card Transport Assembly Parts (596661-002) 8-11 X Carriage Motor Assembly FRU Parts (596691-999) 8-11 Y-Drive Card Carriage Assembly Parts (596686-002) 8-11 Right Support Block Assembly FRU Parts (596690-002) 8-12 Illustrated Card Transport Assembly 8-12

Magnetic Stripe Assembly 8-13
IA/IAT, Hico/Loco Parts (596663-001 in Kit 555103-001) 8-13 J, Hico/Loco Parts (596663-002 in Kit 555103-002) 8-13 Back J, Hico/Loco Parts (596663-007 in Kit 555103-007) 8-13 IAJ, Hico/Loco Floating Heads Parts (596663-009 in Kit 555103-009) 8-14 IAJ, Hico/Loco Floating Heads, PR-MBSD (596663-010 in Kit 555103-010) 8-14 Illustrated Magnetic Stripe 8-16

Embosser/Indent Assemblies 8-17
Embosser Assembly Parts (596664-002) 8-17 Daisy Wheel Assembly, 7BSG, 52Char (596678-001) 8-17

150i Card Personalization System Maintenance Manual

8-1

Daisy Wheel Assembly, 7BSG, 50Char (596678-002) 8-17 Emboss Module Wheel Assemblies 8-18 Illustrated Embosser Assembly 8-19 Upper Emboss Housing Assembly Parts (596684-002) 8-20 Illustrated Upper Emboss Housing Assembly 8-20 Lower Emboss Housing Assembly Parts (596683-002) 8-21 Illustrated Lower Emboss Housing Assembly 8-22 Front Indent Assembly Parts (555110-001) 8-23 Front Indent Installation Kit Parts (555111-003) 8-23 Illustrated Front Indent Assembly 8-23 Rear Indent Assembly (555121-999) 8-24 Rear Indent Installation Kit Parts (555111-002) 8-24 Illustrated Rear Indent Assembly 8-25

Topper Assembly 8-26
C. S. Topper FRU Parts (556787-052) 8-26 Topper Assembly Parts (596665-002) 8-26 Topper Heater Assembly Parts (555094-001) 8-26 Lower Topper Assembly Parts (596675-001) 8-26 Topper Left Side Plate Assembly Parts (555091-001) 8-26 Topper Right Side Plate Assembly Parts (555090-001) 8-27 Topper Cassette Assembly Parts (596666-002) 8-27 Foil Motion Assembly Parts (555092-001) 8-27 Topper Foil Parts 8-28 Illustrated Topper Assembly 8-28

Main Control Board 8-29 Power Supply 8-30
Power Supply Assembly Parts (555093-999) 8-30 Power Cords 8-30 Illustration of Power Supply 8-31

Fan 8-32
Sensor Cable Harness 8-33

Power Cable Harness 8-34 Communications Cable 8-35 Smart Card Development Cable 8-35 Display/Keyboard 8-36 Miscellaneous Spare Parts 8-36 Solenoid Lock Assembly 8-37
Solenoid Lock Assembly Parts (555113-002) 8-37 Key Lock Parts 8-37 Illustrated Solenoid Lock Assembly 8-38

Reject Full Sensor 8-39 Smart Card Assembly 8-40

8-2

Illustrated Parts

Introduction
This chapter provides information on assembly and subassembly part numbers for the 150i.

General
The 150i Series Card Personalization System final assembly may be configured under different part numbers related to the 150i Series Card Personalization System defined in the customer order. Verify the final assembly part number before replacing components.

Parts Lists for Base Assembly
Base System without Topper (596660-102)
Item 1 2 3 4 5 6 8 10 11 12 13 14 15 18 19 20 22 23 24 25 27 31 33 37 Item Description Base Assembly Top Cover Assembly Installation, Transport Install, In/Output Assembly Install, Embosser Washer, Flat, Stl 8x.375 Screw, Hex Washer, Tf 8-32x .750 Right Door Assembly Output Hopper Door Pin, Dowel .1252od .50l Front Bottom Panel Front Access Panel Pin, Pivot, Lid Nut, Hex Loc, Nyl Ins.25-20unc Washer, Friction Washer, Belv .500d .258id .035 Screw, Phil, Ph,Tf, 8-18 X 1.0 Container, Shipping, 150i Disk Assembly, Diag Install Utility Manual Assembly, Admin Guide,150i Guard, Output Hopper Screw, Fh100 Phil 4-40x.250 Checklist, 150i Installation Inductor, Ferrite Bead, 250ohm Qty 1 1 1 1 1 1 9 1 1 1 1 1 3 2 4 4 1 1 0 1 1 2 1 2 Part Number 555099-002 555120-998 555101-002 555102-002 555105-002 800075-004 805991-412 556277-001 556278-001 800257-017 556276-001 556272-001 596767-001 803053-005 555647-001 803297-007 806531-116 552875-001 555071-001 526701-001 555735-001 800072-204 526791-001 805513-007

150i Card Personalization System Maintenance Manual

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Item 39 41

Item Description Clip, Ferrite Bead Pamphlet, Security

Qty 2 1

Part Number 805513-101 598713-001

Base Assembly (555099-002)
Item 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 25 26 27 29 31 32 33 34 35 37 41 45 46 49 50 51 Item Description Clamp, Cable, Adhesive Block, Pivot Pin, Dowel .1252od .50l Link, Tray Screw, Hex Wshr,Tf 4-40x.312 Reject Tray Assembly Screw, Hex Washer, Tf 8-32x.505 Photocell, 1 Ear Pt Lock Bracket Assembly Cable Assembly, Flex Circuit Washer, Lock, Ext Tooth 8 Strap. Black Abs Nut, Hex Ext T Keps 6x32 Lower Left Support Link Assembly Lower Right Support Link Assembly Base, 150i Screw, Cap Button 8-32x.500 Nut, Hex, Ext T Keps 8x32 Strap, Flex Cable Lower Conn, Pin Shroud, Pnl Mt, 9pos Access Panel, Fan Housing Assembly, MCB Plate Cable Assembly, Sensor Assembly, Power Supply Rubber Bumper, No. 8 Cable Assembly, Comm I/O Cable Assembly, Display Spacer Strap, Flex Cable Upper Angle, Display Cable Clamp Assembly, MCB Mounting Pan Cable Assembly, Display Ground Switch-Intlk,Spst,10a,250v,Vde Cable Assembly, Pwr, Blockpoint,150i Screw, Hex Washer, Tf 8-32x.375 Screw, Hex Washer, Tf 8-32x .750 Screw, Hex Washer, Tf 8-32x1.00 Qty 6 1 2 1 1 1 48 1 1 1 3 4 2 1 1 1 3 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 2 7 1 Part Number 803323-006 596720-001 800257-017 596719-001 805991-205 555114-001 805991-408 593463-003 555113-002 555040-001 800506-004 552002-001 506021001 555751-003 555751-004 556786-001 803336-408 506022001 596794-001 806553-009 596758-001 555112-998 555962-001 555096-999 805351-002 555037-002 555039-001 555068-001 596793-001 555600-001 555097-002 555723-001 805957-001 555961-002 805991-406 805991-412 805991-416

8-4

Illustrated Parts

Top Cover Assembly (555120-002, FRU is 555120-008)
Item 3 4 5 6 8 9 10 11 13 14 15 16 17 18 Item Description Display Assembly Nut, Hex, Ext T Keps 8x32 Lock-Key,Tubular,1w90,Key Diff Lock, Plate Lid Guide Bracket Assembly Guard, Hopper, Input Upper Left Support Link Assembly Upper Right Support Link Assembly Top Cover,150i Front Panel (Pushes Interlock) Screw, Phil, Ph,Tf 8-18 X 1/2 Nut, Self-Thd, Washer, .12stud Strap. Black Abs Clamp, Cable, Adhesive Qty 1 4 1 1 1 1 1 1 1 1 16 4 2 3 Part Number 596289-001 506022001 807100-001 596771-001 555755-001 596769-001 555750-003 555750-004 556270-001 556271-001 806531-108 806742-001 552002-001 803323-006

Right Door Assembly (556277-001), Rev E
Item 1 2 4 5 6 7 8 9 Item Description Input Door Plate, Cover, Input Right Door Pivot Assembly Pin, Pivot, Door Spacer, Door Hinge Slide Block, Exception Card Spring, Tor 180lh,.348od X.040w Screw, Ph, Tf, Torx 6-19 X.375 Qty 1 1 1 2 2 2 1 4 Part Number 556275-001 596748-001 555753-001 596766-001 560008-001 596718-001 803940-016 806575-406

Back Side Panel Assembly (555098-002)
Item 1 2 3 4 7 8 10 12 13 14 15 Item Description Filter-Line Assembly, AC Fuse, Fast-Acting, 6.3a, 250VAC Outside Cabinet Cable Assembly, Power Switch Nut, Hex Ext T Keps 6x32 Fan Assembly, 24 VDC Tape, Double Sided,3/4in X.010 Panel, Right, Front Screw, Phil, Ph,Tf, 8-18 X .375 Bezel-Dsub, Snap-In, 9 Pos Screwlock Assembly, Fem, D Conn Qty 1 2 1 1 2 1 0 1 4 4 2 Part Number 594032-001 804960-024 596625-001 596679-001 506021001 594030-002 803133-005 556273-001 806531-106 805551-003 803986-101

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Null Modem Cable, DSub,9P-M-F (596813-001)
Item 1 Item Description Cable Assembly, Null Modem, 9PM-F, 10FT Qty 1 Part Number 806771-001

Output Door Assembly (556788-001)
Ite m 1 2 3 4 Item Description Left Door Assembly Tray Link (from Door to Base) Pivot Block (on Base) Pin, Dowel .1252OD .50L Qty 1 1 1 2 Part Number 556278-001 596719-001 596720-001 800257-017

8-6

Illustrated Parts

Illustrated Cabinet Parts

150i Card Personalization System Maintenance Manual

8-7

Input/Output Assembly (556787-051), Rev Y
Input/Output Assembly Parts (596662-002)
Item 1 2 3 4 5 6 7 8 9 10 12 19 22 24 26 29 37 38 39 41 43 46 47 48 49 50 51 52 Item Description Base Plate Assembly, IH/OS Left Side Plate Assembly, IH/OS Right Side Plate Assembly, IH/OS Roller, Cam Gear, Idler Plate, Card Gap Assembly Plate, Support, Card Gap Screw, Phil, Fh, Tf 4-24 X .375 Screw, Phil, Ph, Tf, 4-24 X .375 Wire Assembly, Input Motor Ground Shaft, Support Throat Gap Motor Assembly (includes motor 596104-001) (pulley is item 66, 555986-001) Motor Assembly, IH/OS Plate Assembly, Stacker, Output (contains PC flag, output rollers, o-ring) Cam (with Shaft) (Idler gear is item 5.) Spacer Washer, Ins .125x.312x.032 Pin, Dowel .0939od .50l Screw. Hex Washer, Tf 4-40 X.375 Screw, Hex Washer, Tf 4-40x.312 Spacer Washer, Uns .127x.250x.015 Ring, Retaining, Ext- .125sd- .094fd Ball Bearing Mr .13id .38od .16w Ball Bearing Mr .13id .31od .14w Input Hopper Card Weight Screw, Shoulder, .125x.188 4-40 Spacer Washer, Ins .126x.250x.015 Washer-Curved,Spring,No.5 Input Hopper Empty Sensor, Input Home Sensor, Output Full Sensor, Card Picked Sensor, Throat Gap Motor Sensor Card Registration Sensor Spring, Extension .19OD .88L .020W Support Plate Block, Leadscrew Pulley, Leadscrew-12 Groove Block, Slide Bracket, Support, Motor Pulley, Leadscrew-20 Groove Leadscrew Throat Gap Motor Belt Qty 1 1 1 1 1 1 1 2 6 1 3 1 1 1 1 1 2 6 17 1 1 4 2 1 2 2 2 5 Part Number 596695-002 596697-001 596698-001 596328-001 596455-001 596333-001 556473-001 806582-106 806531-006 556307-001 596353-001 548992-003 555082-999 596696-001 596454-001 803223-016 800257-002 805991-206 805991-205 803112-026 803113-034 803128-004 803128-005 596713-001 803140-001 803223-045 805439-002 593463-003

53 60 61 65 66 67 69 70 71 72 8-8

1 1 1 1 1 1 1 1 1 1

590067-003 803111-058 555981-001 556280-001 555986-001 556281-001 555989-001 555990-001 555991-001 803129-126 Illustrated Parts

Item 74 75

Item Description Spacer Washer, Uns .127x.250x.015 Washer, Flat, Stl 6x.267

Qty 3 2

Part Number 803112-026 800718-003

Output Stacker Plate Assembly Parts (596696-001), Rev E
Item 1 2 3 5 7 8 10 11 12 Item Description Roller, Output Output Hopper Drive Belt Plate, Support, Stacker Screw, Hex Washer, Tf 4-40x.312 O-Ring, Output Hopper Drive Belt Pulley, Groove Spring, Extension .09od 1.00l .010w Arm, Output Full Flag, Sensor Qty 2 4 1 3 1 1 1 1 1 Part Number 596458-001 803478-009 596465-001 805991-205 803478-019 596459-001 803111-023 596457-001 596478-001

150i Card Personalization System Maintenance Manual

8-9

Illustrated Input/Output Assembly

8-10

Illustrated Parts

Card Transport Assembly
Card Transport Assembly FRU Parts (556787-050)
Item 1 2 Item Description Transport Assembly, 150i Blockpoint Transport FRU Shipping Crate Qty 1 1 Part Number 596661-002 556791-001

Card Transport Assembly Parts (596661-002)
Item 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 24 25 26 28 Item Description Block, Support, Leadscrew Y-Drive Card Carriage Assembly X-Carriage Assembly Motor Assembly, 1.0amp,9 Pos Mml Pulley, 48-Groove Nut, Hex, Ext T Keps 10x32 Screw, Set 8-32x.19 Y Transport Drive Belt Screw, Hex Washer, Tf 4-40 X.375 Y-Carriage Motor Assembly Bracket, Mount, Flex Circuit Conn, Pin Shroud, Pnl Mt, 9pos Screw, Hex Washer, Tf 4-40x.312 Y-Home Sensor, X-Home Sensor Screw, Hex Washer, Tf 8-32x.625 Tube, Support X-Drive Leadscrew Shaft Bearing, Guide (brown piece around black tube) X Transport Drive Belt Brg, Ball R .25id .75od .28w Screw, Shoulder .187x.250 8-32 O-Ring, .114id .06w Buna-N Washer, Flat, Stl 8x.375 Pin, Dowel .1877od .50l Qty 2 1 1 1 3 2 3 1 2 1 1 1 1 1 6 2 1 1 1 2 3 3 3 2 Part Number 596658-001 596686-002 596688-002 598174-002 596446-001 506023001 804020-020 803129-122 805991-206 596687-001 596784-001 806553-009 805991-205 593463-003 805991-410 596312-001 596311-001 596444-001 803129-123 803106-009 803140-010 803478-006 800075-004 800257-025

X Carriage Motor Assembly FRU Parts (596691-999)
Item 0 Item Description Motor Assembly, X Carriage Qty 1 Part Number 596691-001

Y-Drive Card Carriage Assembly Parts (596686-002)
Item 1 2 3 5 6 Item Description Y-Carriage Assembly Cable Assembly, Flex Adapter Screw, Hex Washer, Tf 4-40x.50 Card Pick Cam Link Plate Hinge Qty 1 1 1 2 2 Part Number 555915-001 555041-001 805991-208 596437-001 596438-001 8-11

150i Card Personalization System Maintenance Manual

Item 7 8 9 10 11 12 13 14

Item Description Pin, Dowel .0939od X .25l Pivot Shaft Lever Assembly (Pin) Spring, Comp .36od 1.25l .026w Shaft, Leadscrew, Y-Drive Screw, Hex Washer, Tf 8-32x.625 Latch Plate (clicks the gripper pens shut) Spring, Ext .12od .67l .014w

Qty 2 2 1 1 1 2 1 1

Part Number 800257-056 596471-001 596782-001 803072-105 596307-001 805991-410 596304-001 803111-076

Right Support Block Assembly FRU Parts (596690-002)
Item 1 2 4 Item Description Block, Support, Leadscrew Brg, Ball R .25id .75od .28w Pin, Dowel .1877od .50l Qty 1 1 1 Part Number 596658-001 803106-009 800257-025

Illustrated Card Transport Assembly

8-12

Illustrated Parts

Magnetic Stripe Assembly
IA/IAT, Hico/Loco Parts (596663-001 in Kit 555103-001)
Item 1 2 3 8 11 13 14 15 19 Item Description Roller Assembly, Drive,M/S Plate Assembly, Mount, Base Plate Assembly, Support, Mag Stripe Screw, Cap Soc 2-56x.250 Ring, Retaining, Ext- .250sd- .211fd Screw, Set Silver Tip 4-40x.125 Screw, Set, Cup 10-32x.19 Encoder, Optical, 500cpr,1/4dia Mag Stripe Head Assembly, IA/IAT Qty 1 1 1 2 1 2 2 1 1 Part Number 596692-001 596693-001 596694-001 800200-104 803113-004 805544-202 804020-025 805386-001 555715-003

J, Hico/Loco Parts (596663-002 in Kit 555103-002)
Item 1 2 3 4 8 10 11 13 14 15 19 20 22 Item Description Roller Assembly, Drive,J,M/S Plate Assembly, Mount, Base Assembly, Mounting Plate,J,M/S,150i Assembly, Support Plate,J,M/S,150i Screw, Cap Soc 2-56x.250 Spring, Comp .30od .62l .022w Ring, Retaining, Ext- .250sd- .211fd Screw, Set Silver Tip 4-40x.125 Screw, Set, Cup 10-32x.19 Encoder, Optical, 500cpr,1/4dia Mag Stripe Head Assembly, NTT Clamp, Cable Routing, Adhes,3/8 Tx, Jumper, Static Protection Qty 1 1 1 1 2 1 1 2 2 1 1 2 0 Part Number 596692-002 596693-001 555933-001 555934-001 800200-104 803072-047 803113-004 805544-202 804020-025 805386-001 555715-004 806792-001 580197-901

Back J, Hico/Loco Parts (596663-007 in Kit 555103-007)
Item 1 2 3 8 11 13 14 15 19 21 Item Description Roller Assembly, Drive, J Plate Assembly, Mount, Base Plate Assembly, Support, Mag Stripe Screw, Cap Soc 2-56x.250 Ring, Retaining, Ext- .250sd- .211fd Screw, Set Silver Tip 4-40x.125 Screw, Set, Cup 10-32x.19 Encoder, Optical, 500cpr,1/4dia Mag Stripe Head Assembly, NTT Tx, Jumper, Static Protection Qty 1 1 1 2 1 2 2 1 1 0 Part Number 596692-002 596693-001 596694-001 800200-104 803113-004 805544-202 804020-025 805386-001 555715-004 580197-901

150i Card Personalization System Maintenance Manual

8-13

IAJ, Hico/Loco Floating Heads Parts (596663-009 in Kit 555103-009)
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 26 27 28 29 30 31 32 33 34 35 36 38 39 40 Item Description Plate, Mount, Base Block, Support, Lower Shaft, Support Nut, Thumb Pin, Dowel .2502od 1.00l Block, Support Middle Brg, Ball Mr .25id .50od .19w Pin, Dowel .1252od 1.00l Shaft, Encoder Ring, Retaining, Ext- .125sd- .120fd Ring, Retaining, Ext- .250sd- .211fd Bearing, Head, Roller Roller, Rubber Roller, Rubber .750x.2448x.25 Spring, Comp .30od .62l .022w Block, Upper Plate, Top Cap Yoke Pin, Dowel .0627od .44l Spring, Comp .088od ..38l .010w Block, Mount Head IAJ Encoder, Optical, 500cpr,1/4dia Assembly, M/S Head (IAJ Only) Mag Stripe Head Assembly, NTT Screw, Cap Soc 6-32x1.125 Washer, Lock, Hel Spring 6 Pin, Dowel .0938od .38lg Pin, Dowel .093od 1.0l Screw, Cap Soc 2-56x.250 Screw, Fh100 Phil 4-40x.375 Screw, Set, Cup 4-40x.12 Screw, Set, Cup 10-32x.19 Clamp, Cable Routing,Adhes,3/8 Screw, Cap Soc 8-32x.250 Washer, Lock, Ext Tooth 8 Tx, Jumper, Static Protection Qty 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 2 6 2 2 1 1 1 2 2 1 1 2 2 4 2 2 1 1 0 Part Number 556283-001 548379-001 555143-001 596432-001 800257-010 548380-001 803128-013 800257-020 555142-001 803113-043 803113-004 590128-004 590127-002 520529-008 803072-047 548376-001 548377-001 555145-001 800257-029 803072-098 548378-001 805386-001 555715-005 555715-004 800200-318 800175-003 800257-001 800257-035 800200-104 800072-206 804020-010 804020-025 806792-001 800200-404 800506-004 580197-901

IAJ, Hico/Loco Floating Heads, PR-MBSD (596663-010 in Kit 555103-010)
Item 1 2 3 Item Description Plate, Mount, Base Block, Support, Lower Shaft, Support Qty 1 1 1 Part Number 556283-001 548379-001 555143-001

8-14

Illustrated Parts

Item 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 26 27 28 29 30 31 32 33 34 35 36 38 39 40

Item Description Nut, Thumb Pin, Dowel .2502od 1.00l Block, Support Middle Brg, Ball Mr .25id .50od .19w Pin, Dowel .1252od 1.00l Shaft, Encoder Ring, Retaining, Ext- .125sd- .120fd Ring, Retaining, Ext- .250sd- .211fd Bearing, Head, Roller Roller, Rubber Roller, Rubber .750x.2448x.25 Spring, Comp .30od .62l .022w Block, Upper Plate, Top Cap Yoke Pin, Dowel .0627od .44l Spring, Comp .088od ..38l .010w Block, Mount Head Iaj Encoder, Optical, 500cpr,1/4dia Assembly, M/S Head (IAJ Only) Mag Stripe Head Assembly, NTT Screw, Cap Soc 6-32x1.125 Washer, Lock, Hel Spring 6 Pin, Dowel .0938od .38lg Pin, Dowel .093od 1.0l Screw, Cap Soc 2-56x.250 Screw, Fh100 Phil 4-40x.375 Screw, Set, Cup 4-40x.12 Screw, Set, Cup 10-32x.19 Clamp, Cable Routing,Adhes,3/8 Screw, Cap Soc 8-32x.250 Washer, Lock, Ext Tooth 8 Tx, Jumper, Static Protection

Qty 1 1 1 2 1 1 2 1 1 1 1 1 1 1 2 6 2 2 1 1 1 2 2 1 1 2 2 4 2 2 1 1 0

Part Number 596432-001 800257-010 548380-001 803128-013 800257-020 555142-001 803113-043 803113-004 590128-004 590127-002 520529-008 803072-047 548376-001 548377-001 555145-001 800257-029 803072-098 548378-001 805386-001 555715-005 555715-004 800200-318 800175-003 800257-001 800257-035 800200-104 800072-206 804020-010 804020-025 806792-001 800200-404 800506-004 580197-901

150i Card Personalization System Maintenance Manual

8-15

Illustrated Magnetic Stripe

8-16

Illustrated Parts

Embosser/Indent Assemblies
Embosser Assembly Parts (596664-002)
Item 1 2 4 5 6 7 8 9 10 12 13 14 15 16 17 Item Description Guide, Card Screw, Cap Soc 8-32x.500 Washer, Wave, Gap, 2.425 Od Washer, Driver Spring Spring, Comp Driver Screw, Ca Spc .25-20 X 1.75 Washer, Lock, Hel. Spring, .25 Spacer, Washer, Uns .264x.406x.048 Arm Assembly, Rocker Shaft, Rocker Assembly, Lower Emboss Housing Assembly, Upper Emboss Housing Washer, Flat, Stl 8x.375 Washer, Lock, Hel Spring 8 Qty 1 1 1 1 1 1 3 3 3 1 1 1 1 1 1 Part Number 555996-001 800200-408 806521-001 596415-001 555610-001 596421-001 800200-628 800175-014 803112-057 596680-001 596416-001 596683-998 596684-002 800075-004 800175-004

Daisy Wheel Assembly, 7BSG, 52Char (596678-001)
Item 1 2 3 4 5 6 Item Description Wheel, Daisy (Numbered) Gear, Wheel Home Detect Wheel Pin, Dowel .0783od .25l Set, Strip, P/D, Farr-Stdgot,52ch Standard, Wheel Config. Qty 2 1 1 4 1 0 Part Number 596373-002 596711-001 596712-001 800257-048 596447-001 555970-001

Daisy Wheel Assembly, 7BSG, 50Char (596678-002)
Item 1 2 3 4 5 Item Description Wheel, Daisy (Numbered) Gear, Wheel Home Detect Wheel Pin, Dowel .0783od .25l Set, Strip, P/D, Farr-Stdgot, 52ch Qty 2 1 1 4 1 Part Number 596373-002 596711-001 596712-001 800257-048 596447-001

150i Card Personalization System Maintenance Manual

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Emboss Module Wheel Assemblies
Description
150i C. S. EMB-Standard 150i C. S. EMB-Japan Fin 73 Char 150i C. S. EMB-Japanese HC 63 Char 150i C. S. EMB-Swedish 60 Char 150i C. S. EMB-Russian 73 Char 150i C. S. EMB-Japanese Credit 150i C. S. EMB-Visa Elec 37 Char 150i C. S. EMB-Std W/Ind OCR-A1 150i C. S. EMB-Std W/Ind OCR-B1 150i C. S. EMB STD, MC, A1 0-9 150i C. S. EMB-Std W/MC 0-9r 150i C. S. EMB-Std W/OCRB1 Fine 150i C. S. EMB-Std W/Inv MC 0-9 150i C. S. EMB-Visa Elec Fine 52 150i C. S. EMB-Visa Elec 52 Char 150i C. S. EMB-Korean 75 Char 150i C. S. EMB-Czech 75 Char 150i C. S. EMB-Japan Credit W/MPC 150i C. S. EMB-Japan Credit/Rear J 150i C. S. EMB-Japan FIN W/Rear J 150i C. S. EMB-Japan FIN MPC W/Rear J 150i C. S. EMB-Japan HC W/Rear J 150i C. S. EMB-Japan HC MPC W/Rear J 150i C. S. EMB-Poland Visa Elec 150i C. S. EMB-Poland FIN IND B1 0-9 150i C. S. EMB-Japan FIN Spec 58 Ch 150i C. S. EMB-STD, Helv, A1 0-9 150i C. S. EMB-STD W/Helv 0-9 150i Visa Elect +MC, Indent

Part Number
556787-001 556787-002 556787-003 556787-004 556787-005 556787-006 (inactive) 556787-007 556787-008 556787-009 556787-010 556787-012 556787-013 556787-014 556787-015 556787-016 556787-017 556787-018 556787-019 556787-022 556787-024 556787-025 556787-026 556787-027 556787-028 556787-029 556787-030 556787-032 556787-033 556787-034

8-18

Illustrated Parts

Illustrated Embosser Assembly

150i Card Personalization System Maintenance Manual

8-19

Upper Emboss Housing Assembly Parts (596684-002)
Item 1 2 3 4 5 6 8 9 10 12 13 Item Description Housing, Upper Brg, Ball Mf .38id .88od .28w Pulley, Cam Ring, Retaining, Ext- .375sd- .338fd Dual Profile Cam Screw, Set, Cup 10-32x.38 Belt, Htd .118p 5.787l .354w Cam Motor Assembly (includes motor pulley) Nut, Hex Loc, Nyl Ins 8-32unc Photocell, 1 Ear Pt Screw, Hex Washer, Tf 4-40x.312 Qty 1 2 1 1 1 1 1 1 1 2 2 Part Number 555977-001 803128-020 555051-002 803113-025 547634-001 804020-027 805727-004 596682-999 803053-003 593463-003 805991-205

Illustrated Upper Emboss Housing Assembly

8-20

Illustrated Parts

Lower Emboss Housing Assembly Parts (596683-002)
Item 1 2 3 4 5 6 8 9 10 12 13 14 15 16 18 19 20 21 Item Description Housing, Lower Brg, Ball Mf .38id .88od .28w Pulley, Cam Cam Ring, Retaining, Ext- .375sd- .338fd Screw, Set, Cup 10-32x.38 Belt, Htd .118p 5.787l .354w Motor Assembly, Cam Nut, Hex Loc, Nyl Ins 8-32unc Wheel Home Sensor Screw, Hex Washer, Tf 4-40x.312 Washer, Driver Spring Spring, Comp Driver Arm Assembly, Rocker Shaft, Rocker Motor Assembly, Wheel Screw, Hex Washer, Tf 4-40x.50 Qty 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Part Number 555978-001 803128-020 555051-002 555044-002 803113-025 804020-027 805727-004 596682-999 803053-003 593463-003 805991-205 596415-001 555610-001 596421-001 596680-001 596416-001 596681-999 805991-208

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Illustrated Lower Emboss Housing Assembly

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Illustrated Parts

Front Indent Assembly Parts (555110-001)
Item 1 2 23 27 Item Description Assy, Hsg, Front, Front Indent Assy, Hsg, Rear, Front Indent Flange, Outer Screw. Hex Washer, Tf 4-40 X.375 Qty 1 1 1 2 Part Number 556240-001 556241-001 596789-001 805991-206

Front Indent Installation Kit Parts (555111-003)
Item 1 2 4 5 Item Description Screw, Hex Washer, Tf 4-40x.312 Assembly, Indent Front Ribbon Assembly, Indent, Black Bracket, Mounting Qty 8 1 1 1 Part Number 805991-205 555110-001 596805-001 596701-001

Illustrated Front Indent Assembly

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Rear Indent Assembly (555121-999)
Item 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 Item Description
Left Bracket

Pivot Arm Assembly FRU Screw, Hex Washer, Tf 4-40x.312 Screw, Fh100 Phil 4-40x.250 Wheel, Sensing Spacer, Washer, Uns .198x.250x.032 Photocell Roller Assembly FRU Bearing Plate Assembly FRU Bracket, Right Screw, Cap Button 6-32x.250 Supply Reel Assembly FRU Arm, Solenoid Photocell, 1 Ear Pt Spring, Ext .12od 1.13l .016w Roller, Guide, Ribbon Screw, Cap Soc 4-40x.750 Washer, Lock, Ext Tooth 4

Qty 1 1 6 1 1 1 1 1 1 4 1 1 1 1 2 2 2

Part Number 555176-001 555928-999 805991-205 800072-204 590331-001 803112-015 555924-999 555927-999 555175-001 803336-304 555930-999 555174-001 593463-003 803111-005 557006-001 800200-212 800506-002

Rear Indent Installation Kit Parts (555111-002)
Item 6 7 9 10 11 12 13 14 15 16 17 29 32 38 51 Item Description Pulley Assembly, 90t Core, Ribbon Take-Up Hub Assembly Rear Indent Solenoid Assembly Flange, Outer Printer, Rear Indent, Assembly Label, Ribbon Wind, R Indent Screw, Hex Washer, Tf 8-32x.505 Mount, Solenoid Ribbon Assembly, Indent, Black Rear Indent Motor Assembly Rear Indent Drive Belt Screw, Set Loc, Cup 5-40 X .2 Screw, Torx, Ph, Tf 8-32 X .38 Spacer, Washer, Uns .315x.440x.070 Qty 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 Part Number 555929-999 557205-001 555931-999 555932-999 596789-001 555121-999 555974-001 805991-408 555161-001 596805-001 555122-999 803129-123 804020-036 805314-306 803112-033

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Illustrated Parts

Illustrated Rear Indent Assembly

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Topper Assembly
C. S. Topper FRU Parts (556787-052)
Item 1 2 Item Description Topper Assembly Shipping Crate for FRU Qty 1 1 Part Number 596665-002 556793-001

Topper Assembly Parts (596665-002)
Item 2 3 4 5 6 7 8 9 10 12 13 Item Description Topper Heater Assembly Topper Motor Assembly Topper Solenoid Assembly Screw, Buttonhead Cap 1/4-20x.62 Spring, Comp .36od 0.75l .038w Spacer, Washer, Uns .260x.380x.040 Ring, Lift Screw, Buttonhead Cap 8-32x.5,Tx Conn, Hsg, F, Min, 3 Pos Screw, Set, Knurled 1/4-28x.375 Lower Topper Assembly Qty 1 1 1 4 2 2 1 2 1 1 1 Part Number 555094-001 555096-999 555095-001 806213-610 803072-106 803112-009 597970-001 806213-408 803287-003 804020-037 596675-001

Topper Heater Assembly Parts (555094-001)
Item 1 2 3 7 8 9 10 Item Description Plate, Heater Back-Up Shaft, Bearing Block, Pivot Clamp, Platen Screw, Torx, Ph,Tf 4-40 X .375 Platen Heater Assembly Flag, Photocell, Home Qty 1 2 1 3 5 1 1 Part Number 597994-001 596403-001 597997-001 596383-001 805314-106 598767-001 597981-001

Lower Topper Assembly Parts (596675-001)
Item 1 2 3 14 Item Description Topper Right Side Plate Assembly Topper Left Side Plate Assembly Block, Back-Up Screw, Buttonhead Cap 1/4-20x.62 Qty 1 1 1 4 Part Number 555090-001 555091-001 596393-001 806213-610

Topper Left Side Plate Assembly Parts (555091-001)
Item 1 2 3 Item Description Plate, Topper Left Side Screw, Ph, Tf, Torx 6-19 X.375 Block, Cassette Mounting Qty 1 2 1 Part Number 596382-001 806575-406 597980-001

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Illustrated Parts

Topper Right Side Plate Assembly Parts (555090-001)
Item 1 2 3 4 Item Description Plate, Topper Right Side Screw, Ph, Tf, Torx 6-19 X.375 Block, Cassette Mounting Assembly, Foil Motion Qty 1 2 1 1 Part Number 596382-002 806575-406 597980-001 555092-999

Topper Cassette Assembly Parts (596666-002)
Item 1 2 3 4 5 7 8 9 10 Item Description Left Cassette Plate Assembly Worm Gear Assembly Right Cassette Plate Assembly Take-up Ribbon Spindle Assembly Hex Flat Head 6-32 X .75 Spacer, Washer, Uns .382x.648x.010 Screw, Button Head Cap 10-32x.38 Rod, Foil Release Spindle, Foil Tube (green) Qty 1 1 1 1 4 1 1 1 1 Part Number 555083-001 555084-001 555086-002 555087-001 803719-312 803112-048 806213-706 596406-001 597969-001

Foil Motion Assembly Parts (555092-001)
Item 1 2 3 4 5 6 7 10 11 12 13 14 Item Description Motion Flag Pivot Arm Washer, Wave Spring, .194 Id Spindle, Flag Screw, Ph Phil 4-40x1.00 O-Ring, .484id .13w Buna-N Spindle, O-Ring Screw, Hex Washer, Tf 4-40x.312 Topper Platen Sensor Nut, Hex Mach, Stl 10-24unc Spring, Torsion Screw, Shoulder .250x1.00 10-24 Qty 1 1 1 1 1 1 1 1 1 1 1 1 Part Number 596398-001 556609-001 803451-001 596399-001 800073-216 803478-004 596400-001 805991-205 593463-003 800074-005 555703-001 803140-017

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Topper Foil Parts
Description
Silver Gold Black White Dark Blue Process (Light) Blue Red Silver (Taiwan Special)

Part Number
597950-015 597950-003 597950-002 597950-004 597950-001 597950-008 597950-006 597950-016

Illustrated Topper Assembly

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Illustrated Parts

Main Control Board
The Main Control Board Plate FRU is 555112-998.

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Power Supply
Power Supply Assembly Parts (555093-999)
Item 1 2 3 4 Item Description 36V Power Supply Board Assembly Screw, Ph Phil 6-32x.250 Plate, Mounting, Power Supply Screw, Hex Washer, Tf 8-32x.375 Qty 1 3 1 2 Part Number 555033-001 800073-304 596753-001 805991-406

See Back Side Panel Assembly (555098-002) for Line Filter and Fuse part numbers.

Power Cords
Item Description USA, 120V Australia, 10 amp Europe, 10 amp Denmark, 10 amp India, 10 amp Israel, 10 amp Italy, 10 amp Switzerland, 10 amp Japan, 7 amp United Kingdom, 10 amp Hospital, 10 amp China, 10 amp Part Number 556766-001 556766-002 556766-003 556766-004 556766-005 556766-006 556766-007 556766-008 556766-009 556766-010 556766-011 556766-012

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Illustrated Parts

Illustration of Power Supply

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Fan
The part number for the Fan is 594030-001.

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Illustrated Parts

Sensor Cable Harness
The part number for the Sensor Cable Harness is 555962-001.

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Power Cable Harness
The part number for the Power Cable Harness is 555961-002.

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Illustrated Parts

Communications Cable
The part number for the Communications Cable is 555037-002. (The Null modem, 9pin to 9-pin communications cable is 806771-001.)

Smart Card Development Cable
The Cable Assembly for 150i Smart Card Applications is part number 556226-001.

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Display/Keyboard
The part number for the Display Assembly is 596289-001 and for the Display Cable, 555039-001.

Miscellaneous Spare Parts
Description Character Type Insertion Tool (MasterCardTM Only) Administrator's Guide Kit CPX Protocol/Setup Manual Kit Software Developer's Manual Kit Part Number 556335-001 526701-001 526716-001 526709-001

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Illustrated Parts

Solenoid Lock Assembly
Solenoid Lock Assembly Parts (555113-002)
Item Item Description Qty Part Number 1 Assembly, Bracket, Lock Mounting 0 555756-001 2 Screw, Ph Phil 4-40x.187 0 800073-203 3 Solenoid, Frame, Pull, 12vdc 0 806747-001 4 Pin, Cotter .0620d 0.50l 0 803196-102 5 Link, Latch 0 596764-001 6 Assembly, Latch Lock 0 555754-001 8 Ring, Retaining, Ext- .250sd- .207fd 0 803113-023 9 Spring, Ext .188od 1.125l .014w 0 803111-088 10 Screw, Hex Washer, Tf 8-32x.375 0 805991-406 11 Bracket, Switch, Interlock* 0 596755-001 * The front panel (556271-001) pushes down on the Interlock Switch.

Key Lock Parts
The part number for the Key Lock Assembly (With Key) is 807100-001. Description
DC1 Key Only DC2 Key DC3 Key DC4 Key DC5 Key DC6 Key DC7 Key

Part Number
807100-201 807100-202 807100-203 807100-204 807100-205 807100-206 807100-207

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Illustrated Solenoid Lock Assembly

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Illustrated Parts

Reject Full Sensor
The part number for the Reject Full Sensor is 593463-003.

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Smart Card Assembly
The part number for the Smart Card Front IC Assembly is 596668-003.

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Illustrated Parts