4610 fru

4610 SureMark Three-Station Printer All Models

Hardware Service Manual

GY27-0399-03Updated August 13, 2003

��

NoteBefore using this information and the product it supports, be sure to read “Safety information” on page xvii and the generalinformation under Appendix B, “Notices”, on page B-1.

Fourth Edition (June 2003)

This edition applies to the IBM 4610 SureMark Three-Station Point-of-Sale Printers, Models TNx, GRx, GBx andGE3.

This publication is available on the IBM Retail Store Solutions Electronic Web site.1. Go to www.ibm.com/solutions/retail/store.

2. Select Support (at the left on the main page of the Web site).

3. Select Publications to access IBM Retail Store Solutions Electronic Support Web site.

Order publications through your IBM representative or the IBM branch office serving your locality. Publications arenot stocked at the address given below.

A form for reader’s comments is also provided at the back of this publication. If the form has been removed, addressyour comments to:

IBM Corporation,Information Development, Department CJMAPO Box 12195Research Triangle Park, North Carolina, 27709 U.S.A.

When you send information to IBM, you grant IBM a nonexclusive right to use or distribute whatever information yousupply in any way it believes appropriate without incurring any obligation to you.

© Copyright International Business Machines Corporation 2001, 2003. All rights reserved.US Government Users Restricted Rights – Use, duplication or disclosure restricted by GSA ADP Schedule Contractwith IBM Corp.

Updated August 13, 2003

|

||

||

|

|

||

||

||||

||

Contents

Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiWho should read this manual . . . . . . . . . . . . . . . . . . . . xiPrerequisites to this manual . . . . . . . . . . . . . . . . . . . . xiHow this manual is organized . . . . . . . . . . . . . . . . . . . . xiRelated publications and diskettes . . . . . . . . . . . . . . . . . . xi

Summary of changes . . . . . . . . . . . . . . . . . . . . . . xiiiJune 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . xiiiOctober 2002 . . . . . . . . . . . . . . . . . . . . . . . . . xiiiMay 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . xiiiDecember 2001 . . . . . . . . . . . . . . . . . . . . . . . . xiiiAugust 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Tell us what you think. . . . . . . . . . . . . . . . . . . . . . xv

Safety information. . . . . . . . . . . . . . . . . . . . . . . xvii

Chapter 1. Introduction . . . . . . . . . . . . . . . . . . . . . 1-1Available model designations . . . . . . . . . . . . . . . . . . . 1-1Printer overview . . . . . . . . . . . . . . . . . . . . . . . . 1-5Communications overview . . . . . . . . . . . . . . . . . . . . 1-6Physical requirements . . . . . . . . . . . . . . . . . . . . . . 1-9Software requirements . . . . . . . . . . . . . . . . . . . . . 1-11Miscellaneous information . . . . . . . . . . . . . . . . . . . . 1-12Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13User responsibilities . . . . . . . . . . . . . . . . . . . . . . 1-13

Chapter 2. Installation, service, and utility software adjustments . . . . . 2-14610 diskette download support information . . . . . . . . . . . . . . 2-1Software adjustments for document insert station . . . . . . . . . . . . 2-14610 fonts and logos utility diskette (Models TNx only) . . . . . . . . . . 2-4Firmware update (Models TNx only) . . . . . . . . . . . . . . . . . 2-4Emulating the IBM Model 3 or Model 4 printers (Models TNx only) . . . . . 2-6MICR data parser sample code (Model TN4 only) . . . . . . . . . . . . 2-7

Chapter 3. Problem determination for the 4610 Three-Station Printer . . . 3-1Fiscal unit return codes . . . . . . . . . . . . . . . . . . . . . 3-1Offline tests . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Chapter 4. FRU removal and replacement . . . . . . . . . . . . . . 4-1Top covers procedures (Models TNx) . . . . . . . . . . . . . . . . 4-2Document insert station procedures (Models with DI only) . . . . . . . . . 4-9Logic cards procedure . . . . . . . . . . . . . . . . . . . . . 4-43Customer receipt station procedures . . . . . . . . . . . . . . . . 4-49Journal station procedures . . . . . . . . . . . . . . . . . . . . 4-71Interface Card Assembly Procedures . . . . . . . . . . . . . . . . 4-81

Chapter 5. Hardware adjustment procedures . . . . . . . . . . . . 5-1


© Copyright IBM Corp. 2001, 2003 iii

||

Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . . 5-1Mechanical adjustments . . . . . . . . . . . . . . . . . . . . . 5-2

Chapter 6. Operation . . . . . . . . . . . . . . . . . . . . . . 6-1Indicators, controls, and stations – thermal/impact printers . . . . . . . . 6-1Check verification and printing (model TN4 only) . . . . . . . . . . . . 6-2Ribbon loading (Models with DI) . . . . . . . . . . . . . . . . . . 6-6Clearing jams in the check flipper area . . . . . . . . . . . . . . . . 6-8Cleaning the MICR reader read head . . . . . . . . . . . . . . . . 6-10Thermal printheads cleaning . . . . . . . . . . . . . . . . . . . 6-11

Chapter 7. Parts listing . . . . . . . . . . . . . . . . . . . . . 7-1Assembly 1: Printer assembly . . . . . . . . . . . . . . . . . . . 7-2Assembly 2: Journal station cover and button assembly . . . . . . . . . 7-4Assembly 3: Customer receipt station operator button assembly . . . . . . 7-6Assembly 4: Logic cards and shock mounts . . . . . . . . . . . . . . 7-8Assembly 5: Document insert station . . . . . . . . . . . . . . . . 7-10Assembly 6: Customer receipt thermal printhead assembly and cover . . . . 7-12Assembly 7: Printhead transport and ribbon drive assembly. . . . . . . . 7-14Assembly 8: Impact printhead assembly . . . . . . . . . . . . . . . 7-16Assembly 9: Document insert station platen and lever . . . . . . . . . . 7-18Assembly 10: Document insert drive shaft assembly . . . . . . . . . . 7-20Assembly 11: Document insert station gears and motor . . . . . . . . . 7-22Assembly 12: Customer receipt drive, cutter, and platen . . . . . . . . . 7-24Assembly 13: Models TN3, TN4, and TN5 interface assembly . . . . . . . 7-26Assembly 14: Model GRx (RS-485) fiscal interface assembly . . . . . . . 7-28Assembly 15: Model GBx and GEx (USB) fiscal interface assembly . . . . . 7-30Assembly 16: Journal assembly — both sides view . . . . . . . . . . . 7-32Assembly 17: Models GR3 and GE3 power supply assembly (Argentina only) 7-34Assembly 18: Hardware Kits . . . . . . . . . . . . . . . . . . . 7-36Assembly 19: Cable assemblies, filler panel, power supply . . . . . . . . 7-37Assembly 20: Complete printer replacement as a FRU . . . . . . . . . 7-38Assembly 21: Paper roll holder, (Argentina only) . . . . . . . . . . . . 7-40

Appendix A. Removal and replacements for Argentina Model GR3 andGE3 printers . . . . . . . . . . . . . . . . . . . . . . . . A-1

Remove the paper roll holder . . . . . . . . . . . . . . . . . . . A-1Remove the security shield . . . . . . . . . . . . . . . . . . . . A-3Remove the interface assembly . . . . . . . . . . . . . . . . . . A-5Remove the power switch and/or cable . . . . . . . . . . . . . . . A-7Logic card procedures . . . . . . . . . . . . . . . . . . . . . A-10Remove the power cable . . . . . . . . . . . . . . . . . . . . A-13Remove the power supply . . . . . . . . . . . . . . . . . . . . A-14

Appendix B. Notices . . . . . . . . . . . . . . . . . . . . . . B-1Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . B-2Electronic emission notices . . . . . . . . . . . . . . . . . . . . B-3Japanese voluntary control council for interference (VCCI) statement . . . . B-4Taiwanese class A warning statement . . . . . . . . . . . . . . . . B-5Korean communications statement . . . . . . . . . . . . . . . . . B-5Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . . B-5

Part Number Index . . . . . . . . . . . . . . . . . . . . . . C-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1


iv Three Station Printer: Service

||

Figures

1-1. IBM 4610 SureMark point-of-sale printer . . . . . . . . . . . . . . . . . . . . . 1-51-2. Cable Connectors and RS-232 Mode Switch for Thermal/Impact SureMark Printers 1-71-3. SureMark Printer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 1-102-1. Adjustment and Alignment Printouts . . . . . . . . . . . . . . . . . . . . . . 2-33-1. Offline Printer Test Pattern (Thermal/Impact SureMark Printers) . . . . . . . . . . . . 3-33-2. MICR Reader Test Results – Good Noise Level . . . . . . . . . . . . . . . . . . 3-43-3. MICR Reader Test Results – Noise Level Needs Adjusting . . . . . . . . . . . . . . 3-54-1. Removing the Paper and Ribbon Covers . . . . . . . . . . . . . . . . . . . . 4-44-2. Release the Rear Latch Tabs . . . . . . . . . . . . . . . . . . . . . . . . . 4-54-3. Mounting Posts on Front Face of Cover . . . . . . . . . . . . . . . . . . . . . 4-54-4. Removing the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64-5. Removing the operator buttons in the top cover . . . . . . . . . . . . . . . . . . 4-84-6. Removing the Document Insert Feed Cover and the Flipper Cartridge . . . . . . . . . . 4-94-7. Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104-8. Disconnecting the Home Sensor . . . . . . . . . . . . . . . . . . . . . . . 4-114-9. Replacing the Home Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 4-124-10. Removing the Ribbon Drive Assembly . . . . . . . . . . . . . . . . . . . . . 4-144-11. Removing the Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . 4-154-12. Removing the Timing Belt. . . . . . . . . . . . . . . . . . . . . . . . . . 4-174-13. Removing the Printhead/Home Sensor Cable . . . . . . . . . . . . . . . . . . 4-174-14. Removing the Carriage Assembly, Front or Rear Transport Shafts . . . . . . . . . . . 4-184-15. Removing the Front Transport Carrier Bearing . . . . . . . . . . . . . . . . . . 4-194-16. Removing the Transport Motor . . . . . . . . . . . . . . . . . . . . . . . . 4-214-17. Disconnecting the Printhead Cable and Home Sensor . . . . . . . . . . . . . . . 4-234-18. Disconnecting the Sensor Spring and Removing the DI Insert Assembly . . . . . . . . 4-254-19. Removing the Document Insert Platen Assembly . . . . . . . . . . . . . . . . . 4-274-20. Removing the Front Shock Mount. . . . . . . . . . . . . . . . . . . . . . . 4-294-21. Removing the MICR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-294-22. Disconnecting the MICR Cable . . . . . . . . . . . . . . . . . . . . . . . . 4-314-23. Removing the Lower Forms Entry Frame . . . . . . . . . . . . . . . . . . . . 4-324-24. Removing the Flipper Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-324-25. Removing the Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-334-26. Removing the DI Backup Roller . . . . . . . . . . . . . . . . . . . . . . . 4-354-27. Removing the DI Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-364-28. Removing the Front Shock Mount and Disconnecting the MICR Cable . . . . . . . . . 4-384-29. Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-384-30. Removing the Document Insert Feed Roller . . . . . . . . . . . . . . . . . . . 4-394-31. Removing the Front Shock Mount and Disconnecting the MICR Cable . . . . . . . . . 4-404-32. Removing the Motor Gear and Idler Gear . . . . . . . . . . . . . . . . . . . . 4-414-33. Removing the Document Insert Feed Motor . . . . . . . . . . . . . . . . . . . 4-414-34. Removing the Switch Card and Printhead Spacer . . . . . . . . . . . . . . . . . 4-424-35. Removing the Interface Card Assembly. . . . . . . . . . . . . . . . . . . . . 4-444-36. Printhead cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-454-37. Main logic cable connectors . . . . . . . . . . . . . . . . . . . . . . . . . 4-464-38. Main logic cable connectors . . . . . . . . . . . . . . . . . . . . . . . . . 4-474-39. Removing the receipt and ribbon covers . . . . . . . . . . . . . . . . . . . . 4-504-40. Removing the Thermal Cover . . . . . . . . . . . . . . . . . . . . . . . . 4-514-41. Removing the Spiral Wraps . . . . . . . . . . . . . . . . . . . . . . . . . 4-524-42. Disconnecting the Thermal Printhead Cable from the Main Logic Card . . . . . . . . . 4-524-43. Thermal Printhead Latch Assembly . . . . . . . . . . . . . . . . . . . . . . 4-534-44. Removing the Thermal Printhead Latch Spring . . . . . . . . . . . . . . . . . . 4-544-45. View of Drag Strip from Back of Printer. . . . . . . . . . . . . . . . . . . . . 4-554-46. Removing the Drag Strip . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56


© Copyright IBM Corp. 2001, 2003 v

4-47. Thermal Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-584-48. Removing the Spiral Wraps . . . . . . . . . . . . . . . . . . . . . . . . . 4-584-49. Removing the Cutter Stud, Stationary Blade, and Printhead Shaft (Model GR3 or TN3) 4-594-50. Removing the Cutter Stud, Stationary Blade, and Printhead Shaft (Model GR3 or TN4) 4-594-51. Removing the Thermal Platen Assembly . . . . . . . . . . . . . . . . . . . . 4-604-52. Removing the Customer Receipt Motor. . . . . . . . . . . . . . . . . . . . . 4-634-53. Removing the Rotating Blade and Thermal Guide (Model GR3 or TN3) . . . . . . . . . 4-644-54. Removing the Rotating Blade and Thermal Guide (Model TN4) . . . . . . . . . . . . 4-654-55. Removing the Cutter Gears . . . . . . . . . . . . . . . . . . . . . . . . . 4-664-56. Removing the Customer Receipt Paper Guide . . . . . . . . . . . . . . . . . . 4-684-57. Removing the Front Shock Mount and Disconnecting the MICR Cable . . . . . . . . . 4-694-58. Customer Receipt Paper Bucket . . . . . . . . . . . . . . . . . . . . . . . 4-704-59. Journal station — button . . . . . . . . . . . . . . . . . . . . . . . . . . 4-714-60. Journal Station —Thermal Printhead Assembly . . . . . . . . . . . . . . . . . . 4-734-61. Journal Station —Thermal Printhead Cover Assembly . . . . . . . . . . . . . . . 4-744-62. Journal Station — Platen Assembly . . . . . . . . . . . . . . . . . . . . . . 4-754-63. Journal Station — Motor Assembly . . . . . . . . . . . . . . . . . . . . . . 4-764-64. Journal Station — Motor Assembly . . . . . . . . . . . . . . . . . . . . . . 4-784-65. Journal Station — Gear Kit with Clutch and E-clip Assembly . . . . . . . . . . . . . 4-794-66. Journal Station — Top Cover Sensor switch Assembly . . . . . . . . . . . . . . . 4-804-67. Remove Printer Seal and the Secure Screw from Rear Panel . . . . . . . . . . . . 4-824-68. Loosen the Fiscal Interface Assembly Screw and Tilt and Remove Assembly . . . . . . . 4-834-69. Remove Processor Card . . . . . . . . . . . . . . . . . . . . . . . . . . 4-844-70. Remove Interface Card from Assembly . . . . . . . . . . . . . . . . . . . . . 4-854-71. Release the Rear Latch Tabs . . . . . . . . . . . . . . . . . . . . . . . . 4-894-72. Mounting Posts on Front Face of base Cover . . . . . . . . . . . . . . . . . . 4-905-1. DI forms adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35-2. Placement of gap setting tool . . . . . . . . . . . . . . . . . . . . . . . . . 5-55-3. Platen gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55-4. DI open lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65-5. Cutter blade run-In (Models TN3 and TN4) . . . . . . . . . . . . . . . . . . . . 5-75-6. Thermal printhead adjustment for customer receipt and journal stations . . . . . . . . . 5-95-7. Thermal paper switch adjustment . . . . . . . . . . . . . . . . . . . . . . . 5-106-1. Indicators, controls, and printing stations – Thermal/Impact SureMark Printers . . . . . . . 6-16-2. Positioning checks and documents for reading and printing . . . . . . . . . . . . . . 6-36-3. Printable area of an inserted document (portrait) . . . . . . . . . . . . . . . . . . 6-46-4. Printable area of an inserted document (landscape) . . . . . . . . . . . . . . . . 6-56-5. Opening the ribbon cover . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66-6. Ribbon cartridge loading . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76-7. Ribbon path around the printhead . . . . . . . . . . . . . . . . . . . . . . . 6-76-8. Removing the lower document insert (DI) cover . . . . . . . . . . . . . . . . . . 6-86-9. Removing the check flipper cartridge . . . . . . . . . . . . . . . . . . . . . . 6-96-10. Printhead and print line area. . . . . . . . . . . . . . . . . . . . . . . . . 6-11A-1. Distributed paper roll holder . . . . . . . . . . . . . . . . . . . . . . . . . A-1A-2. Integrated paper roll holder . . . . . . . . . . . . . . . . . . . . . . . . . A-2A-3. Removing the distributed paper roll holder . . . . . . . . . . . . . . . . . . . . A-3A-4. Remove the security shield . . . . . . . . . . . . . . . . . . . . . . . . . A-4A-5. Security shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4A-6. Remove the printer seal and the secure screw from rear panel . . . . . . . . . . . . A-6A-7. Loosen the fiscal interface assembly screw and tilt the assembly to disconnect electrical

connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6A-8. Disconnect the electrical connectors and remove the assembly . . . . . . . . . . . . A-7A-9. Location of the power on/off switch . . . . . . . . . . . . . . . . . . . . . . A-8A-10. Power switch and cable with bracket . . . . . . . . . . . . . . . . . . . . . . A-9A-11. Power cable beside main logic card . . . . . . . . . . . . . . . . . . . . . . A-10A-12. Removing the Printer Logic Cards . . . . . . . . . . . . . . . . . . . . . . A-12


vi Three Station Printer: Service

||

A-13. Removing the Interface Card Assembly . . . . . . . . . . . . . . . . . . . . A-13A-14. Loosen the screws and lower the power module cover assembly . . . . . . . . . . . A-14A-15. Loosen the connectors and remove the power supply . . . . . . . . . . . . . . . A-15A-16. Reassembly of the power module into the printer . . . . . . . . . . . . . . . . . A-16A-17. Complete the insertion of the interface assembly housing into the printer . . . . . . . . A-16


Figures vii

||


viii Three Station Printer: Service

Tables

1-1. SureMark Three-Station printer model numbers and the features. . . . . . . . . . . . 1-23-1. Printer Symptoms or Messages . . . . . . . . . . . . . . . . . . . . . . . . 3-64-1. Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45


© Copyright IBM Corp. 2001, 2003 ix

||


x Three Station Printer: Service

Preface

This manual provides information about problem determination, testing,field-replaceable unit (FRU) removal and replacement procedures, and parts listingfor the IBM 4610 SureMark™ Three-Station Point-of-Sale Printers.

Who should read this manualThis manual is intended for use by trained service representatives.

Prerequisites to this manualYou should be familiar with the contents of the IBM 4610 SureMark Point-of-SalePrinters: User’s Guide, GA27-4291

How this manual is organizedv Chapter 1, “Introduction”, on page 1-1 provides an overview of the IBM SureMark

4610 Three-Station 4610 Printer.

v Chapter 2, “Installation, service, and utility software adjustments”, on page 2-1provides information on installation, service, and utility software.

v Chapter 3, “Problem determination for the 4610 Three-Station Printer”, on page3-1 provides information on testing, messages, and symptoms for determiningany failing components of the 4610 printer.

v Chapter 4, “FRU removal and replacement”, on page 4-1 provides informationabout procedures for removing and replacing printer components. providesinformation about procedures for removing and replacing components specific tothe Model GR3 — fiscal printer.

v Chapter 5, “Hardware adjustment procedures”, on page 5-1 provides informationabout procedures for operation of the printer.

v Chapter 6, “Operation”, on page 6-1 provides part numbers of the fieldreplaceable units (FRUs) for the SureMark printer.

v Appendix A, “Removal and replacements for Argentina Model GR3 and GE3printers”, on page A-1 provides information about procedures for removing andreplacing the internal power supply for the Model GR3 printer for Argentina.

v Appendix B, “Notices”, on page B-1 contains electronic emission notices andother general information.

v “Safety Information” on page 4-86 contains the lithium battery safety statement.

Related publications and diskettesv IBM 4610 SureMark Point-of-Sale Printers: User’s Guide, GA27-4291

v IBM 4610 SureMark Point-of-Sale Printers Installation Utilities Diskette

v IBM 4694/4695 Point-of-Sale Terminals Service Diskette

v IBM Safety Information – Read This First, GA27-4004.

The service diskette materials are available only for download from the Internet.Publications for the SureMark Three-Station Printer are available only by downloadfrom the internet.


© Copyright IBM Corp. 2001, 2003 xi

For information about ordering IBM publications not shipped with the 4610SureMark Point-of-Sale Printers, contact your IBM representative or your place ofpurchase.


xii Three Station Printer: Service

Summary of changes

June 2003Added/Changed part numbers in the parts catalog.

Modified table 1–1.

Updated various graphics.

October 2002Added:

v New SureMark Three-Station printer USB Models GB3, GB5 and GE3information has been added.

v Table 1-1 on page 1-2 has been updated that shows the Printer Model Numbersand the main characteristics of the models.

v Updated Assembly 14 in parts listing.

May 2002Added information for:

v The printer for Greece and Turkey

v New security shield for Argentina

v Argentina paper specification.

December 2001Updates include:

Corrections to parts catalog

Model clarifications to chapter 1

Various minor changes throughout.

August 2001Updates for Models TN3 and TN5 information and Models GR3 and GR5information has been added.

A table has been added that shows the Printer Model Numbers and the maincharacteristics of the various models.

Includes information about how to service the Argentine printer’s power supply.

Includes information about the utility service diskette and how to use it when youchange the main logic card on the DI-less model.


© Copyright IBM Corp. 2001, 2003 xiii

|

|

|

|


xiv Three Station Printer: Service

Tell us what you think

Your feedback is important in helping us to provide the most accurate andhigh-quality information. Please take a few moments to tell us what you think aboutthis book. The only way for us to know if you are satisfied with our books, or howwe might improve their quality is through feedback from customers like you. If youhave any comments about this book, please fill out one of the forms at the back ofthis book and return it by mail, by fax, or by giving it to an IBM representative. Ifapplicable, include a reference to the specific location of the text on which you arecommenting. For instance, include the page or table number. If you desire ananswer to a query, please include your name and either your address, FAX number,or telephone number.

Between major revisions of this manual we may make minor technical updates. Thelatest softcopy version of this manual is available under Publications on the IBMRetail Store Solutions Web site.


© Copyright IBM Corp. 2001, 2003 xv


xvi Three Station Printer: Service

Safety information

Danger:Before you begin to install this product, read the safety information in IBMSafety Information — Read This First, GA27-4004. This booklet describes safeprocedures for cabling and plugging in electrical equipment.

Gevaar:Voordat u begint met de installatie van dit produkt, moet u eerst deveiligheidsinstructies lezen in de brochure Veiligheidsinstructies—Lees diteerst, GA27-4004. Hierin wordt beschreven hoe u electrische apparatuur opeen veilige manier moet bekabelen en aansluiten.

Perigo:Antes de começar a instalar este produto, leia as informações de segurançacontidas em Informações Sobre Seguranaça—Leia Isto Primeiro, GA27-4004.Esse folheto descreve procedimentos de segurança para a instalação decabos e conexões em equipamentos elétricos.


© Copyright IBM Corp. 2001, 2003 xvii

Fare!Før du installerer dette produkt, skal du læse sikkerhedsforskrifterne iSikkerhedsforskrifter—Lœs dette først GA27-4004. Vejledningen beskriver denfremgangsmåde, du skal bruge ved tilslutning af kabler og udstyr.

GevaarVoordat u begint met het installeren van dit produkt, dient u eerst deveiligheidsrichtlijnen te lezen die zijn vermeld in de publikatie IBM SafetyInformation — Read This First, GA27-4004. In dit boekje vindt u veiligeprocedures voor het aansluiten van elektrische appratuur.

VAARAEnnen kuin aloitat tämän tuotteen asennuksen, lue julkaisussaTurvaohjeet—Luetämä ensin, GA27-4004, olevat turvaohjeet. Tässä kirjasessaon ohjeet siitä, miten sähkölaitteet kaapeloidaan ja kytketään turvallisesti.


xviii Three Station Printer: Service

DangerAvant d’installer le présent produit, consultez le livret Informations pour lasécurité–Lisez-moi d’abord, GA27-4004, qui décrit les procédures à respecterpour effectuer les opérations de câblage et brancher les équipementsélectriques en toute sécurité.

VorsichtBevor mit der Installation des Produktes begonnen wird, dieSicherheitshinweise in Sicherheitsinformationen—Bitte zuerst lesen, IBM FormGA27-4004. Diese Veröffentlichung beschreibt die Sicherheitsvorkehrungen fürdas Verkabeln und Anschlieβen elektrischer Geräte.

VigyázatMielôtt megkezdi a berendezés üzembe helyezését, olvassa el a IBM SafetyInformation — Read This First, GA27-4004 könyvecskében leírt biztonságiinformációkat. Ez a könyv leírja, milyen biztonsági intézkedéseket kellmegtenni az elektromos berendezés huzalozásakor illetve csatlakoztatásakor.

Pericoloprima di iniziare l’installazione di questo prodotto, leggere le informazionirelative alla sicurezza riportate nell’opuscolo Informazioni di sicurezza—Primeinformazioni da leggere in cui sono descritte le procedure per il cablaggio ed ilcollegamento di apparecchiature elettriche.


Safety information xix

FareFør du begynner å installere dette produktet, må du lesesikkerhetsinformasjonen i Sikkerhetsinformasjon—Les dette først, GA27-4004som beskriver sikkerhetsrutinene for kabling og tilkobling av elektrisk utstyr.

PerigoAntes de iniciar a instalação deste produto, leia as informações de segurançaInformações de Segurança—Leia Primeiro, GA27-4004. Este documentodescreve como efectuar, de um modo seguro, as ligações eléctricas dosequipamentos.

PeligroAntes de empezar a instalar este producto, lea la información de seguridad enInformación de Seguridad—Lea Esto Primero, GA27-4004. Este documentodescribe los procedimientos de sequridad para cablear y enchufar equiposeléctricos.

Varning—livsfaraInnan du börjar installera den här produkten bör du läsasäkerhetsinformationen i dikumentet Säkerhetsföreskrifter—Läs detta först,GA27-4004. Där beskrivs hur du på ett säkert sätt ansluter elektrisk utrustning.


xx Three Station Printer: Service

IBM

IBM

GA27-4004

GA27-4004


Safety information xxi


xxii Three Station Printer: Service


Safety information xxiii


xxiv Three Station Printer: Service

Chapter 1. Introduction

Available model designations . . . . . . . . . . . . . . . . . . . 1-1Model TNx non-fiscal printer application . . . . . . . . . . . . . . 1-3Model GRx, GBx, and GE3 fiscal printer application . . . . . . . . . . 1-3Features available for the 4610 Three-Station printer . . . . . . . . . 1-3Differences in the Models TNx printers and the Model GRx, GBx and GE3

printers . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Printer overview . . . . . . . . . . . . . . . . . . . . . . . . 1-5Communications overview . . . . . . . . . . . . . . . . . . . . 1-6

Communications requirements . . . . . . . . . . . . . . . . . . 1-6Communication interfaces – for Models TNx . . . . . . . . . . . . . 1-6RS-232 XON/XOFF mode selection switch (Models TNx only) . . . . . . 1-7RS-232/RS-485 connections for Models TNx . . . . . . . . . . . . 1-7Communication interface baud rates. . . . . . . . . . . . . . . . 1-8

Physical requirements . . . . . . . . . . . . . . . . . . . . . . 1-9Temperature and humidity limits for all models . . . . . . . . . . . . 1-9Physical dimensions of all models . . . . . . . . . . . . . . . . 1-9Hardware requirements . . . . . . . . . . . . . . . . . . . . 1-11

Software requirements . . . . . . . . . . . . . . . . . . . . . 1-11Operating system levels for Models TNx . . . . . . . . . . . . . . 1-11Operating system levels for Models GRx. . . . . . . . . . . . . . 1-11

Miscellaneous information . . . . . . . . . . . . . . . . . . . . 1-12Resident code pages . . . . . . . . . . . . . . . . . . . . . 1-12Bar codes . . . . . . . . . . . . . . . . . . . . . . . . . 1-12Resources on the internet . . . . . . . . . . . . . . . . . . . 1-12

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13User responsibilities . . . . . . . . . . . . . . . . . . . . . . 1-13

Available model designationsThe IBM SureMark Three-Station printers are available for fiscal and non-fiscalapplications. The various models are shown below with the model numberdesignations and the features that are included in each model. Refer to this chartfor details of the model numbers and the features associated with each model. Thereferences to the printers in this document that apply to all models of printers aredesignated as TNx (for models TN3, TN4, and TN5) or GRx (for models GR3 andGR5), GBx (for models GB3 and GB5) or model GE3.


© Copyright IBM Corp. 2001, 2003 1-1

Table 1-1. SureMark Three-Station printer model numbers and the features

ModelNumber

Top CoverColor

Base Color Interface(RS-485,RS-232,orUSB)

MICR DocInsert

POSTerminal

PowerSource

4610-TN3 Pearl White Litho Gray RS-485&RS-232

No Yes 4694

POSTerminal(RS-485)orExternalsupply(RS-232)


Yes Yes 4694


No No 4694

4610-GR3 Pearl White Litho Gray RS-485 No Yes 4694 POSTerminal(exceptArgentinasupplyinternalto printer)

4610-GR5 Pearl White Litho Gray RS-485 No No 4694 POSTerminal

4610-GB3 Iron Gray Iron Gray USB No Yes 4810(SP300),4840(SP500,&SP600)

ExternalSupply

4610–GB5 Iron Gray Iron Gray USB No No 4810(SP300),4840(SP500,&SP600)

ExternalSupply

4610–GE3 Iron Gray Iron Gray USB No Yes 4810(SP300),4840(SP500,&SP600)

PrinterInternal


1-2 Three Station Printer: Service

||

|||||||||||

|||||||

||||||

|||

|||||||

||||||

|||

||||||

|||

||||||||||||||

|||||||||

||||||||||||

||

||||||||||||

||

||||||||||||

||

|

Model TNx non-fiscal printer applicationThis section lists the following non-fiscal 4610 Models:

Model TN3 Standard Model that supports receipt, journal, and documentprinting.

Model TN4 High-function Models that feature check handling. Check handlinguses the MICR Reader and Check Flipper that are included inthese Models.

With one insertion of a check, the Model TN4 printer reads themagnetic-ink-character line on the check, franks the check, andprints the face of the check. While the printer is processing thecheck, the operator is free to attend to the customer’s needs, whichshortens the total transaction time.

Model TN5 A Model that supports receipt and journal printing. The TN5 doesnot have a document insert station.

Model GRx, GBx, and GE3 fiscal printer applicationThis section lists the following fiscal 4610 Models:

Model GR3 (Fiscal Printer)An RS-485 printer Model that supports receipt, journal, anddocument printing. This printer Model contains special hardwareand microcode required by certain countries.

Model GR5 (Fiscal Printer)An RS-485 printer Model that supports receipt and journal printing.The Model GR5 does not have a document insert station. Thisprinter Model contains special hardware and microcode required bycertain countries.

Model GB3 (Fiscal Printer)A USB printer Model that supports receipt, journal, and documentprinting. This printer Model contains special hardware andmicrocode required by certain countries.

Model GB5 (Fiscal Printer)A USB printer Model that supports receipt and journal printing. TheModel GB5 does not have a document insert station. This printerModel contains special hardware and microcode required by certaincountries.

Model GE3 (Fiscal Printer)A USB printer Model that supports receipt, journal, and documentprinting, and includes an internal power supply. This printer Modelcontains special hardware and microcode required by certaincountries.

Features available for the 4610 Three-Station printerThe following features are available:v 40-Character VFD Post Extensionv Distributed Printer Cable (RS-485)v Integrated Cable (RS-485)v Short RS-232 Communications Cable, 2 m (about 6.6 ft), P/N 86H2192 (TNx

only)v Long RS-232 Communications Cable, 4 m (about 13.1 ft), P/N 86H2195 (TNx

only)


Chapter 1. Introduction 1-3

v Power Supply, P/N 42H1176 (RS-232 TNx, and USB GBx models only)v Power Cords (country-specific)v Journal Keylockv POS Terminal Fiscal Fence (Gxx models only)v Cash drawer (TN3 and TN4 only)v Audit port RS-232 null modem cable, P/N 47P0284 (Models GBx, GEx, and GRx

only)

Differences in the Models TNx printers and the Model GRx, GBx andGE3 printers

Differences between Models TNx of the 4610 printer and Models GRx, GBx andGE3 occur in three categories:v Hardwarev Microcodev Compatibility Modes

HardwareThe Model GRx, GBx, and GE3 printers have a different ″trap door″ on the bottomof the printer with hardware supporting fiscal features including a fiscal seal andmemory epoxied to the circuit board. The 4610 Models GR3 and GE3 for Argentinahave an internal power supply.

Models GRx support only hardware for a RS-485 interface assembly.

Models GBx and GE3 support only hardware for a USB interface assembly.

MicrocodeModels TNx can download microcode loads. The microcode download feature is notavailable on the GRx, GBx and GE3 models due to the fiscal regulations limitingcode changes.

Compatibility modesModels TNx support Model 4 Emulation. Model 4 Emulation is not supported in alloperating system environments. Models GRx, GBx and GE3 are generallycompatible with 3F models. Application changes are required when printing inserteddocuments.



|

||

||||

Printer overview

The IBM SureMark Point-of-Sale Printer is a high-performance, high-function printerthat features a:v Thermal printer customer receipt stationv Thermal printer journal stationv Impact printer document insert station

The dual thermal printheads enable quiet, fast printing of customer receipts andstore journals. The printer also has the capability to print and frank checks and toprint multipart forms through the document insert station.

All SureMark printers provide:v Fast quiet receipt printingv Fast quiet journal printing with a take-up spoolv Easy to load paper and easy-to-load ribbon cartridgev Bar code generation

The SureMark Model TNx printers provide:v Dual interface support: RS-232 (EIA 232) and RS-485 (EIA 485)v Downloadable microcodev Downloadable fonts and code pagesv Single-pass handling of checks (Model TN4)

The SureMark Model GRx printers provide:v Interface support for only RS-485 (EIA 485)v Conformance to fiscal printer regulations. Check the IBM Retail Store Solutions

web site for availability in a specific fiscal country.

The SureMark Model GBx and GE3 printers provide:v Interface support for only USBv Conformance to fiscal printer regulations. Check the IBM Retail Store Solutions

web site for availability in a specific fiscal country.

Journal Feed Button

Customer ReceiptPrinter Station

Ribbon Cover(Document insert cover)

Document InsertPrinter Station

Printer Ready LED

Customer Receipt Feed Button

Document Present LED

Document Feed Button

CustomerReceiptPaper Cover

Journal papercover

Journal PrinterStation

Figure 1-1. IBM 4610 SureMark point-of-sale printer



|

Communications overviewCommunications overview contains requirements, interface information, baud rates,and mode selection.

Communications requirementsFor Models TNx, with RS-232 communications, a 24 V DC power supply with apower cord and the RS-232 cable is required.

Note: If a three-wire RS-232 cable is used, set the printer to XON/XOFF mode.

If you are using RS-485 communications, only the RS-485 cable is required. TheRS-485 cable supplies power directly to the printer.

Models TNx support both RS-232 and RS-485 interfaces. See the 4610 SureMarkThree-Station Printer: Programming Guide for more information about the RS-232interface.

Models GRx support the RS-485 interface. The RS-485 cable supplies powerdirectly to the printer.

Models GBx support the USB interface and require a 24V DC power supply with apower cord and a standard USB cable.

Models GE3 support the USB interface and contains an internal ower supply.

Communication interfaces – for Models TNxThese SureMark printer Models feature a standard RS-232 and an IBM RS-485interface. RS-485 operates at a 187.5K baud rate. RS-232 (TN3, TN4, and TN5only) supports 9600 and 19,000 baud rates. The baud rate is selected using SW1 -1 on the main logic card. The switch is located on the lower left corner of the logiccard and is accessible without removing the printer covers. See Figure 1-2 onpage 1-7. Set the switch as follows:

SW1-1 OFF - 9600 baudSW1-1 ON - 19,200 baud

The card is normally factory-set with SW1-1 in the OFF position, which selects the9600 baud rate. See Figure 1-2 on page 1-7 for thermal/impact SureMark printers.



||

||

|

RS-232 XON/XOFF mode selection switch (Models TNx only)The SureMark printer, Models TNx, support RS-232 protocol using DTR/DSR linesto control data transmission. It also supports XON/XOFF modes where system andprinter software control the flow of data. Select these modes using SW1-2 on themain logic card. The switch is located on the lower left corner of the logic card andis accessible without removing the printer covers. Set the switch as follows:

SW1-2 OFF - DTR/DSR ControlSW1-2 ON - XON/XOFF Control (Required when using

a 3-wire RS-232 cable)

The card is normally factory-set with SW1-2 in the OFF position, which selectsDTR/DSR mode of operation. See Figure 1-2.

RS-232/RS-485 connections for Models TNxThe SureMark printer operates using either RS-232 or RS-485 communicationsprotocol. RS-232 is typically associated with PC systems. The printer contains a9-pin D-shell connector for RS-232 communications. This connector is located onthe interface card and is accessible under the printer without the need to removethe printer covers. The connector has the following pin functions:

Pin Signal Pin Signal

1 Not Connected 6 DSR

2 Transmit 7 Not Connected

3 Receive 8 Not Connected

4 DTR 9 Not Connected

5 Signal Ground

RS-485 mode of communication is obtained when attaching the appropriate cable toPort 7 on an IBM POS system. The RS-485 mode has a higher baud rate thanRS-232.

RS 232ModeSwitch

CashDrawerPort

Power SupplyPort (RS 232Only)

RS 232Port

RS 485 Port

12

OF

F

Figure 1-2. Cable Connectors and RS-232 Mode Switch for Thermal/Impact SureMarkPrinters. (View is from the bottom rear of the printer) (Models TNx only)



Communication interface baud ratesThe RS-485 interface operates at a 187.5K baud rate. RS-232 (TNx only) supports9600 and 19,200 baud rates. Models GRx work on RS-485 only. Models GBx workwith USB only.



|||

Physical requirements

Temperature and humidity limits for all modelsShipping –40 to 60 degrees C (-40 to 140 degrees F) with 5% to 100%

relative humidity including condensation, but excluding rain.

Storage 0 to 60 degrees C (32 to 140 degrees F)

Operating 0 to 40 degrees C (32 to 104 degrees F) with 8% to 80% relativehumidity.

To allow convection cooling, do not block the ventilation holes in the cover.

Physical dimensions of all modelsWidth 322 mm (12.68 in)

Depth 258.7 mm (10.19 in)

Height Front: 140 mm (5.5 in) Rear: 190 mm (7.5 in)

Weight 6.89 kg (15.15 lb)



Front

Top

7.48 inches(190.07 mm)

12.68 inches(322 mm)

7.48 inches(190.07 mm)



Figure 1-3. SureMark Printer Dimensions



Power requirements for external power supply modelsWith the exception of the Argentina GR3 and GE3 models, the SureMark printerdoes not contain a power supply. For the Models GBx and TNx, (operating inRS-232 or USB mode), an external power supply must be attached to the interfacecard of the printer. This connector is located under the printer and is accessiblewithout removing the printer covers. The power connector has the following pinfunction:Pin Signal1 +24 V dc2 Not connected3 Ground

For the models GRx and TNx printers that are operating in RS-485 mode, power issupplied to the printer from the IBM POS terminal. The terminal supplies 38V dcand 5V dc to the printer.

Hardware requirementsSureMark printers work with the following terminals:v PC or other store controller with an RS-232 – Models TNx only with power

supplyv 4683 (RS-485 connection only)v 4693v 4694v 4695 (RS-232 connection only and with a power supply — Models TNx only)v SurePOS 300/500/600/700 Series (RS-232 or USB connection only)

Software requirementsThe full function of Models TNx is supported only in native mode with RS-232attachment. No unique driver is required. If you use the RS-232 interface, use thecommands described in the 4610 SureMark Three-Station Printer: ProgrammingGuide.

Operating system levels for Models TNxModel TNx printers can be attached as a Model 4 printer to systems running 4690OS. When attached as a Model 4 printer, the 4610 Models TN3 bar code printingfunction and Model TN4 bar code printing and check handling functions cannot beaccessed.

Operating system levels for Models GRxFiscal Model GRx driver support is available on 4690 OS, POSSWIN, and DOS.The driver is the same one used for support of the Models 3F, 3FA, 3BS, 3BM, and3F2 fiscal printers.v 4690 OS V1 Level K010 or laterv 4690 OS V2R2 Level 0020 or laterv 4690 OS V2R3 Level 00A0 or laterv POSS for Windows 1.42 or laterv POSS for DOS 1.6A or later

If you use the RS-485 interface, you must use POSS or 4690 OS drivers. See“Resources on the internet” on page 1-12 for information about downloading thedrivers.



||||||||||||||

|||

POSS drivers can be downloaded from the Retail Store Solutions Web site. See“Resources on the internet” for more information.

Miscellaneous information

Resident code pagesThese code pages are resident in the Model TNx printers:v Genericv 437 (US)v 858 (International)v 860 (Portuguese)v 863 (Canadian French)v 865 (Norwegian)

Additional code pages (four thermal and two impact) can be downloaded, if desired,using the 4610 Installation, Fonts, and Logos Utility Diskette. The diskette isavailable on the Web. See “Resources on the internet” for more information.

For fiscal Models GBx, GRx, and GE3, the code pages are controlled by the fiscalmicrocode.

Bar codesSureMark printers can generate these bar codes:v UPC-Av UPC-Ev JAN13 (EAN-13)v JAN8 (EAN-8)v Code 39v ITFv Codabarv Code 128Cv Code 93v PDF 417

Note: The command to generate the above bar codes is not available in Model 4emulation mode.

Resources on the internetThe IBM Retail Store Solutions Web site at:http://www.ibm.com/solutions/retail/store contains publications, downloads,and a knowledge base for the 4610 Printer. On the main page of the Web site,select Support. The resources that relate to the 4610 Printer are found on the pageunder ″SurePOS Peripherals″. Use the links for:v Peripheral Drivers folder, if you use RS-485 connectionsv IBM SureMark Printerv IBM Fiscal POS Printersv Peripheral Drivers

Note: Published IBM manuals can be accessed using the Publications icon. Accessdiskettes, drivers, and miscellaneous documentation, such as README filesand OEM paper certification information by using the Downloads icon. TheKnowledgebase icon provides access to previously asked questions andtheir answers.



||

LimitationsThe SureMark printer protects the hardware from potential damage if excessiveduty cycles are used. This should not be noticeable during normal operation.

Electromagnetic noise sources can interfere with the MICR read head. If the MICRreader does not function properly, rearranging the printer relative to the noisesource may improve performance. The noise source should be as far away aspossible from the right side of the printer.

Damaged checks may not be readable or may not feed reliably.

User responsibilitiesYou are responsible for replenishing consumable supplies, such as roll paper for thethermal printer, forms, ribbon cartridges for the impact printer, and MICR headcleaner cards, if MICR is attached.

You are responsible for understanding that the Model GRx fiscal printers are usedin a legal manner, and for obtaining all of the software in a manner that isconsistent with the regulations of your country. This may include requirements toattach certain displays to your POS terminal or for obtaining your POS software.



Chapter 2. Installation, service, and utility softwareadjustments

4610 diskette download support information . . . . . . . . . . . . . . 2-1Software adjustments for document insert station . . . . . . . . . . . . 2-1

Using the reference/service diskettes (RS-485 or RS-232). . . . . . . . 2-14610 fonts and logos utility diskette (Models TNx only) . . . . . . . . . . 2-4Firmware update (Models TNx only) . . . . . . . . . . . . . . . . . 2-4

Using a firmware update diskette . . . . . . . . . . . . . . . . . 2-4Updating Models TNx firmware using temporary RS-232 attachment . . . . 2-5Limitation on updating firmware on Models TNx . . . . . . . . . . . 2-5

Emulating the IBM Model 3 or Model 4 printers (Models TNx only) . . . . . 2-6Enabling emulation using utility diskettes . . . . . . . . . . . . . . 2-6Limitations for emulation . . . . . . . . . . . . . . . . . . . . 2-6

MICR data parser sample code (Model TN4 only) . . . . . . . . . . . . 2-7

This chapter describes how to make software adjustments using the 4690Operating System (4690 OS), IBM Point-of-Sale Device Diagnostics (POSS forWindows and RS-485), or diskettes and other resources that are available from theRetail Store Solutions Web site.

4610 diskette download support informationService tools for the 4610 SureMark Printer can be downloaded fromhttp://www.ibm.com/solutions/retail/store, which is the Retail Store SolutionsWeb site. After you select Support at the left side of the screen, select IBMSureMark Printer to access the following downloads:

v 4610 Configure MCT Utility Diskette

v 4610 GR5 DI-Less MCT Diskette

v 4610 TN x Attended Update Diskette

v 4610 TN x Unattended Update Diskette

v 4693 Terminal Reference and Diagnostic Diskette

v 4694/4695 Service Diagnostic Diskette

v SurePOS 500/600 Series Service Diskette

Software adjustments for document insert stationDepending on your operating system, you can use the following to make softwareadjustments to the impact printer (document insert) station of a SureMark printer:v Reference/service diskettes

Using the reference/service diskettes (RS-485 or RS-232)1. Load the reference/service diskette. See the hardware service manual for your

system for reference/service diskette procedures.

2. Select Test Menu.

3. Select Run POS Device Tests for an RS-485 connection. Select RS232 4610Printer Test for an RS-232 connection.

4. If another system is attached, select the system whose printer you want toadjust. This is unnecessary when there is no other system attached.

5. Select Printer Utilities.



6. Select the adjustment you want to make from the menu.v Print current adjustment valuesv Character alignment procedurev DI front load print line adjustmentv Document landscape adjustmentv Engineering use onlyv Change 4610 Model Configurationv Reset printer statistics

7. Follow the instructions that are printed on the printer or displayed on the screen.

8. Press S1 (Esc on the Enhanced A/N Keyboard) to return to the previous menu.

Software Adjustments Updated August 13, 2003


CURRENT ADJUSTMENT VALUESH 5 = Character alignmentTL5 = Top line front insertBL3 = Bottom line top insert

Press the key (1-9) that correspondsto the pair of H's that appear to bemost aligned

5 = selected line

CHARACTER ALIGNMENT PROCEDURE

Measure from the top edge of thispaper to the top of each print line.Press the key (1-9) that correspondsto the print line that is closest to 5MM.

TL1

TL4

TL7

TL2

TL5

TL8

TL3

TL6

TL9

Figure 2-1. Adjustment and Alignment Printouts

Software AdjustmentsUpdated August 13, 2003

Chapter 2. Installation, service, and utility software adjustments 2-3

4610 fonts and logos utility diskette (Models TNx only)This utility is for both RS-232 and RS-485 operation. You can download the utilityfrom the Retail Store Solutions Web site.

The utility program allows you to perform the following functions:v Configure the printer Modelv Create, edit, and download user-defined character fonts, logo images, and

messagesv Convert fonts and logo files from impact to thermal

From the same Web site, you can also download the following sample files for usewith the utility program:v User-defined characters filev Message filev Logo file

Firmware update (Models TNx only)The non-fiscal versions of the SureMark printer can receive SureMark firmwareupdates from the host system unit to which it is attached for either RS-485attached, or RS-232 attached SureMark printers.

The following media can be used to update the SureMark firmware:

v Firmware update diskettes

v Alternative 4610 firmware update method via RS-232 attachment cable

Use the appropriate procedure that follows to update the SureMark firmware, afterdownloading the latest level software from the Retail Store Solutions Web site.

Using a firmware update disketteUse a firmware update diskette to update the firmware in configurations when theSureMark printer is attached by either an RS-232 or RS-485 cable, and the systemhas a diskette drive, a PC keyboard, and a display.

Note: There is no firmware update diskette for the model GRx printer.

1. Download the latest level of firmware update diskette from the Web (see“Resources on the internet” on page 1-12). You can select from several updatemethods, including attended, unattended, and automatic.

2. Insert the firmware update diskette in drive A.

3. Power on the system unit that has the SureMark printer attached by either anRS-232 or RS-485 cable.

4. Select RS-485 or RS-232 connection.

5. Follow the messages displayed to complete the firmware update.

a. Press Enter (OK) at the logo screen to proceed.

b. Choose connection type (RS-485 or RS-232). For RS-232 connections, alsomake the following selections (refer to the Customer receipt test under“Offline tests” on page 3-1, to determine the following selections):v Communications port (COM1, COM2, COM3, COM4)v Baud Rate (9600 or 19 200)v Control Flow (DTR/DSR or XON/XOFF)

c. Press Enter (OK) to proceed.

d. Press F10 (Menu).

Software Adjustments Updated August 13, 2003


e. Select O (Operations).

f. Select A (Advanced Options).

g. Select U (Update Firmware).

h. Press Enter twice to select the desired firmware image file (usually only thelatest firmware image file is available for selection).

i. Press Enter (YES) again to commit to firmware update.

j. The Information panel will display the update percent completed.

Note: The SureMark printer flash update will take several minutes. Do notpower off the host system or the SureMark printer after the updatehas started.

6. After the firmware update is complete, the SureMark printer will be reset.a. Press Enter (OK) to confirm.b. Press Alt-X (Exit).c. Press Enter to exit.

7. Remove the diskette from drive A.

8. Press Ctrl-Alt-Del to reboot the system.

Updating Models TNx firmware using temporary RS-232 attachmentTo use the firmware update diskettes to update SureMark printer firmware forconfigurations that do not have a diskette drive and PC display and keyboard, youmust provide a temporary RS-232 attachment to a host PC that does have adiskette drive.

Note: A 4610 firmware update diskette at V3.10 or greater is required to use thisutility.

Before starting the firmware update, you must obtain the following parts:

v RS-232 attachment cable, either 2 meters in length (P/N 86H2192) or 4 meters inlength (P/N 86H2195).

v SureMark Printer Power Supply (for RS-232 configurations only), P/N 42H1176.

If the SureMark printer is currently attached to a host system unit that does notsupport a diskette drive, use the following procedure to temporarily connect theprinter to a host PC that has a diskette drive, RS-232 port, PC keyboard and adisplay.1. Disconnect the SureMark printer (RS-485 #7) attachment cable and temporarily

connect a RS-232 attachment cable to the SureMark printer.2. Connect the SureMark printer via the RS-232 port connector to an alternate

host PC that has a diskette drive.3. Follow the procedure in “Using a firmware update diskette” on page 2-4, starting

with Step 1, to complete the SureMark printer firmware update.4. Reconnect the SureMark printer to the original host system unit using the

original attachment cables.

Limitation on updating firmware on Models TNxThe following limitation must be considered when updating firmware on theSureMark printer:

v SureMark printer firmware updates cannot be performed if the printer currentlyhas Model 4 emulation enabled. If emulation is enabled, temporarily disableModel 4 emulation, then start the SureMark printer firmware update. After the

Firmware Update (non-fiscal)Updated August 13, 2003


firmware update is complete, re-enable Model 4 emulation. See “Emulating theIBM Model 3 or Model 4 printers (Models TNx only)” for additional information.

Emulating the IBM Model 3 or Model 4 printers (Models TNx only)It is possible to emulate the IBM Model 3 or Model 4 printer with the SureMarkprinter. You must change the configuration to enable the SureMark printer toemulate the Model 3 or Model 4 printers.

The following media can be used to set up Model 3 or Model 4 emulation:

v For systems with diskette drives, use the Font and Logos Utility Diskette or theConfigure MCT Utility Diskette. Download the latest-level diskette from the RetailStore Solutions Web site.

v For medialess systems using the 4690 OS, use the 4690 OS Online TerminalDiagnostics (see Enabling emulation using utility diskettes in the next section).

Enabling emulation using utility diskettesThe following information is also available in the file named 4610MOD4.TXT on thediskette.

Note: All SureMark printer firmware levels support emulation.

To set up Model 3 or Model 4 emulation using the Font and Logos Utility Diskette orthe Configure MCT Utility Diskette:

1. Insert the utility diskette in drive A.

2. Power on the system unit.

3. Select MOD4 when the menu is displayed.

4. Perform the specified steps to either enable or disable emulation.

To enable when emulation is currently disabled:1. Select: Model 4 emulation with Offline mode disabled. The printer is

reconfigured.2. Press Ctrl-Alt-Delete to reboot the system. The system IPLs.

To disable when emulation is currently enabled:1. Select Disable Model 4 emulation.2. Enter Ctrl-Alt-Delete to reboot the system. The system IPLs.

Limitations for emulationThe following limitations must be considered when using the SureMark printer toemulate the Model 3 or Model 4 printer.

v Printing the face of checks requires application changes (franking the back ofchecks should not).

v Printing wide documents may require changes. The document station on theModel 4 printer supports 86 characters, the SureMark printer supports 47characters.

v There is no top document registration (documents must be inserted from thefront).

v User-defined special characters are not supported.

v Emulation mode does not support the Model 4A double-byte character set.

Firmware Update (non-fiscal) Updated August 13, 2003


MICR data parser sample code (Model TN4 only)The MICR data parser download package includes:

v Sample source code (in C) that contains algorithms for parsing MICR data from acheck.

v An exception data file that is used with the parsing code. You can edit this file toadd new check formats, if necessary.

Refer to the README file in this download package for additional information.

Emulating Model 3 or 4 printersUpdated August 13, 2003


Emulating Model 3 or 4 printers Updated August 13, 2003


Chapter 3. Problem determination for the 4610 Three-StationPrinter

Fiscal unit return codes . . . . . . . . . . . . . . . . . . . . . 3-1Offline tests . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Customer receipt test . . . . . . . . . . . . . . . . . . . . . 3-1Journal station test . . . . . . . . . . . . . . . . . . . . . . 3-1Document insert test (except Models TN5, GR5 and GB5) . . . . . . . 3-2MICR reader and check flipper test (Model TN4 only) . . . . . . . . . 3-4

Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Fiscal unit return codesFiscal return codes vary by country. Refer to the Retail Store Solutions ElectronicSupport Web site for specific country return codes.

1. Go to www.ibm.com/solutions/retail/store

2. Select Support at the left on the main page of the web site

3. Select Publications to access IBM Retail Store Solutions Electronic Supportpublications.

4. Scroll down to ″IBM 4610 SureMark Printers″.

Offline testsUse the following offline tests as diagnostic tools to ensure the printer is operatingcorrectly.

Customer receipt test1. Press and hold both the customer receipt and document insert buttons/switches

to enter offline mode. (Buttons and switches are used interchangably in thisdocument.) When the Printer Ready indicator begins blinking, release bothbuttons.

2. Press and release the customer receipt feed button to start this test.

3. See Figure 3-1 on page 3-3 and verify that your printer has printed correctinformation for your model and configuration:v MICR reader enabled and check flipper enabled (Model TN4)v Applicable parameters for (Model TN4) — RS-232 communications:

– 9600 or 19,200 baud rate– DTR/DSR or XON/XOFF control

v A solid line should appear as the last line of the test pattern.

If any characters that appear in Figure 3-1 on page 3-3 are missing from the testpattern you print, or if the solid line is missing, go to “Symptoms” on page 3-6.

Journal station test1. Press and hold both the customer receipt and document insert buttons/switches

to enter offline mode. When the Printer Ready indicator begins blinking, releaseboth buttons.

2. Press and release the journal station feed button to start this test.

3. See Figure 3-1 on page 3-3 and verify that your printer has printed correctinformation for your model and configuration:v MICR reader enabled and check flipper enabled (Model TN4)



|

|

v Applicable parameters for (Model TN4) — RS-232 communications:– 9600 or 19,200 baud rate– DTR/DSR or XON/XOFF control

v A solid line should appear as the last line of the test pattern.


Document insert test (except Models TN5, GR5 and GB5)1. Insert a document in the Document Insert station. The Document Present

indicator should come on.

v If the Document Present indicator does not come on, realign the document. Ifthe Document Present indicator still does not come on, go to “Documentsensor threshold reset” on page 5-10.

v If pressing the document feed button does not feed the document, go to“Symptoms” on page 3-6.

2. Press and hold both the customer receipt and document insert buttons to enteroffline mode. When the Printer Ready indicator begins blinking, release bothbuttons.

3. Press and release the document feed button to print the test pattern. The testpattern includes all printable characters in the resident code page, printed in thedefault font.

4. See Figure 3-1 on page 3-3 and verify that your printer has printed correctinformation for your model and configuration:v Model type (MICR reader enabled, check flipper enabled for Model TN4)v Communication options (RS-232 or RS-485)v RS-232 parameters, if applicablev A solid line should appear as the last line of the test pattern


Offline Test Updated August 13, 2003


|

Test Pattern Notes:

1. The serial number that prints will be the actual serial number of your printer.

2. The microcode level will be the actual level of your printer’s microcode.

The fiscal microcode EC level information appears only in fiscal models of theprinter.

3. The serial interface will be specified as RS232 or RS485, depending on whichinterface is used to attach the printer to the system unit.

4. The line speed information appears only when the RS-232 interface is used.The value can be either 9.6K baud or 19.2K baud, depending on the RS-232switch settings. (See “RS-232 XON/XOFF mode selection switch (Models TNxonly)” on page 1-7.)

5. RS-232 is not supported on Model GRx.

The RS-232 control mode information appears only when the RS-232 interfaceis used. The value can be either DTR/DSR or XON/XOFF, depending on theRS-232 switch settings.

6. The feature enabled lines will appear only when the feature is installed.

7. These lines break at different points for the test pattern printed in the documentinsert (DI) station.

8. This section contains printer usage statistics that you can use for problemdetermination. (Some of this information is not printed on Model xx5 printers.)

9. The line across the bottom should be solid with no blank spaces.

The Printers S/N is 1234567

Microcode EC level is 30Fiscal Microcode EC level is 16.01Serial Interface: RS232

: 19.2K Baud, XON / XOFFMICR reader enabledCheck Flipper enabled|"#$%&'()*+,-./0123456789:;<->?ABCDEFGHIKJK

LMNOPQRSTUVWXYZ[\]^_ abcdefghijklmnopqrstuvwxyz{|}~.CüéâäàåcêëèïîìÄÅÉæÆôöòûùÿÖÜø£ØSsáíóúÁÑGg¿ · · · · ¡ · · ÁÂÀ ¢ · · · · · · · · ãÃ ·H III · · · · · · · · · · · · · Ð ·

Cuts: 125850CR Characters Printed: 142834CR Motor Steps: 659340CR Cover Openings: 593DI Characters Printed:DI Feed Motor Steps:DI Transpor t Motor Passes:DI Home Errors:DI Cover Openings:DI Documents Inser ted:MICR Reads:High Interference MICR Reads:MICR Read Failures:

Serial Interface

II õ ÊËÈÍÎÏÌÓßOO õÕµþÞUUUyY±÷

Serial Interface

·

1

3

9

8

2

6

7

`` ` ^^ ` `

4 5,

Figure 3-1. Offline Printer Test Pattern (Thermal/Impact SureMark Printers). This pattern isfrom the customer receipt (CR) station.

Offline TestUpdated August 13, 2003

Chapter 3. Problem Determination for All Models 3-3

|

|||

MICR reader and check flipper test (Model TN4 only)

Attention: If the printer is in Model 3 or 4 emulation mode, failure to performthese steps in the sequence shown will cause the entire electronic journal to printon the CR station. Printing the electronic journal erases the information from flashstorage.

1. Insert the check face down with the magnetic ink characters to the right.

2. Press and hold both buttons to enter offline mode. When the printer readyindicator begins blinking, release both buttons.

3. Press and release both buttons again.

4. Remove the check.

Characters that match the magnetic ink characters are printed on the customerreceipt and the check is flipped over. Go to “Symptoms” on page 3-6 if:

v Characters that match the magnetic ink characters are not printed on thecustomer receipt.

v Question marks or an ’X’ appear in the printed line.

v Characters that match the magnetic ink characters are printed but the check isnot flipped.

If the Model TN4 detects noise, it prints a message on the customer receipt belowthe magnetic characters from the check (Figure 3-2 and Figure 3-3 on page 3-5 areexamples and actual numbers may vary). The message shows noisecharacteristics. You can use the noise level to position your printer to minimizeoutside interference with the MICR reader.

Sources of electromagnetic noise (for example, displays, security towers, and othersources) can interfere with the MICR reader read head. If the printer shows anexternal noise source, rearrange the printer to make the noise source as far awayas possible from the right side of the printer. This may eliminate the external noise.

Figure 3-2. MICR Reader Test Results – Good Noise Level

Offline Test Updated August 13, 2003


Figure 3-3. MICR Reader Test Results – Noise Level Needs Adjusting

Offline TestUpdated August 13, 2003


SymptomsReview the following symptoms or messages and take the suggested actions.

Table 3-1. Printer Symptoms or Messages

Symptom Repair actions listed in most likely order of failure

Printer does not power ON (All LEDs areoff).

1. Check for a good connection and that the printer is plugged in.

2. Replace the printer’s external power supply or system unit.

3. Exchange the printer interface card. Go to “Removing and replacingthe main logic and sub-logic cards and connector-attached interfacecard” on page 4-43.

4. Exchange the main logic card. Go to “Removing and replacing themain logic and sub-logic cards and connector-attached interface card”on page 4-43

Printer indicators do not come on. 1. Check that the printer is plugged in and has power.

2. Check for a broken LED.

3. Exchange the switch card. Go to “Removing and replacing the switchcard and printhead spacer” on page 4-42.

4. Exchange the main logic card. Go to “Removing and replacing themain logic and sub-logic cards and connector-attached interface card”on page 4-43.

Printer Ready LED is blinking. 1. Press the customer receipt feed button.

2. Check the paper supply to ensure that the receipt paper is loadedcorrectly.

3. Ensure that the covers are closed.

4. Adjust the thermal paper switch. Go to “Thermal paper switchadjustment” on page 5-10.

5. Run the printer offline tests. Go to “Offline tests” on page 3-1.

Customer receipt (thermal) does notadvance paper.

1. Check to see if the thermal paper is jammed or loaded incorrectly.

2. Go to “Customer receipt paper movement and cutter problems” onpage 4-60 to isolate the problem.

Customer receipt (thermal) randomlymissing rows of print, accompanied byone thin line on receipt.

Problem is caused by operator pulling the receipt out of the printer.Instruct operators to use the CR feed button to advance the paper,instead of pulling the paper.

Customer receipt cutter does not workcorrectly.

1. Check that the paper is loaded correctly.

2. Check that the clear plastic paper guide is in the correct position.

3. Perform the cutter blade run-in procedure. Go to “Cutter blade run-in”on page 5-7.

4. If paper is folded or partially cut, go to “Customer receipt papermovement and cutter problems” on page 4-60.

Customer receipt (thermal) is missingcharacter dots.

1. Check to see if the thermal paper is correctly installed.

2. Check to see if the printhead cables are seated correctly. Go to“Removing and replacing the thermal printhead assembly” onpage 4-57.

3. Check and clean the printhead area, if contaminated.

4. Adjust the printhead. Go to “Thermal printhead adjustment forcustomer receipt and journal station” on page 5-8.

5. Exchange the CR (thermal) latch and print assembly. Go to“Removing and replacing the thermal printhead latch” on page 4-53.

Symptoms Updated August 13, 2003


Table 3-1. Printer Symptoms or Messages (continued)


Journal station (thermal) does notadvance paper.

1. Check to see if the thermal paper is jammed or loaded incorrectly.

2. Go to “Journal station paper movement” on page 4-77 to isolate theproblem.

Journal station (thermal) randomlymissing rows of print, accompanied byone thin line on journal paper.

Check for paper jams.

Journal station (thermal) is missingcharacter dots.

1. Check to see if the thermal paper is correctly installed.

2. Check to see if the printhead cables are seated correctly. Go to“Removing and replacing thermal printhead assembly” on page 4-73.

3. Check and clean the printhead area, if contaminated.

4. Adjust the printhead. Go to “Thermal printhead adjustment forcustomer receipt and journal station” on page 5-8.

DI print has missing dots. 1. Ensure that the nose of the printhead is clear of debris.

2. Check the printhead platen gap adjustment. Go to “Printhead platengap adjustment” on page 5-4.

3. Check the printhead cable for continuity. Unplug the cable at theprinthead and logic card for access.

4. Check the printhead for bent print wires. Remove the printhead (see“Removing and replacing the printhead” on page 4-10) for access.

5. Exchange the printhead. Go to “Removing and replacing theprinthead” on page 4-10.

6. Exchange the logic card. Go to “Removing and replacing the mainlogic and sub-logic cards and connector-attached interface card” onpage 4-43.

7. Exchange one or more of the following components: DI gears, DI feedroll shaft assembly, and feedroll assembly. Go to “Removing andreplacing the printhead carriage assembly” on page 4-16 and“Removing and replacing the cutter gears and cutter clutch” onpage 4-66.

DI station does not advancedocument/check.

1. Check the paper feed throat for an obstruction.

2. Ensure that the gear train is free.

3. Check the DI open lever adjustment. Go to “Document insert openlever adjustment” on page 5-6.

4. Ensure that the DI forms compensation is correctly set. Go to “DIforms compensation adjustment (Models with DI only)” on page 5-2.

5. Exchange the DI motor. Go to “Removing and replacing the documentinsert motor and gears (Models with DI)” on page 4-40.

6. Exchange the DI gears, DI feed roll shaft assembly, and feedrollassembly. Go to “Removing and replacing the printhead carriageassembly” on page 4-16 and “Removing and replacing the cuttergears and cutter clutch” on page 4-66.

7. Replace the main logic card. Go to “Removing and replacing the mainlogic and sub-logic cards and connector-attached interface card” onpage 4-43.

SymptomsUpdated August 13, 2003




DI (impact) printhead does not movecorrectly.

1. Ensure that the printhead path is free.

2. Check that the transport shafts are not loose.

3. Check the timing belt assembly. If you need to exchange it, go to“Removing and replacing the printhead carriage assembly” onpage 4-16.

4. Check the tensioner. If you need to exchange it, go to “Removing andreplacing the tensioner” on page 4-15.

5. Check the home sensor cable for continuity.

6. Exchange the home sensor (see “Removing and replacing the homesensor” on page 4-11).

7. Exchange the transport motor. Go to “Removing and replacing thetransport motor” on page 4-20.

8. Replace the main logic card. Go to “Removing and replacing the mainlogic and sub-logic cards and connector-attached interface card” onpage 4-43.

Ribbon does not advance. 1. Exchange the ribbon cartridge. Go to “Ribbon loading (Models withDI)” on page 6-6.

2. Ensure that the ribbon drive is connected to the main logic card (seeFigure 4-17 on page 4-23).

3. Check the printhead gap and ribbon guide. Go to “Printhead platengap adjustment” on page 5-4.

4. Exchange the ribbon drive assembly. Go to “Removing and replacingthe transport motor” on page 4-20.


Printer Ready and/or Document PresentLEDs are blinking.

1. Press the customer receipt feed button.

2. Check the paper supply.

3. Ensure that both covers are closed.

4. Run the printer offline tests. Go to “Offline tests” on page 3-1.

5. Insert a document.

6. Reflash microcode.

7. Examine journal station’s cover sensor switch

8. Verify that the journal station’s sensor switch cable is seated properlyto the logic card.

9. Verify that the journal station’s sensor screw is tight.

10. Replace the journal station’s sensor switch.





MICR does not read correctly. 1. Clean the MICR head with cleaning card. Go to “Cleaning the MICRreader read head” on page 6-10.

2. Ensure that the MICR read head connector is secure.

3. Check for correct assembly of the sensor spring. Replace the spring,if missing. (Refer to Figure 4-18 on page 4-25.)

4. Exchange the MICR read head. Go to “Removing and replacing theMICR read head (Models with DI)” on page 4-28.

5. Exchange the pressure pad. Go to “Removing and replacing thedocument insert (DI) sensor assembly (Models with DI)” on page 4-24.


Flipper is not working. 1. Check the cover for missing or incorrectly installed roller and springshaft.

2. Remove any debris.

3. Using brush, clean belts of any dust.

4. Ensure that the toggle actuator is correctly installed and not damaged.(Refer to Figure 4-21 on page 4-29.)

5. Exchange the flipper cartridge assembly. Go to “Removing andreplacing the document insert lower cover and flipper cartridge” onpage 4-9.

6. Exchange the flipper drive assembly. Go to “Removing and replacingthe lower forms entry frame or flipper assembly (TN4)” on page 4-30.

DI not moving documents correctly. Perform the DI forms compensation adjustment procedure. Go to “DIforms compensation adjustment (Models with DI only)” on page 5-2.

Uneven print on receipt. Go to “Thermal printhead adjustment for customer receipt and journalstation” on page 5-8.

T7151 Printer card or cable is failing. 1. Check or exchange the printer interface cable.

2. Exchange the printer main logic card. Go to “Removing and replacingthe main logic and sub-logic cards and connector-attached interfacecard” on page 4-43.

T7152 home sensor error. 1. Remove any obstruction to printhead movement.

2. Check the printhead gap.

3. Check the home sensor cable continuity. Replace, if necessary.

4. Replace the home sensor. Go to “Removing and replacing theprinthead carriage assembly” on page 4-16.

5. Exchange the logic card.

6. Exchange the transport motor. Go to “Removing and replacing thetransport motor” on page 4-20

T7153 Ribbon cover is open. 1. Close the cover.

2. Exchange the ribbon cover. Go to “Removing and replacing the printercovers” on page 4-3.


SymptomsUpdated August 13, 2003




T7156 Document is inserted in the printerand printer fails.

1. Check for obstructions.

2. Rerun the diagnostic test.

3. Exchange the DI sensor, then reset the sensor threshold. Go to“Removing and replacing the document insert (DI) sensor assembly(Models with DI)” on page 4-24, then “Document sensor thresholdreset” on page 5-10.

T7157 Document was not removed whenexpected or DI sensor is failing.

1. Exchange the document and run the test again.

2. Exchange the DI sensor. Reset the sensor threshold. Go to“Removing and replacing the document insert (DI) sensor assembly(Models with DI)” on page 4-24, then “Document sensor thresholdreset” on page 5-10.

T7159 EEPROM error. Exchange the main logic card. Go to “Removing and replacing the mainlogic and sub-logic cards and connector-attached interface card” onpage 4-43.

T7161 Command reject. An invalid command was sent to the printer.

T7163 Flipper error. See “Flipper is not working” symptom.

T7164 MICR check movement error. 1. Be sure that the check does not exceed 277 mm (10.9 in) long.

2. Run the check offline procedure. Go to “Offline tests” on page 3-1.The printer should move the check all the way up through the DIstation then back while reading the MICR.

T7165 CR paper is empty or cover isopen.

1. Ensure that paper is in the printer and both covers are closed.

2. Press the customer receipt feed button to advance about 76 mm (3 in)of paper.

3. Check to see if the paper is installed correctly in the customer receiptstation.

4. Open the customer receipt cover and manually press the switch.

5. Adjust the switch. Go to “Thermal paper switch adjustment” onpage 5-10.


T7166 Firmware error. 1. Update the SureMark printer firmware by downloading a new imagefrom the utility diskette.




Chapter 4. FRU removal and replacement

Top covers procedures (Models TNx) . . . . . . . . . . . . . . . . 4-2Removing and replacing the printer covers . . . . . . . . . . . . . 4-3Removing and replacing the top cover operator buttons . . . . . . . . 4-8

Document insert station procedures (Models with DI only) . . . . . . . . . 4-9Removing the Document Insert Station Cover . . . . . . . . . . . . 4-9Removing and replacing the document insert lower cover and flipper

cartridge . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Removing and replacing the printhead . . . . . . . . . . . . . . 4-10Removing and replacing the home sensor . . . . . . . . . . . . . 4-11Removing and replacing the ribbon drive assembly . . . . . . . . . . 4-13Removing and replacing the tensioner . . . . . . . . . . . . . . 4-15Removing and replacing the printhead carriage assembly . . . . . . . 4-16Removing and replacing the transport motor . . . . . . . . . . . . 4-20Removing and replacing the printhead cable . . . . . . . . . . . . 4-22Removing and replacing the document insert (DI) sensor assembly (Models

with DI) . . . . . . . . . . . . . . . . . . . . . . . . . 4-24Removing and replacing the document insert platen assembly (Models with

DI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26Removing and replacing the MICR read head (Models with DI) . . . . . 4-28Removing and replacing the lower forms entry frame or flipper assembly

(TN4) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30Removing and replacing the document insert backup roller and insert lever

assembly (Models with DI) . . . . . . . . . . . . . . . . . . 4-34Removing and replacing the document insert (DI) feed roller (Models with

DI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37Removing and replacing the document insert motor and gears (Models with

DI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40Removing and replacing the switch card and printhead spacer . . . . . 4-42

Logic cards procedure . . . . . . . . . . . . . . . . . . . . . 4-43Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . 4-43Removing and replacing the main logic and sub-logic cards and

connector-attached interface card . . . . . . . . . . . . . . . 4-43Customer receipt station procedures . . . . . . . . . . . . . . . . 4-49

Removing the customer receipt station cover . . . . . . . . . . . . 4-49Removing and replacing the thermal cables and paper switch . . . . . . 4-51Removing and replacing the thermal printhead latch . . . . . . . . . 4-53Removing and replacing the thermal printhead drag strip. . . . . . . . 4-55Removing and replacing the thermal printhead assembly. . . . . . . . 4-57Removing and replacing the thermal platen assembly . . . . . . . . . 4-60Customer receipt paper movement and cutter problems . . . . . . . . 4-60Removing and replacing the customer receipt motor . . . . . . . . . 4-62Removing and replacing the rotating cutter blade and thermal guide . . . 4-64Removing and replacing the cutter gears and cutter clutch . . . . . . . 4-66Removing and replacing the customer receipt paper guide . . . . . . . 4-67Removing and replacing the customer receipt paper bucket. . . . . . . 4-69

Journal station procedures . . . . . . . . . . . . . . . . . . . . 4-71Removing the journal station cover . . . . . . . . . . . . . . . . 4-71Removing and replacing the journal station button . . . . . . . . . . 4-71Removing and replacing the journal printhead cover assembly . . . . . 4-72Removing and replacing thermal printhead assembly . . . . . . . . . 4-73Removing and replacing the platen assembly . . . . . . . . . . . . 4-75Removing and replacing the journal motor assembly . . . . . . . . . 4-76Journal station paper movement . . . . . . . . . . . . . . . . . 4-77



Removing and replacing the optical paper sensor . . . . . . . . . . 4-78Removing the gear kit with clutch and E-clip . . . . . . . . . . . . 4-79Removing and replacing the journal cover sensor switch . . . . . . . . 4-80

Interface Card Assembly Procedures . . . . . . . . . . . . . . . . 4-81Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . 4-81Removing and replacing the Interface card Assembly (models TNx). . . . 4-81Removing and replacing fiscal interface assembly for model Gxx printers 4-82

This section includes removal and replacement procedures for the SureMark printertop covers and base cover. The base cover is attached to the printer base, and itcovers the major printer and journal station internal structures. The top covers coverthe user accessible parts of the printer, such as the paper for the customer receiptand summary journal station and the document insert printer ribbon.

For the Model GRxYou must remove the fiscal interface assembly in order to remove the two topcover retention screws. Removal of the two screws is essential to the removalof the top cover. See “Removing the Model GRx fiscal printer cover” on page4-89.

Top covers procedures (Models TNx)The paper cover refers to the cover for the customer receipt station. The ribboncover refers to the cover for the document insert station. These terms are usedinterchangeably. These covers are shown in Figure 4-1 on page 4-4.

The top covers for the SureMark printer consist of the cover for the customerreceipt station, the cover for the document insert station, and the cover for thejournal station.



Removing and replacing the printer covers

ImportantThis procedure shows you how to remove the printer covers (FRUs). Stopwhen you get to the failing FRUs, exchange the FRUs, and reassemble. TheFRUs are highlighted.

Removing the printer cover1. Ensure that the printer is powered off by either powering off the system or

unplugging the printer’s power source from the wall outlet. See Figure 4-2 onpage 4-5.

2. Open the journal station cover by unlocking the keylock on the front of thecover. You can use a screwdriver point to place between the bottom corner tabof the journal station cover and the printer and pull down on the top front part ofthe cover. Repeat for the left side if necessary. Slide the journal cover up andout. Set the journal cover aside.

3. Open the customer receipt paper cover. Place the top of a screwdriver handlebetween the side of the printer and the top cover. Then close the top cover onthe screwdriver, do this one side at a time. This frees the pivots on both sides.Slide the paper cover forward and out. See Figure 4-1 on page 4-4.

4. Open the ribbon cover using the lift tab. With the cover partially open, push thedocument insert cover towards the left side while pressing the lock tab, andremove the cover.

Note: When reassembling, be sure that the clear plastic paper guide is insertedthrough the slot in the paper cover.

Top CoversUpdated August 13, 2003

Chapter 4. Cover removal and replacement 4-3

5. With both the paper cover removed and the journal station cover frame upright,the latch tabs inside the printer cover are visible.

6. Remove the two screws from the mounting posts located on the front of theprinter top cover. Lift the top cover up high enough to permit removal of therubber grommet from the binding post.

7. Release the latch tabs by placing your finger against the inside of the left sideof the cover and push down until your finger reaches the plastic latch tab. Pullthe latch tab forward away from the cover and lift the left side of the section upuntil it is free from the cover. Do this on the right side by releasing the latch taband lifting up on the right side of the printer cover.

8. Lift the front of the top cover outward and upward until it clears the bindingposts. Pull the left side of the top cover out and up to clear the tab from thetrack guide on the base. Pull out slightly on both the left and right sides. Lift thetop cover up and away from the printer.

9. Reassemble.

Figure 4-1. Removing the Paper and Ribbon Covers

Top Covers Updated August 13, 2003


Latch tabs

Figure 4-2. Release the Rear Latch Tabs

Mounting post

Impact printercover

Figure 4-3. Mounting Posts on Front Face of Cover



Notes:

1. Ensure that the rubber front shock mount is correctly seated in the top coverbefore installing the top cover.

2. Ensure that the clear plastic paper guide is inserted through the slot in thepaper cover.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the top cover operator buttons” on page 4-8v “Removing and replacing the printhead” on page 4-10v “Removing and replacing the home sensor” on page 4-11v “Removing and replacing the ribbon drive assembly” on page 4-13v “Removing and replacing the tensioner” on page 4-15v “Removing and replacing the printhead carriage assembly” on page 4-16v “Removing and replacing the transport motor” on page 4-20v “Removing and replacing the printhead cable” on page 4-22v “Removing and replacing the document insert (DI) sensor assembly (Models with

DI)” on page 4-24v “Removing and replacing the document insert platen assembly (Models with DI)”

on page 4-26v “Removing and replacing the MICR read head (Models with DI)” on page 4-28

Top Cover

Mounting Post

Gasket

Latch

Figure 4-4. Removing the Top Cover



v “Removing and replacing the lower forms entry frame or flipper assembly (TN4)”on page 4-30

v “Removing and replacing the document insert backup roller and insert leverassembly (Models with DI)” on page 4-34

v “Removing and replacing the document insert (DI) feed roller (Models with DI)”on page 4-37

v “Removing and replacing the document insert motor and gears (Models with DI)”on page 4-40

v “Removing and replacing the switch card and printhead spacer” on page 4-42v “Removing and replacing the main logic and sub-logic cards and

connector-attached interface card” on page 4-43v “Removing and replacing the thermal cables and paper switch” on page 4-51v “Removing and replacing the thermal printhead latch” on page 4-53v “Removing and replacing the thermal printhead drag strip” on page 4-55v “Removing and replacing the thermal printhead assembly” on page 4-57v “Removing and replacing the thermal platen assembly” on page 4-60v “Removing and replacing the customer receipt motor” on page 4-62v “Removing and replacing the rotating cutter blade and thermal guide” on page

4-64v “Removing and replacing the cutter gears and cutter clutch” on page 4-66v “Removing and replacing the customer receipt paper guide” on page 4-67v “Removing and replacing the customer receipt paper bucket” on page 4-69v “Removing and replacing the journal station button” on page 4-71v “Removing and replacing the journal printhead cover assembly” on page 4-72v “Removing and replacing thermal printhead assembly” on page 4-73v “Removing and replacing the platen assembly” on page 4-75v “Removing and replacing the journal motor assembly” on page 4-76v “Journal station paper movement” on page 4-77v “Removing and replacing the optical paper sensor” on page 4-78v “Removing the gear kit with clutch and E-clip” on page 4-79v “Removing and replacing the journal cover sensor switch” on page 4-80



Removing and replacing the top cover operator buttons

ImportantThis procedure shows you how to remove the top cover and the operatorbuttons (FRUs). Stop when you get to the failing FRUs, exchange the FRUs,and reassemble. The FRUs are highlighted.

1. Ensure that the printer is powered OFF by either powering off the system orunplugging the printer’s power source from the wall outlet.

2. Remove the covers. Go to “Removing and replacing the printer covers” onpage 4-3 and then return to this procedure.

3. On the under side of the base cover, press both sides of the key switch latchinward and lift the button out. See Figure 4-5.

4. Reassemble.

Insulator

Switch Card

Hex Screw

Printhead Spacer

Figure 4-5. Removing the operator buttons in the top cover



Document insert station procedures (Models with DI only)

Removing the Document Insert Station CoverThis procedure does not apply to a Model TN5 or GR5 printer. Open the documentinsert cover using the lift tab. From the right side, push the document insert covertowards the left side while pressing the lock tab, and remove the cover.

Note: When reassembling, be sure that the clear plastic paper guide is insertedthrough the slot in the paper cover.

Removing and replacing the document insert lower cover and flippercartridge

ImportantThis procedure shows you how to remove the flipper cover and the flippercartridge (FRUs). Stop when you get to the failing FRUs, exchange the FRUs,and reassemble. The FRUs are highlighted.

1. Ensure that the printer is powered off by either powering off the system orunplugging the printer’s power source from the wall outlet.

2. Remove the flipper cover. Lift up and outward to remove the flipper cover. SeeFigure 4-6.

3. Use the lift tab to remove the flipper cartridge.

4. Reassemble.

Figure 4-6. Removing the Document Insert Feed Cover and the Flipper Cartridge

Document Insert Station ProceduresUpdated August 13, 2003


Removing and replacing the printhead

ImportantThis procedure shows you how to remove the printhead FRU. Stop when youget to the failing FRU, exchange the FRU, and reassemble. The FRUs arehighlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the lower forms entry frame or flipper assembly (TN4)”

on page 4-30.


2. Open the ribbon cover. Go to “Removing and replacing the printer covers” onpage 4-3 and then return to this procedure.

3. Remove the ribbon cartridge.

4. Remove the mounting screw from the printhead. See Figure 4-7.

5. Lift the printhead out of the carrier and disconnect the printhead cable.

6. Remove any dust from the home sensor.

7. Reassemble.

8. Adjust the printhead gap. Go to “Printhead platen gap adjustment” on page 5-4and then return to this procedure.

9. When you replace the impact printhead, run the service diskette and selectReset Statistics for the FRU. See “Software adjustments for document insertstation” on page 2-1.

Figure 4-7. Replacing the Printhead

Document Insert Station Procedures Updated August 13, 2003


Removing and replacing the home sensor

ImportantThis procedure shows you how to remove the home sensor FRU. Stop whenyou get to the failing FRU, exchange the FRU, and reassemble. The FRUs arehighlighted.


2. Open the document insert ribbon cover. Go to “Removing and replacing theprinter covers” on page 4-3 and then return to this procedure.


4. Disconnect the home sensor cable. See Figure 4-8.

5. Move the impact printhead assembly to the middle of the printer.

6. Loosen the home sensor mounting screw.

7. Remove the home sensor from beneath the impact printhead carriage (seeFigure 4-15 on page 4-19 and then return to this procedure).

8. Reassemble.

Figure 4-8. Disconnecting the Home Sensor



Figure 4-9. Replacing the Home Sensor



Removing and replacing the ribbon drive assembly

ImportantThis procedure shows you how to remove the ribbon drive FRUs. Stop whenyou get to the failing FRUs, exchange the FRUs, and reassemble. The FRUsare highlighted.

After completing this procedure, return to the procedure you were performingfrom the following list:v “Removing and replacing the transport motor” on page 4-20v “Removing and replacing the printhead cable” on page 4-22



3. Remove the front shock mount by turning the front shock mount 1/4 turncounterclockwise (end rib will be horizontal), then pull it out. See Figure 4-10 onpage 4-14.

4. Disconnect the ribbon drive assembly cable from the main logic card. SeeFigure 4-10 on page 4-14.

5. Disconnect the printhead cable before lifting the printer assembly.

6. Remove the ribbon drive assembly by lifting the frame upward and pulling outthe ribbon drive assembly locking arm.

7. Pull the ribbon drive toward the front of the printer and move it down and out.

Note: Ensure that the logic card is completely seated in the base whenreassembling.

8. Reassemble.

9. Ensure cables are seated properly on the logic card.



Front Shock Mount

Ribbon Drive Assembly

Ribbon Drive Assembly Cable

Main Logic

Printer Assembly

Figure 4-10. Removing the Ribbon Drive Assembly



Removing and replacing the tensioner

ImportantThis procedure shows you how to remove the tensioner FRUs. Stop when youget to the failing FRUs, exchange the FRUs, and reassemble. The FRUs arehighlighted.


2. Open the ribbon cover.

3. Position the carriage assembly in the center. See Figure 4-11.

4. Push the tensioner inward and remove the timing belt from the transport motorpulley.

5. Remove the tensioner spring.

6. Remove the tensioner by sliding it towards the right and lifting it out.

7. Reassemble.

8. Run one of the 4610 diagnostic and adjustment utilities. See “Softwareadjustments for document insert station” on page 2-1 for additional informationand return here.

Timing Belt

Tensioner

Tensioner Spring

Transport Motor

Figure 4-11. Removing the Tensioner



Removing and replacing the printhead carriage assembly

ImportantThis procedure shows you how to remove the printhead carriage assemblyFRUs. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the home sensor” on page 4-11v “Removing and replacing the printhead carriage assembly” on page 4-16


2. Remove the cover. Go to “Removing and replacing the printer covers” onpage 4-3 and then return to this procedure.

3. Position the carriage assembly to the right side of the printer.

4. Push the tensioner inward and remove the timing belt from the transportmotor pulley. See Figure 4-12 on page 4-17.

5. Disconnect the printhead/home sensor cable from the printhead and homesensor. Thread the cable through the printhead carrier. See Figure 4-13 onpage 4-17.

6. Turn the bushing on the right side of the printer transport shaftcounterclockwise until the locking tabs align with the release slots, which arevisible on the inside of the frame. Remove the rear transport shaft. Ifnecessary, replace the bushing. See Figure 4-14 on page 4-18.

7. Remove the printhead carriage assembly. See Figure 4-14 on page 4-18.

Note: Steps 8, 9, and 10 describe the removal of individual FRUs. You canremove each FRU separately without removing the other FRUs. Chooseone or all of these steps to remove the failing FRUs, and then proceedwith step 11.

8. Remove the screw holding the home sensor to the printhead carriageassembly. Remove the home sensor. See Figure 4-15 on page 4-19.

9. Remove the two screws from the ribbon guide, pivot the platen toward therear, and remove the ribbon guide. See Figure 4-13 on page 4-17.

10. Remove the timing belt from the printhead carriage assembly. SeeFigure 4-12 on page 4-17 and Figure 4-14 on page 4-18.

11. Remove the screw from the front transport shaft and slide it out from the leftside. See Figure 4-14 on page 4-18.

12. Remove the front transport carrier bearing. See Figure 4-14 on page 4-18.

13. Reassemble.

14. Adjust the printhead.

15. Run one of the 4610 diagnostic and adjustment utilities. See “Softwareadjustments for document insert station” on page 2-1 and then return to thisprocedure.



Timing Belt

Tensioner

Tensioner Spring

Transport Motor

Figure 4-12. Removing the Timing Belt

Figure 4-13. Removing the Printhead/Home Sensor Cable



Backup Roller

Screw

Front Carrier Bearing

Front Transport Shaft

SlotPrinthead GapEccentric Detail

LeftPrintheadGap Eccentric

Rear Transport Shaft

Right Eccentric

Printer Carriage Assembly

Ribbon Guide

Upper Feed Roller

Figure 4-14. Removing the Carriage Assembly, Front or Rear Transport Shafts



Figure 4-15. Removing the Front Transport Carrier Bearing



Removing and replacing the transport motor

ImportantThis procedure shows you how to remove the transport motor FRU. Stopwhen you get to the failing FRUs, exchange the FRUs, and reassemble. TheFRUs are highlighted.


2. Remove the cover. Go to “Removing and replacing the printer covers” onpage 4-3 and return to this procedure.

3. Remove the ribbon drive assembly. Go to “Removing and replacing the ribbondrive assembly” on page 4-13.

4. Disconnect the printhead cable from the main logic card. Go to “Removing andreplacing the printhead cable” on page 4-22.

5. Position the carriage assembly to the right side of the printer. Push thetensioner inward and remove the timing belt from the transport motor pulley.

6. Turn the bushing on the right side of the printer transport shaftcounterclockwise until locking tabs align with the release slots. Remove therear transport shaft. If necessary, replace the bushing.

Note: This step can be omitted if the rear transport motor screw can beremoved and secured with the transport shaft in place.

7. Disconnect the transport motor cable from the main logic card.

8. Remove the two screws holding the transport motor to the frame.

9. Lift the printer frame upward enough to remove the transport motor. Removethe transport motor. See Figure 4-16 on page 4-21.

10. Reassemble.

11. If the transport shaft was removed, adjust the printhead gap. Go to “Printheadplaten gap adjustment” on page 5-4.

12. When you replace the transport motor, run the service diskette and selectReset Statistics for the FRU. See “Software adjustments for document insertstation” on page 2-1.



Transport Motor

Figure 4-16. Removing the Transport Motor



Removing and replacing the printhead cable

ImportantThis procedure shows you how to remove the printhead cable FRU. Stopwhen you get to the failing FRUs, exchange the FRUs, and reassemble. TheFRUs are highlighted.

After completing this procedure, return to the procedure you were performingfrom the following list:v “Removing and replacing the transport motor” on page 4-20v “Removing and replacing the MICR read head (Models with DI)” on page 4-28



3. Remove the ribbon drive assembly. Go to “Removing and replacing the ribbondrive assembly” on page 4-13.

4. Disconnect the printhead cable from the main logic card.

5. Disconnect the printhead cable and the home sensor from the printhead andpull it through and out of the carriage assembly (see Figure 4-17 onpage 4-23).

6. Make an alignment mark across the edge of the cable, partly on the cable andpartly on the frame (see Figure 4-17 on page 4-23).

7. Peel the adhesive loose from the frame.

8. Lift the printer frame upward and unsnap the two front latches, which hold theupper document guide, by pressing forward and down with a screwdriver toloosen the upper document guide (see Figure 4-13 on page 4-17)

9. Pull the printhead cable through and out of the frame.

Note: Take note of how the cable is routed through the frame. The cable isaffixed to the frame with adhesive.

10. Lay the old and new printhead cables side by side. Copy the alignment markfrom the old printhead cable to the same location on the new printhead cable.

11. Reassemble.

Note: Route and connect the printhead cable at both ends before using theadhesive strip to affix the cable to the frame. Use the alignment mark toposition the printhead cable.



Figure 4-17. Disconnecting the Printhead Cable and Home Sensor



Removing and replacing the document insert (DI) sensor assembly(Models with DI)

ImportantThis procedure shows you how to remove the document insert (DI) assemblyFRUs. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.

After completing this procedure, return to the procedure you were performingfrom the following list:v “Removing and replacing the MICR read head (Models with DI)” on page 4-28v “Removing and replacing the lower forms entry frame or flipper assembly (TN4)”

on page 4-30v “Removing and replacing the document insert backup roller and insert lever

assembly (Models with DI)” on page 4-34v “Removing and replacing the document insert (DI) feed roller (Models with DI)”

on page 4-37


2. Remove the cover and the ribbon cartridge. Go to “Removing and replacingthe printer covers” on page 4-3 and then return to this procedure.


4. Disconnect the document sensor assembly cable (red five-pin connector) fromthe top of the main logic card.

5. Remove the sensor spring.

v If the DI sensor rotates forward past the carriage assembly, go to the nextstep.

v If the DI sensor does not rotate forward past the carriage assembly, removethe pressure pad holder and the wear plate to provide the requiredclearance. See Figure 4-18 on page 4-25.

6. Position the carriage assembly to the right side of the printer.

7. Pivot the document insert sensor assembly towards the front and pull itforward to remove.

8. Reassemble.

9. Perform the document threshold reset procedure. Go to “Document sensorthreshold reset” on page 5-10.

10. Run one of the 4610 diagnostic and adjustment utilities. See “Softwareadjustments for document insert station” on page 2-1.



DI Sensor

Sensor Spring

Pressure Pad Holder

Pressure Pad

Wear Plate

Figure 4-18. Disconnecting the Sensor Spring and Removing the DI Insert Assembly



Removing and replacing the document insert platen assembly (Modelswith DI)

ImportantThis procedure shows you how to remove the platen FRUs. Stop when youget to the failing FRUs, exchange the FRUs, and reassemble. The FRUs arehighlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the MICR read head (Models with DI)” on page 4-28v “Removing and replacing the lower forms entry frame or flipper assembly (TN4)”

on page 4-30v “Removing and replacing the document insert (DI) feed roller (Models with DI)”

on page 4-37v “Removing and replacing the cutter gears and cutter clutch” on page 4-66v “Removing and replacing the customer receipt paper guide” on page 4-67v “Removing and replacing the customer receipt paper bucket” on page 4-69



3. Open the thermal printhead assembly.

4. Disconnect the clip springs on both sides of the platen shaft. See Figure 4-19on page 4-27.

Note: The clip spring on the right side is installed reversed from the clip springon the left side.

5. Disengage the platen spring and remove the platen assembly and the platenspring.

6. Reassemble.

7. Check the printhead gap. Go to “Printhead platen gap adjustment” on page 5-4.



Platen

Platen Spring

Platen with Scanner(Model Ti8)

E-Clips

Clip Spring

Platen Shaft

Figure 4-19. Removing the Document Insert Platen Assembly



Removing and replacing the MICR read head (Models with DI)

ImportantThis procedure shows you how to remove the MICR FRUs. Removing andReplacing the MICR Read Head. Stop when you get to the failing FRUs,exchange the FRUs, and reassemble. The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the lower forms entry frame or flipper assembly (TN4)”

on page 4-30v “Removing and replacing the document insert (DI) feed roller (Models with DI)”

on page 4-37


2. Remove the covers and the ribbon cartridge. Go to “Removing and replacingthe printer covers” on page 4-3 and then return to this procedure.

3. Remove the front shock mount. See Figure 4-20 on page 4-29.

4. Disconnect the printhead cable from the logic card. Go to “Removing andreplacing the printhead cable” on page 4-22.

5. Lift the front of the frame high enough to reach in and disconnect the MICRreader cable.

6. Remove the document insert platen assembly. Go to “Removing and replacingthe document insert platen assembly (Models with DI)” on page 4-26.

7. Remove the pressure pad holder, the wear plate, and the sensor spring. Go to“Removing and replacing the document insert (DI) sensor assembly (Modelswith DI)” on page 4-24.

8. Remove the screw holding the MICR to the lower form entry frame. SeeFigure 4-21 on page 4-29.

9. Move the printhead carrier to the full right position. Rotate the DI sensortoward the front of the printer.

10. Slide the MICR over towards the right side of the printer until it clears themounting post, and remove it. Note the cable routing. See Figure 4-21 onpage 4-29.

11. Reassemble.

Note: Polarity of the connector is important. Do not force the connector.




Bottom Cover

Frame

Front Shock Mount

Printer Assembly

Main Logic Card

MICR Cable

Figure 4-20. Removing the Front Shock Mount

Mounting Post

MICR

Bail

Screw

Toggle Actuator

Figure 4-21. Removing the MICR



Removing and replacing the lower forms entry frame or flipperassembly (TN4)

ImportantThis procedure shows you how to remove the lower forms entry frame FRUs.Stop when you get to the failing FRUs, exchange the FRUs, and reassemble.The FRUs are highlighted.

After completing this procedure, return to the procedure you were performingfrom the following:

v “Removing and replacing the document insert (DI) feed roller (Models with DI)”on page 4-37



3. Depending on the printer model, gently remove the cables connected to themain logic card.

4. Twist the front shock mount to the horizontal position and pull it out. SeeFigure 4-22 on page 4-31.

5. Lift the front of the printer frame high enough to reach in and disconnect theMICR reader cable.

6. If you need to replace the upper DI forms entry, do so at this point, instead ofdisconnecting the MICR cable. See Figure 4-23 on page 4-32.

Note: Snaps for the upper DI forms entry are inside the frame under the fronttransport shaft. See Figure 4-7 on page 4-10.

7. Lift the frame out of the bottom cover.


9. Remove the document insert sensor spring. Go to “Removing and replacing thedocument insert (DI) sensor assembly (Models with DI)” on page 4-24.

10. For Models TN3 and TN4 only, remove the screw holding the MICR to lowerthe form entry frame. See Figure 4-21 on page 4-29.

11. Remove the E-clips from each side of the drive shaft. Slide and remove thedrive shaft. See Figure 4-23 on page 4-32.

12. For Models TN3 and TN4 only, remove the toggle actuator clip. SeeFigure 4-23 on page 4-32.

13. For Model TN3 only, remove the document insert lower forms entry frameby maneuvering the bail through the DI backup roller and the feed roller andunsnapping the document insert sensor from the right side of the forms entryframe . See Figure 4-23 on page 4-32.

14. For Models TN3 and TN4 only, remove the flipper assembly by maneuveringthe bail through the DI backup roller and the feed roller. See Figure 4-24 onpage 4-32.

Note: It is important to note the position of the drive gear for reassembling.See Figure 4-25 on page 4-33.



15. Remove the bail from the document insert lower forms entry frame assembly.Press the bail downward in the center until the bail clears the locking postsand pull outward. See Figure 4-25 on page 4-33.

16. Reassemble.

17. Adjust the printhead gap. Go to “Printhead platen gap adjustment” onpage 5-4.

18. If you came here from another FRU removal and replacement procedure,return to that procedure to complete it (see the following list of procedures). Ifyou did not come from another procedure, continue to the next step.

19. If you did not need to replace any FRUs, reassemble and replace the covers(the replacement procedure is the reverse of the removal procedure).

20. When replacing the covers, ensure that:

a. The rubber front shock mount is correctly seated.

b. The clear plastic paper guide is inserted through the slot.

Bottom Cover

Frame

Front Shock Mount

Printer Assembly

Main Logic Card

MICR Cable

Figure 4-22. Disconnecting the MICR Cable



Drive Shaft

Upper DocumentInsert Forms Entry

DI Feed Roller

E Clip

Bail

E Clip

Flipper Drive Gear

Toggle Actuator

DI Backup Roller

Flipper

Figure 4-23. Removing the Lower Forms Entry Frame

Flipper Assembly

Bail

Flipper Drive Gear

Flipper Drive Belt

Figure 4-24. Removing the Flipper Assembly



Bail

Flipper Assembly

Hooked Tabs

Figure 4-25. Removing the Bail



Removing and replacing the document insert backup roller and insertlever assembly (Models with DI)

ImportantThis procedure shows you how to remove the document insert backup rollerFRUs. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the document insert (DI) feed roller (Models with DI)”

on page 4-37


2. Remove the document insert sensor assembly. Go to “Removing and replacingthe document insert (DI) sensor assembly (Models with DI)” on page 4-24 andthen return to this procedure.

3. Remove the pressure spring between the frame and shaft eccentric bearing.See Figure 4-26 on page 4-35.

4. Remove the E-clip from the document insert backup roller.

5. Slide the document insert backup roller to the left side and pull forward toremove.

Note: Be careful not to misplace the bushing on the right side.

6. Remove the rear transport shaft.

7. Remove the E-clip from the document insert lever assembly. See Figure 4-27on page 4-36.

8. Remove the document insert lever assembly.

9. Reassemble.

10. Reset the pressure shaft eccentric bushing. Go to “DI forms compensationadjustment (Models with DI only)” on page 5-2.

11. Reset the DI open lever adjustment. Go to “Document insert open leveradjustment” on page 5-6.





Figure 4-26. Removing the DI Backup Roller



Figure 4-27. Removing the DI Lever Assembly



Removing and replacing the document insert (DI) feed roller (Modelswith DI)

ImportantThis procedure shows you how to remove the DI feed roller FRU. Stop whenyou get to the failing FRUs, exchange the FRUs, and reassemble. The FRUsare highlighted.



3. Remove the ribbon.

4. Gently remove the cables connected to the main logic card.

5. Twist the front shock mount to the horizontal position and pull it out. SeeFigure 4-28 on page 4-38.

6. Lift the front of the printer frame high enough to reach in and disconnect theMICR reader cable.


8. Remove the document insert sensor assembly. Go to “Removing and replacingthe document insert (DI) sensor assembly (Models with DI)” on page 4-24.

9. Remove the MICR read head. Go to “Removing and replacing the MICR readhead (Models with DI)” on page 4-28 and follow steps 10 and 9.

10. Follow steps 11 through 14 for “Removing and replacing the lower forms entryframe or flipper assembly (TN4)” on page 4-30.

11. Remove the document insert backup roller. Go to “Removing and replacing thedocument insert backup roller and insert lever assembly (Models with DI)” onpage 4-34.

12. Remove the DI gear. See Figure 4-29 on page 4-38.

13. Remove the E-clip from the left side of the document insert feed roller. SeeFigure 4-30 on page 4-39.

14. Move the left feed bearing to the right side enough to clear it from the frame.Pull forward and remove the left end of the feed roller.

15. Align the retention pin on the right side of the feed roller with the opening inthe frame and remove the feed roller.

16. Reassemble.





Bottom Cover

Frame

Front Shock Mount

Printer Assembly

Main Logic Card

MICR Cable

Figure 4-28. Removing the Front Shock Mount and Disconnecting the MICR Cable

DI Gear

Idler Gear

DI Motor Gear

E-Clip

E-Clip

E-Clip

DI Motor

Flipper Assembly

Figure 4-29. Gear Removal



Figure 4-30. Removing the Document Insert Feed Roller



Removing and replacing the document insert motor and gears (Modelswith DI)

ImportantThis procedure shows you how to remove the document insert motor and gearFRUs. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.



3. Remove the customer receipt paper guide. Go to “Removing and replacing thecustomer receipt paper guide” on page 4-67.

4. Gently remove the cables connected to the main logic card, except the cablethat is attached to the interface card.

5. Remove the front shock mount. See Figure 4-31.

6. Lift the front of the printer frame high enough to reach in and disconnect theMICR reader cable. See Figure 4-31.


8. Remove the E-clip that is holding the motor gear to the motor. See Figure 4-32on page 4-41.

9. Remove the motor gear.

10. Remove the two screws and then remove the document insert feed motor.See Figure 4-33 on page 4-41.

11. Reassemble.

12. When you replace the DI motor, run the service diskette and select ResetStatistics for the FRU. See “Software adjustments for document insert station”on page 2-1.

Bottom Cover

Frame

Front Shock Mount

Printer Assembly

Main Logic Card

MICR Cable




E-Clips

Idler GearMotor GearScrew

Screw

Figure 4-32. Removing the Motor Gear and Idler Gear

Screws

Document Insert Feed Motor

Figure 4-33. Removing the Document Insert Feed Motor



Removing and replacing the switch card and printhead spacer

ImportantThis procedure shows you how to remove the switch card and printheadspacer. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the ribbon drive assembly” on page 4-13



3. Disconnect the switch card cable from the main logic card.

4. Unfasten the screw and remove the switch card. See Figure 4-34.

5. Remove the printhead spacer from the frame.

6. Reassemble.

Insulator

Switch Card

Hex Screw

Printhead Spacer

Figure 4-34. Removing the Switch Card and Printhead Spacer



Logic cards procedure

Electrostatic discharge (ESD)

Attention: Electrostatic discharge (ESD) damage can occur when there is adifference in charge between the part, the product, and the service person. Nodamage occurs if the service person and the part being installed are at the samecharge level as the product.

ESD damage preventionWhenever a service action involves physical contact with logic cards, modules,back-panel pins, or other ESD-sensitive (ESDS) parts, the service person must beconnected to an ESD common ground point on the product through the ESD wriststrap and cord.

The ESD ground clip can be attached to any frame ground, ground braid, greenwire ground, or the round ground prong on the AC power plug. Coax or connectoroutside shells can also be used.

Handling removed cardsLogic cards removed from a product must be placed in ESD protective containers.No other object should be allowed inside the ESD container with the logic card.Attach all tags or reports that must accompany the card to the outside of the ESDcontainer.

Removing and replacing the main logic and sub-logic cards andconnector-attached interface card

Note: The interface card attaches to the logic card through a connector.

ImportantThis procedure shows you how to remove the logic FRUs. Stop when you getto the failing FRUs, exchange the FRUs, and reassemble. The FRUs arehighlighted.

After completing this procedure, return to the procedure you were performingfrom the following list:v “Customer receipt paper movement and cutter problems” on page 4-60


2. Invert the fully assembled printer.

3. Loosen the screw that holds the interface card assembly. This releases themain logic card from the interface assembly.

4. Pull down on the interface card assembly at the end nearest to the screw.

5. Slide the interface card assembly out of the bottom cover.

6. Remove the top covers. Go to “Removing and replacing the printer covers” onpage 4-3.

7. Remove all cables from the main logic card.

8. Lift the main logic card out of the bottom cover.

9. Whenever you exchange the main logic card, you must remove the sub-logiccard for reattachment to the new main logic card. The sub-logic card is

Logic Cards ProcedureUpdated August 13, 2003


removed by gently pulling on the sub-logic card where the two plastic standofftabs are located at the top on each side of the card. To reassemble thesub-logic card on the new logic card, simply align the plastic standoff tabs withthe two holes in the main logic card and snap the tabs into the card.

Note: Before replacing the main logic card, verify that you have the correct cardassociated with your model.

Main Logic Card

Screws

Nuts

Sub-logiccard

Plasticstandoffs

AssemblyCardShield

Figure 4-35. Removing the Interface Card Assembly

Logic Cards Procedure Updated August 13, 2003


Logic card replacement verifications for all modelsPrior to replacing the logic card, perform the following steps:

1. Resistance checks must be performed prior to installing the new card. Thisensures that there are no existing shorts that can damage the new logic card.

2. Make sure all the following procedures are performed and completed insequence.

3. Always replace the printer card and the failing or shorted FRU at the same time.

Printer resistance checks: Some printers do not have a document insert (DI)station. Check the resistance at the cable end for the following failing applicableFRUs:

Note: Disconnect the cable from the logic card and measure for resistance at thecable connector.

Following are the symptoms indicating a resistances check.

Table 4-1. Resistance Check

Symptom FRU/Cable Resistance Check

Missing wire due to coil short Print head

Jitter (hear or see) due to coil short Transport motor

Ribbon motor does not turn Ribbon motor

Jitter (hear or see) due to coil short Document insert (DI) feed (if present)

Jitter (hear or see) due to coil short Cutter/Customer receipt motor

Print head: Resistance should be greater than 5 ohms between pin 7 and pins (1,2, 3, 4, 8, 9, 10, 11, 12). Replace the print head if the value is less than 5 ohms.See Figure 4-36.

Figure Figure 4-37 on page 4-46 shows the position of all of the connectors on themain logic card.

Figure 4-36. Printhead cable



Customer receipt cutter motor cable: Measure resistance per Figure 4-38 onpage 4-47. Replace the cutter motor if the resistance is not within the range of 12 –18 ohms.

Transport motor cable: Measure resistance per Figure 4-38 on page 4-47.Replace the transport motor if the resistance is not within the range of 4 – 6 ohms.

Document insert motor cable (if present): Measure resistance per Figure 4-38on page 4-47. Replace the document insert motor if the resistance is not within therange of 68– 92 ohms.

Ribbon drive motor cable: Measure resistance between pins 1 and 3 perFigure 4-38 on page 4-47. Replace the ribbon drive assembly if the resistance is notwithin the range of 15 – 52 ohms.

Figure 4-37. Main logic cable connectors



Switch settings, card installation, and printer adjustments: Perform thefollowing steps:

1. Ensure that the dip switch settings on the new card are the same as the settingon the old card.

2. Install the printer main logic card.

4610 DI-Less (Model TN5 only): After replacing the 4610 Planar FRU in a 4610DI-Less printer, you must run the 4610 Configure MCT Utility Diskette. Running thediskette sets the DI-Less MCT value to ensure correct operation of the printer.

To set the DI-Less MCT value:

1. Go to http://www.ibm.com/solutions/retail/store, select Support at the leftside of the screen.

2. Select the IBM 4610 SureMark Printer.

3. Select the download for the Configure MCT Utility Diskette.

4. Attach the 4610 to a PC or 469x terminal. For RS-485 communication, use port7, For RS-232 communication, use the COM1 port.

5. Boot the diskette and follow the menus to set 4610 MCT values to enable the4610 for DI-Less operation.

4610 DI-Less (Model GR5 only): After replacing the 4610 Planar FRU in a 4610DI-Less printer, you must run the 4610 GR5 DI-Less MCT Utility Diskette. Runningthe diskette sets the DI-Less MCT value to ensure correct operation of the printer.

To set the DI-Less MCT value:

1. Go to http://www.ibm.com/solutions/retail/store, select Support at the leftside of the screen.

2. Select the IBM 4610 SureMark Printer.

3. Select the download for the 4610 GR5 DI-Less MCT Utility Diskette.

4. Make a diskette from the downloaded diskette image.

( )

Figure 4-38. Main logic cable connectors



5. Attach the 4610 to a PC or 469x terminal. For RS-485 communication, useport 7.

6. Boot the diskette. The diskette will run by itself. It will sound the beeper fivetimes consecutively, and then it will reboot.

7. Whenever you exchange the main logic card, you must configure the printermodel and then update the firmware. Make a note of the printer model andserial number, which are located on the label that is either on or under thefront cover of the printer, then go to “Software adjustments for document insertstation” on page 2-1.

8. Go to “Firmware update (Models TNx only)” on page 2-4.

9. For the RG5 printer, skip this step; otherwise, go to “Software adjustments fordocument insert station” on page 2-1.

10. Only for the RG5 printer, load the reference/service diskette. Set the modeland serial number when prompted.



Customer receipt station procedures

Removing the customer receipt station coverOpen the customer receipt cover. Place the top of the screwdriver handlebetween the side of the printer and the top cover. Then close the top cover on thescrewdriver, one side at a time. This frees the pivots on both sides. Slide the receiptcover forward and out. See Figure 4-39 on page 4-50

The receipt cover refers to the cover for the customer receipt station. The ribboncover refers to the cover for the document insert station. These terms are usedinterchangeably. These covers are shown below in figure Figure 4-39 on page 4-50.

Customer Receipt Station ProceduresUpdated August 13, 2003


Paper Cover

Top Cover

Ribbon Cover

Lift Tab

Lock Tab

Clear PlasticGuide

Ribbon Cover

Top Cover

Top Cover

Paper Cover

Screwdriver

Figure 4-39. Removing the receipt and ribbon covers

Customer Receipt Station Procedures Updated August 13, 2003


Removing and replacing the thermal cables and paper switch

ImportantThis procedure shows you how to remove the thermal cover, thermal cables,and the thermal paper switch FRUs. Stop when you get to the failing FRUs,exchange the FRUs, and reassemble. The FRUs are highlighted.



3. Remove the thermal cover. See Figure 4-40.

4. Remove the tie wraps and spiral wraps from the thermal printhead cables.Make note of the cable and spiral wrap locations. See Figure 4-41 onpage 4-52.

5. Disconnect the cable from the main logic card and from the thermal printhead.

6. Remove the thermal cables.

7. Unfasten the screw and remove the thermal paper switch.

8. Reassemble.

9. Check the thermal paper switch operation and adjust as necessary. Go to“Thermal paper switch adjustment” on page 5-10.

Thermal Latch Spring

Latch Return Spring

Printhead Mounting Bracket

Shoulder Screws

Platen Latch

Thermal Cover

Rear Tabs

Front Tabs

Figure 4-40. Removing the Thermal Cover



Figure 4-41. Removing the Spiral Wraps

Impact Ribbon DriveConnector (Yellow)

Transport MotorConnector (Red)

Impact Printhead Connector

MICR Head Connector

Thermal PrintheadConnector

Interface Card Connector

Thermal Paper-Out Sensor Connector (Green)

Document Insert Sensor Connector (Red)

Document Insert Motor Connector (Green)

Cutter Motor Connector (White)

Switch Card Connector (Yellow)

Powered Flipper(White) (Model TI8 only)

Future Use(White) (Model TI8 only)

OCR Scanner (White)Model TI8 only)

Figure 4-42. Disconnecting the Thermal Printhead Cable from the Main Logic Card



Removing and replacing the thermal printhead latch

ImportantThis procedure shows you how to remove the thermal-Printhead latch FRUs.Stop when you get to the failing FRUs, exchange the FRUs, and reassemble.The FRUs are highlighted.


2. Remove the paper cover. Go to “Removing and replacing the printer covers” onpage 4-3 and then return to this procedure.

3. Remove the thermal printhead cover. See Figure 4-43.

4. Remove the latch return spring from the platen latch.

5. Push outward on the platen latch and remove. See Figure 4-43.

6. Pull the locking tabs on both sides of the latch spring outward from theprinthead mounting bracket.

7. Slide the thermal printhead latch spring to one side and remove it. SeeFigure 4-44 on page 4-54.

8. Reassemble.


Latch Return Spring


Shoulder Screws

Platen Latch

Thermal Cover

Rear Tabs

Front Tabs

Figure 4-43. Thermal Printhead Latch Assembly



Figure 4-44. Removing the Thermal Printhead Latch Spring



Removing and replacing the thermal printhead drag strip

ImportantThis procedure shows you how to remove the thermal printhead drag stripFRUs. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the thermal printhead assembly” on page 4-57


2. Remove the paper cover. Go to “Removing the customer receipt station cover”on page 4-49 and then return to this procedure.

3. Remove the E-clip and disconnect the drag strip from the printhead shaft. SeeFigure 4-46 on page 4-56.

4. Remove the drag strip by pulling it through the drag shaft housing. Make noteof the orientation for reassembling.

5. Reassemble. You must flex the tip of the drag strip to get it back into position.

Figure 4-45. View of Drag Strip from Back of Printer



Drag Strip

E-clip

Paper Guide

Locking Post

Locking Post

Figure 4-46. Removing the Drag Strip



Removing and replacing the thermal printhead assembly

ImportantThis procedure shows you how to remove the thermal printhead assemblyFRUs. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the customer receipt motor” on page 4-62


2. Remove the paper cover. Go to “Removing the customer receipt station cover”on page 4-49 and then return to this procedure.

3. Disconnect the thermal cables from the main logic card.

4. Follow steps 3 and 4 in “Removing and replacing the thermal printhead dragstrip” on page 4-55.

5. Cut the tie wraps securing the thermal cables to the thermal frame. SeeFigure 4-48 on page 4-58.

6. Remove the hinge by rotating it approximately 45° and squeezing the hingepost through the pivot openings. See Figure 4-47 on page 4-58.

7. Remove the thermal printhead assembly.

8. Remove the E-clip from the cutter stud.

9. If you have the cutter blade configuration shown in Figure 4-49 on page 4-59,remove the cutter stud by sliding it though the opening in the thermalprinthead bracket.

If you have the cutter blade configuration shown in Figure 4-50 on page 4-59,remove the E-clip, slide the cutter blade to the left, and pull the right side ofthe blade from the frame.

10. Remove the stationary blade. See Figure 4-49 on page 4-59 or Figure 4-50on page 4-59.

11. Remove the thermal cover.

12. Remove the E-clips from the left side of the printhead shaft. Remove theprinthead shaft by sliding it through the printhead bracket. See Figure 4-49 onpage 4-59 or Figure 4-50 on page 4-59.

13. Remove the leaf spring.

14. The thermal paper switch is attached to either the thermal frame or the thermalprinthead assembly. Remove and replace the switch, if necessary.

15. Reassemble.

16. Check the thermal paper switch operation and adjust, if necessary. Go to“Thermal paper switch adjustment” on page 5-10.

17. When you replace the thermal printhead, run the service diskette and selectReset Statistics for the FRU. See “Software adjustments for document insertstation” on page 2-1.



Figure 4-47. Thermal Printhead Assembly

Figure 4-48. Removing the Spiral Wraps



Figure 4-49. Removing the Cutter Stud, Stationary Blade, and Printhead Shaft (Model GR3 orTN3)

Figure 4-50. Removing the Cutter Stud, Stationary Blade, and Printhead Shaft (Model GR3 orTN4)



Removing and replacing the thermal platen assembly

ImportantThis procedure shows you how to remove the thermal platen assembly FRUs.Stop when you get to the failing FRUs, exchange the FRUs, and reassemble.The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the customer receipt motor” on page 4-62



3. Open the thermal printhead assembly.

4. Rotate the right thermal platen bearing 90° and lift the right side of the platen sothat the locating tab on the platen stripper is above the locating notch in theright frame.

5. Unsnap and remove the platen stripper.

Note: Handle the platen stripper carefully. The edges may be sharp.

6. Remove the E-clip from the idler gear. Remove the thermal idler gear andthermal drive gear.

7. Lift the right side of the thermal platen and slide the left side of the platen out ofthe frame.

8. Reassemble.

Customer receipt paper movement and cutter problemsThis procedure helps isolate customer receipt (thermal) paper movement orpaper-cutting problems.

If paper is “accordian” or wrapped around the platen, the paper guide may becaught under the main cover or something may have blocked the paper from freelyexiting the printer.

Thermal Feed Gear

Spiral Pin

Cutter GearThermal Idler Gear

E-Clip

Stripper

Thermal Platen BearingE-Clip

Thermal Paper Guide

Figure 4-51. Removing the Thermal Platen Assembly




2. Ensure that the thermal paper is loaded and the thermal printhead is latched.

3. Turn the thermal idler gear clockwise (see 4). All four gears should turn and theplaten should move the paper forward.

Note: It is normal for there to be a time lag of more than 1/2 rotation of thegear before the paper starts moving.

v If a gear does not turn, exchange the failing gear.

v If the platen did not turn the paper, exchange the platen and the bearings.See “Removing and replacing the document insert platen assembly (Modelswith DI)” on page 4-26.

v If it is difficult to turn the gears and advance the paper, replace the clutch.See “Removing and replacing the cutter gears and cutter clutch” onpage 4-66.

4. Turn the thermal idler gear counterclockwise 1-1/4 rotations, and then clockwise1-1/4 rotations. All four gears should turn and the two gears on the inside of theframe should turn and move the lever on the rotating blade to cut the paper.

v If the blades closed, but did not cut the paper, replace both blades.

v If it was difficult to close the blades or there was a noticeable hang-pointduring the cut, replace both blades. Go to “Cutter blade run-in” on page 5-7.

v If the blades did not close, replace the failing gear.

v If the blades closed, but did not open, replace the clutch.

5. If all of the above hardware worked correctly:

a. Temporarily restore power to the printer. With the customer receipt coveropen, press the customer receipt feed button to ensure that the motorrotates the platen. Remove power from the printer by either unplugging itfrom the wall outlet or turning off the system unit.

b. If the platen does not rotate, exchange the customer receipt motor. See“Removing and replacing the customer receipt motor” on page 4-62. Ensurethat the thermal paper is loaded and the paper cover is latched.

c. If the platen still does not rotate, exchange the main logic card. Dependingon how the main logic card is attached, see“Removing and replacing themain logic and sub-logic cards and connector-attached interface card” onpage 4-43.



Removing and replacing the customer receipt motor

ImportantThis procedure shows you how to remove the customer receipt motor FRUs.Stop when you get to the failing FRUs, exchange the FRUs, and reassemble.The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Customer receipt paper movement and cutter problems” on page 4-60v “Removing and replacing the cutter gears and cutter clutch” on page 4-66v “Journal station paper movement” on page 4-77



3. Disconnect the motor connector from the logic card.

4. Open the thermal frame and remove the paper.

5. Slide the left wall of the paper bucket as far to the left as it will go.

Note: This may be difficult. Pull up on the bucket wall while pushing down onthe tabs that latch to the bottom of the guide.

6. Remove the two screws from the customer receipt motor and remove the motorby sliding it under the edge of the paper guide and then out through the paperbucket area.

7. Reassemble.

8. Slide the left wall of the paper bucket back to its original position.

Note: This may be difficult. Pull up on the bucket wall while pushing down onthe tabs that latch to the bottom of the guide.

9. When you replace the customer receipt motor, run the service diskette andselect Reset Statistics for the FRU. See “Software adjustments for documentinsert station” on page 2-1.



Figure 4-52. Removing the Customer Receipt Motor



Removing and replacing the rotating cutter blade and thermal guide

ImportantThis procedure shows you how to remove the rotating cutter blade FRUs. Stopwhen you get to the failing FRUs, exchange the FRUs, and reassemble. TheFRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following:v “Removing and replacing the cutter gears and cutter clutch” on page 4-66



3. Remove the rotating cutter blade and the thermal guide by prying outward onthe right side of the frame with a screwdriver. See Figure 4-53 or Figure 4-54 onpage 4-65.

4. Reassemble.

E-Clip

Stud

Pin

Thermal Paper Guide

Rotating Blade

Figure 4-53. Removing the Rotating Blade and Thermal Guide (Model GR3 or TN3)



Figure 4-54. Removing the Rotating Blade and Thermal Guide (Model TN4)



Removing and replacing the cutter gears and cutter clutch

ImportantThis procedure shows you how to remove the cutter gear FRUs. Stop whenyou get to the failing FRUs, exchange the FRUs, and reassemble. The FRUsare highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Customer receipt paper movement and cutter problems” on page 4-60v “Journal station paper movement” on page 4-77



3. Remove the spiral pin that holds the cutter gear and remove the cutter gear.See Figure 4-55.

4. Remove the cutter clutch assembly.

5. Remove the rotating cutter blade. Go to “Removing and replacing the rotatingcutter blade and thermal guide” on page 4-64.

6. Remove the E-clip that holds the pin gear and remove the pin gear.

7. Remove the cutter stop spring (see Figure 4-52 on page 4-63).

8. Reassemble.

Figure 4-55. Removing the Cutter Gears



Removing and replacing the customer receipt paper guide

ImportantThis procedure shows you how to remove the customer receipt paper guideFRUs. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.

After completing this procedure, return to the procedure you were performing fromthe following list:v “Removing and replacing the document insert motor and gears (Models with DI)”

on page 4-40



3. Remove the rotating cutter blade. Go to “Removing and replacing the rotatingcutter blade and thermal guide” on page 4-64.

4. Remove the thermal printhead assembly. Go to “Removing and replacing thethermal printhead assembly” on page 4-57.

5. Remove the thermal platen. Go to “Removing and replacing the thermal platenassembly” on page 4-60.

6. Remove the document insert platen. Go to “Removing and replacing thedocument insert platen assembly (Models with DI)” on page 4-26.

7. Release the two locking posts from the frame and remove the customerreceipt paper guide. See Figure 4-56 on page 4-68.

Attention: Be careful that you do not break the locking posts.

8. Reassemble.



Locking Post

Old Style New Style

Paper Guide

Locking Post

Paper Guide/Bucket

Figure 4-56. Removing the Customer Receipt Paper Guide



Removing and replacing the customer receipt paper bucket

ImportantThis procedure shows you how to remove the customer receipt paper bucketFRUs. Stop when you get to the failing FRUs, exchange the FRUs, andreassemble. The FRUs are highlighted.



3. Gently remove the cables (except the cable attached to the interface card)connected to the main logic card.

4. Twist the front shock mount to the horizontal position and pull it out. SeeFigure 4-57.

5. Lift the front of the printer frame high enough to reach in and disconnect theMICR reader cable. See Figure 4-57. Return to this procedure.


7. Unlock the locking tabs from the underside of the frame and remove thecustomer receipt paper bucket. See Figure 4-58 on page 4-70.

8. The right side of the bucket will have to be snapped by the triangular guide ribon the paper guide.

9. Reassemble.

Bottom Cover

Frame

Front Shock Mount

Printer Assembly

Main Logic Card

MICR Cable




Figure 4-58. Customer Receipt Paper Bucket



Journal station procedures

Removing the journal station cover1. Open the journal station top cover by unlocking the keylock on the front of the

cover.

2. Press on the front tab and raise the cover up to the rest position.

3. Place your hands on each side of the back of the cover. Gently push down andtoward the rear of the printer until the cover is released from the tabs on eachside of the cover.

4. Set the journal cover aside.

Removing and replacing the journal station button

The journal station button is housed on the journal cover in the rectangular cutout inthe front of the cover.


2. Remove the screw next to the physical switch.

3. Lift up the card on the left side and then unplug the wire.

4. Reassemble.

Switch assembly

Thermal print-head cover

Figure 4-59. Journal station — button

Journal Station ProceduresUpdated August 13, 2003


Removing and replacing the journal printhead cover assembly1. Ensure that the printer is powered off by either powering off the system or

unplugging the printer’s power source from the wall outlet.


3. Remove the two screws and washers (one on each side) from the bushing atthe top rear of the housing.

4. Bend the tension rods on each side far enough to unhook them from thehousing.

5. Lift up on the top and gently guide the black plastic tab out of the tab’s holderon the inside left of the housing.

Journal Station Procedures Updated August 13, 2003


Removing and replacing thermal printhead assembly

The thermal printhead is located near the middle of the journal cover.


2. Remove the cover. Go to “Removing the journal station cover” on page 4-71 andthen return to this procedure.

3. Remove the black plastic printhead cover by gently straightening the bend tabson the rear of the cover.

4. Slide the cover forward over the metal tabs that are located on the front of thecover.

5. Remove the two cable connectors that are located on each side of the thermalprinthead.

6. Remove the two screws holding the thermal printhead to the journal cover.

Cable

Thermal print head

Cover

Latch

Journal switch card

Figure 4-60. Journal Station —Thermal Printhead Assembly



7. Reassemble.

8. Check the thermal paper switch operation and adjust, if necessary. Go to“Thermal paper switch adjustment” on page 5-10.

9. When you replace the thermal printhead, run the service diskette and selectReset Statistics for the FRU. See “Software adjustments for document insertstation” on page 2-1.

Screws

Figure 4-61. Journal Station —Thermal Printhead Cover Assembly



Removing and replacing the platen assembly

The platen assembly is located in the middle top portion of the journal housing.



3. Disconnect the cable from the logic card, and remove the journal station fromthe printer.

4. Remove the E-clip to release the drive gear.

5. With the drive gear removed, remove the two outer E-clips that hold the brassbushings.

6. Remove the brass bushings.

7. Remove the writing plate spring from its lower end.

8. Lift up and out on the platen assembly.

9. Reassemble.

Writing plate

Platen gear

Optical papersensor

Spring

Platen

E-clips

Bushings

Figure 4-62. Journal Station — Platen Assembly



Removing and replacing the journal motor assembly

The journal motor assembly is located on the right side of the journal housing in themiddle lower portion.




4. Remove the E-clip on the bottom outside gear spindle.

5. Remove the outside gear.

6. There are two screws to the left of the motor gear. Remove the top screw.

7. Cut the cable tie securing the cable or cables to the left side of the journalhousing.

8. Pull down on the gear and motor and slide the motor and gear out through thehole in the journal housing.

9. Reassemble.

Slip clutch

Motor

Figure 4-63. Journal Station — Motor Assembly



Journal station paper movementThis procedure helps isolate customer receipt (thermal) paper movement.

If paper is “accordiion” or wrapped around the platen, the paper guide may becaught under the main cover or something may have blocked the paper from freelyexiting the printer.


2. Ensure that the thermal paper is loaded and the thermal printhead is latched.

3. Turn the thermal idler gear clockwise (see step 4). All four gears should turnand the platen should move the paper forward.

Note: It is normal for there to be a time lag of more than 1/2 rotation of thegear before the paper starts moving.

v If all the gears did not turn, exchange the failing gear.

v If the platen did not turn the paper, exchange the platen and the bearings.See “Removing and replacing the platen assembly” on page 4-75.

v If it is difficult to turn the gears and advance the paper, replace the clutch.See “Removing the gear kit with clutch and E-clip” on page 4-79.

4. Turn the thermal idler gear counterclockwise 1-1/4 rotations, then clockwise1-1/4 rotations. All four gears should turn.

5. If all of the above hardware worked correctly:

a. Temporarily restore power to the printer. With the journal station cover open,press the journal station feed button to ensure that the motor rotates theplaten. Remove power from the printer by either unplugging it from the walloutlet or turning off the system unit.

b. If the platen does not rotate, exchange the journal station motor. See“Removing and replacing the journal motor assembly” on page 4-76. Ensurethat the thermal paper is loaded and the journal cover is latched.

c. If the platen still does not rotate, exchange the main logic card.

6. Reassemble.



Removing and replacing the optical paper sensor

The optical paper sensor is located below the platen assembly in the middle portionof the journal housing.




4. Remove the screw immediately to the left of the journal cover switch located onthe left middle of the journal housing.

5. Cut the cable tie securing the optical sensor cable to the housing.

6. Invert the journal housing and remove the sensor by lifting it out through thebottom of the housing.

7. Reassemble.

Optical paper sensor

Figure 4-64. Journal Station — Motor Assembly



Removing the gear kit with clutch and E-clip

The gear kit is located on the right side of the journal housing.




4. Remove the E-clips from the spindles for the four larger gears. Remove thegears.

5. Remove the E-clips from the spindle on the clutch.

6. Remove the E-clip from the slip clutch.

7. Pull the clutch assembly forward and out.

8. Reassemble.

Slip clutch

Figure 4-65. Journal Station — Gear Kit with Clutch and E-clip Assembly



Removing and replacing the journal cover sensor switch

The journal cover switch is on the left side of the journal housing assembly. Whenthe cover is open the switch is open. The cover must be closed to activate theswitch and permit printing of the journal.




4. Remove the sensor switch cable.

5. Remove the screw holding the sensor switch to the frame.

6. Reassemble.

Top coversensor switch

Figure 4-66. Journal Station — Top Cover Sensor switch Assembly



Interface Card Assembly ProceduresThe first procedure listed below is for the Models TNx. These models do not havethe securing locks and seals featured on the Model Gxx printers. The secondprocedure listed is for the Model Gxx printers, and it is more complex and lengthy.

Note: For the Argentina printer, see Appendix A, “Removal and replacements forArgentina Model GR3 and GE3 printers”, on page A-1.






Removing and replacing the Interface card Assembly (models TNx)1. Turn the printer over exposing the bottom part

2. Unplug any communication connectors attached to the front of the interfaceassembly card

3. Remove the two screws from the journal station access panel and lift up andpivot the cover out of the slot at the rear

4. Remove the two screws for the interface assembly

5. Reassemble.

Interface Card Assembly ProceduresUpdated August 13, 2003


|||

||

Removing and replacing fiscal interface assembly for model Gxxprinters

This section describes removal and replacement procedures for the followingfield-replaceable units (FRUs) in the 4610 SureMark Three-Station Printer, ModelGRx and GBx.

Note: For the Argentina fiscal printer you must also remove the security shield, see“Remove the security shield” on page A-3.

Removing and replacing the fiscal interface assemblyThe secure seal is specified by country regulations, contact your local serviceplanner.

See Appendix A, “Removal and replacements for Argentina Model GR3 and GE3printers”, on page A-1 for information on powering off the Argentina Model GR3 andGE3 printers.

1. Power OFF the printer by either powering off the terminal or unplugging theexternal power source from the electrical outlet.

2. Remove the printer seal from the secure screw at the back of the printer.

3. Remove the secure screw.

4. Invert the printer.

5. Loosen the interface assembly screw on the bottom of the printer.

6. Gently tilt and lift the interface assembly out of the printer.

7. Make a note of the printer model, which is located on the label that is on thefront of the cover.

Bottom viewof printer

Powermodulecover

SecureScrew

Fiscalprinterseal

Figure 4-67. Remove Printer Seal and the Secure Screw from Rear Panel

Interface Card Assembly Procedures Updated August 13, 2003


|||

||


Fiscal interfaceassembly

Screw

Figure 4-68. Loosen the Fiscal Interface Assembly Screw and Tilt and Remove Assembly



Processor card1. Remove the interface assembly from the printer.

2. Remove the four screws in the four standoffs that are attached to the processorcard.

3. Gently pull the card upward.

Screws

FiscalProcessorCard

Standoffs

Figure 4-69. Remove Processor Card



Interface cardSee Appendix A, “Removal and replacements for Argentina Model GR3 and GE3printers”, on page A-1 for information on removing the interface assembly from theArgentina Model GR3 and GE3 printers.

1. Remove the interface assembly from the printer.

2. Remove the processor card.

3. Unscrew the four standoffs from the interface assembly.

Attention: Use a hex nut driver to unscrew the four standoff screws to avoidbending the nearby connector pins on the interface card.

4. On the vertical part of the base of the interface assembly, remove the two hexnuts, two lock washers, and two flat washers from the RS-232 port connector.

5. Tilt and pull the interface card upwards until it is free from the fiscal printer cardassembly.

Attention: The main logic card incorporates a lithium battery. You donot replace this battery.See the safety notice below.

6. Reassemble.

Note: After the repair, reinstall the interface card and follow the local procedures toreseal (if applicable) the machine, and put the machine back into service.Additional procedures or paperwork may apply.

Standoff

Memorycard

Fiscalinterfacecard

Figure 4-70. Remove Interface Card from Assembly



|||

Safety InformationBefore you begin to install or service this product, read the following safetyinformation.

The main logic card incorporates a lithium battery.

Refer to IBM Safety Information - Read This First, GA27-4004 for properhandling procedures

Safety Information-Brazilian Portuguese:

Cuidado:

Uma bateria de lítio pode causar incêndio, explosão ou queimaduras graves. Nãorecarregue, desmonte ou aqueça acima de 100°C (212°F), não utilize soldadiretamente na célula, nem incinere ou exponha o conteúdo da célula à água.

Mantenha longe do alcance de crianças.

Substitua apenas pelo número de peça especificado para este produto IBM. Autilização de uma bateria diferente representa risco de incêndio ou explosão. Oconector da bateria é polarizado; não tente reverter a polaridade.

Descarte a bateria de acordo com as regulamentações locais.

Safety Information-French:

Attention:

Prenez garde aux risques d’incendie, d’explosion ou de brûlures graves liés àl’utilisation d’une pile au lithium. Ne la rechargez pas et ne la déamontez pas. Nel’exposez pas à une température supéeriure à 100 °C, ne la soudez pas, ne lafaites pas brûler et n’en exposez pas le contenu à l’eau.

Gardez la pile hors de portée des enfants.

Si vous la remplacez, commandez une pile de rechange de e. même référence.Toute autre pile risquerait de prendre feu ou d’exploser. Le connecteur de la pile estpolarisé. N’essayez pas d’inverser la polarité.

Pour le recyclage ou la mise au rebut, reportez-vous à. la ré.glementation envigueur.

Safety Information-Italian:

Attenzione:

Una batteria al litio può incendiarsi, esplodere o causare ustioni. Non ricaricarla,non smontarla, non riscaldarla ad una temperatura superiore a 100° C, nonsaldarla, non incenerirla, non gettarla in acqua.

Tenere la batteria lontano dalla portata dei bambini.



Sostituirla soltanto con una batteria contrassegnata dal numero parte specifico perquesto prodotto IBM. L’utilizzo di un altro tipo di batteria può determinare rischi diincendio o di esplosione. Il connettore della batteria è polarizzata; non tentare diinvertire la polarità.

Smaltire la batteria secondo la normativa in vigore (D.Lgs. 22 del 5/2/97) esuccessive disposizioni nazionali e disposizioni locali.

Safety Information-Spanish:

Caution:

Una batería de litio puede causar un incendio, una explosión o quemaduras graves.No recargar, desmontar, calentar por encima de los 100 grados C (212 grados F),soldar directamente a la pila, incinerar o mojar el contenido de la pila.

Manténgala alejada de los niños.

Sustitúyala sólo con el número de pieza que se especifica para este producto IBM.El uso de una batería distinta puede causar riesgos de incendio o explosión. Elconector de batería está polarizado; no intente invertir la polaridad.

Deseche la batería se acuerdo con la normativa local.

Safety Information-German:

Achtung:

Lithiumbatterien sind feuergefährlich, explosiv und können schwere Verbrennungenverursachen. Batterie nicht wiederaufladen, öffnen oder über 100 Grad Celsiuserhitzen; die Zelle nicht direkt anlöten, verbrennen oder den Inhalt der Zelle mitWasser in Berührung bringen.

Batterie nicht in Reichweite von Kindern aufbewahren.

Eine verbrauchte Batterie nur durch eine Batterie mit der für dieses IBM Produktspezifizierten Teilenummer ersetzen. Andere Batterien können sich entzünden oderexplodieren. Der Batterieanschluß hat zwei verschiedene Pole; beim Anschließendie Pole nicht vertauschen.

Batterie gemäß den örtlichen Richtlinien für Sondermüll entsorgen.



Memory card1. Remove the interface assembly from the printer.

2. Remove all other FRUs from the interface housing.

3. Dispose of the old interface housing with the bonded memory card according tolocal regulations.

4. Using a new interface housing with the bonded memory card, reassemble theinterface assembly.

Attention: The memory card is permanently bonded to the interface assembly.Remove all FRUs from the interface assembly before replacing the memory card.Procedures for serializing the new memory are defined locally. Country regulationsmay require storing the failed memory.



||

Removing the Model GRx fiscal printer cover1. Power OFF the printer by either powering off the terminal (the printer on/off

switch in Argentina) or unplugging the external power source from the electricaloutlet.

2. Remove the interface assembly (see “Removing and replacing the fiscalinterface assembly” on page 4-82).

3. Remove the two screws from the bottom of the printer. The screws are locatedbehind the fiscal interface assembly, note that they are inaccessible until thefiscal interface assembly is removed. See Appendix A, “Removal andreplacements for Argentina Model GR3 and GE3 printers”, on page A-1 for howto remove the printer power supply module from the Model GR3 Argentinaprinter.

4. With the bottom screws removed, begin removing the components by removingthe document insert station/ribbon cover, the journal-station cover, the customerreceipt paper cover, and the entire printer base cover from the printer. See“Removing and replacing the printer covers” on page 4-3.


Latch tabs

Figure 4-71. Release the Rear Latch Tabs



6. Remove the two screws from the mounting posts located on the right side of thefront of the printer top cover. Lift the top cover up high enough to permitremoval of the rubber grommet from the binding post.

7. With both the paper cover and the journal station cover upright, the latch tabsinside the printer cover are visible.


9. Lift the front of the top cover outward and upward until it clears the bindingposts. Pull the left side of the top cover out and up to clear the tab from thetrack guide on the base. Pull out slightly on both the left and right sides. Lift thetop cover up and away from the printer.

10. Complete the necessary repair.

11. Reassemble.

Notes:

a. Ensure that the rubber front shock mount is correctly seated in the topcover before installing the top cover.

b. When reassembling, ensure that the clear plastic paper guide is insertedthrough the slot in the paper cover.

Mounting post

Impact printercover

Figure 4-72. Mounting Posts on Front Face of base Cover



Chapter 5. Hardware adjustment procedures

Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . . 5-1ESD damage prevention . . . . . . . . . . . . . . . . . . . . 5-1Handling removed cards . . . . . . . . . . . . . . . . . . . . 5-1

Mechanical adjustments . . . . . . . . . . . . . . . . . . . . . 5-2DI forms compensation adjustment (Models with DI only) . . . . . . . . 5-2Printhead platen gap adjustment . . . . . . . . . . . . . . . . . 5-4Document insert open lever adjustment . . . . . . . . . . . . . . 5-6Cutter blade run-in . . . . . . . . . . . . . . . . . . . . . . 5-7Thermal printhead adjustment for customer receipt and journal station . . . 5-8Thermal paper switch adjustment . . . . . . . . . . . . . . . . 5-10Document sensor threshold reset . . . . . . . . . . . . . . . . 5-10

DANGER

Never work on equipment or connect or disconnect signal cables duringperiods of lightning activity.

CAUTION:For your safety, connect equipment requiring electrical power to a correctlywired and grounded outlet.

Note: For translations of these safety notices, see “Safety information” on page xvii.


Attention: ESD damage can occur when there is a difference in charge betweenthe part, the product, and the service person. No damage will occur if the serviceperson, the product, and the part being installed are at the same charge level.

ESD damage preventionAnytime a service action involves physical contact with logic cards, modules,back-panel pins, or other ESD sensitive (ESDS) parts, the service person must beconnected to an ESD common ground point on the product through the ESD wriststrap and cord.


Handling removed cardsLogic cards removed from a product should be placed in ESD-protective containers.No other object should be allowed inside the ESD container with the logic card.Attach tags or reports that must accompany the card to the outside of the container.



Mechanical adjustmentsThe following adjustment procedures are included in this section.

Important: Procedures 1 through 3 must be done in sequence.1. DI forms compensation adjustment2. Printhead/platen gap adjustment3. DI open lever adjustment4. Cutter blade run in5. Thermal printhead adjustment6. Thermal switch adjustment7. Document sensor threshold reset

DI forms compensation adjustment (Models with DI only)Before making this adjustment, make sure the printhead is not pushed against theplaten.

1. Turn the printhead gap adjustment bushings away from the platen (clockwisewhen looking at the left side of the printer). Ensure that the printhead is not inthe far-right position. See Figure 5-1 on page 5-3.

2. Rotate the shaft eccentric bearing until the DI backup roll is away from the DIfeed roll shaft (clockwise). A single sheet of paper should be able to slipbetween the backup roll and the feed roll.

3. Rotate the shaft eccentric bearing counterclockwise so that the backup rollmoves toward the feed roll. Make sure that the paper is removed beforecontinuing the adjustment.

4. Rotate the shaft eccentric bearing until the feed roll shaft end nearest to theeccentric moves away from the pressure roll shaft 0.05 mm (0.002 in). You canmeasure this by using a feeler gauge between the frame and the left feed rollbearing.


6. Continue with “Printhead platen gap adjustment” on page 5-4.

Mechanical Adjustments Updated August 13, 2003


Figure 5-1. DI forms adjustment

Mechanical AdjustmentsUpdated August 13, 2003

Chapter 5. Hardware Adjustments 5-3

Printhead platen gap adjustmentThe printhead platen gap needs to be adjusted to 0.508 mm (0.02 in) nominallyacross the length of the platen. This is accomplished by adjusting the printhead gapbushings located at the left and right ends of the carriage shaft. The gap setting toolFRU part number is 42H1190. A sealant might be required to reseal the SureMarkcover set.

1. The printer mechanism must be installed in the printer base and resting on aflat and level surface.

For printers with a flipper installed, the flipper cover must be installed.

The thermal print mechanism must be closed. The thermal paper cover doesnot have to be in place.

2. Remove the ribbon from the printer (see “Ribbon loading (Models with DI)” onpage 6-6).

3. Move the printhead carriage to the left. Check the printhead gap by sliding thegap setting tool between the printhead and the ribbon guide. See Figure 5-2 onpage 5-5.v The gap setting tool only needs to be pushed down until it reaches the print

wires on the printhead.v The force used to move the gap setting tool up and down in the gap needs

to be very light.v There should be no movement of the printhead.

4. Move the printhead carriage to the right and check the printhead gap asdescribed in step 3.

5. If both adjustments are correct, no further action is required. If eitheradjustment is incorrect, return the printhead carriage to the left.

6. Adjust the left printhead gap eccentric using a screwdriver. The gap betweenthe ribbon guide and the print wires on the printhead should be 0.388 +/- 0.02mm (0.0153 +/- 0.0008 in). Adjust it with the printhead gap setting tool that isprovided with the printhead FRU.

7. For right printhead gap adjustment, remove the SureMark cover set.

8. Move the printhead carriage to the right and adjust the right printhead gapeccentric using a screwdriver (see step 6).

9. Check the left side and the right side again. Re-adjust if necessary.

10. If the eccentrics appear snug during the adjustment phase (steps 6 through 8),replace the SureMark cover set and proceed. If the eccentrics did not appearsnug during the adjustment phase, apply a small amount of an appropriatesealant (nail polish or a sealant from Glyptal, Inc.) across the original seals. Ifthe eccentrics appear excessively loose, they may require replacement.

Note: Loctite is not an acceptable sealant.

11. Replace the SureMark cover set.

12. Check the left side and the right side again. Replacing the cover may introducevariations. Readjust if necessary.

13. Reinstall the ribbon and perform a print test to check function and print quality.See “Customer receipt test” on page 3-1 for information on performing a CRprint test.



Figure 5-2. Placement of gap setting tool

Backup Roller

Screw

Front Carrier Bearing

Front Transport Shaft

SlotPrinthead GapEccentric Detail

LeftPrintheadGap Eccentric

Rear Transport Shaft

Right Eccentric

Printer Carriage Assembly

Ribbon Guide

Upper Feed Roller

Figure 5-3. Platen gap adjustment



Document insert open lever adjustment1. Move the impact printhead carriage to the right until it is 2 mm from the right

wall of the frame.

2. Use a screwdriver to adjust the DI open adjustment bushing. Adjust until the leftend of the backup roll shaft has moved 2.5 mm (0.098 in or 0.1 in) from theclosed position. This can be measured by the distance the left backup rollbearing moves back relative to the frame (see Figure 5-4).


Figure 5-4. DI open lever adjustment



Cutter blade run-in

Note: This procedure needs to be done whenever the cutter blades are replaced.

1. Make sure the thermal bracket is closed and there is no paper in the printer.

2. Manually rotate the cutter blade for 5 cycles by rotating the thermal feed gears.This ensures that the blades are correctly run-in. See Figure 5-5.

3. Metal debris left on the blades must be removed by manually operatingadditional cycles.

Figure 5-5. Cutter blade run-In (Models TN3 and TN4)



Thermal printhead adjustment for customer receipt and journal station

Note: The thermal printhead should be adjusted prior to adjusting the thermalswitch.

The thermal printhead adjustment procedure is the same for both the printerstation and the journal station — only the cover information differs.

1. The thermal printhead must be mounted in the printer and the respective coverremoved.

2. With the thermal bracket open, loosen both of the shoulder screws until thethermal printhead and the shoulder screws slide smoothly within the thermalprinthead mounting bracket slots. See Figure 5-6 on page 5-9.

3. Close the thermal bracket.

4. Use a small screwdriver to press on the shaft of the shoulder screw, betweenthe mounting bracket and the printhead bracket.

5. Slide the printhead to the end of the slots, towards the back of the printer.

6. Run the CR offline test (see “Customer receipt test” on page 3-1). Observe thethermal print density as it prints.

7. Slide the thermal printhead using steps 4 and 5, one side at a time, towardsthe front of the printer. As you move the printhead, the printing will becomedarker. When the print is most dense and uniform across the entire print line,the thermal printhead adjustment is complete.

8. Tighten the two shoulder screws until they are snug. Do not overtighten theshoulder screws.

9. Test the printer to ensure continued print quality. Go to “Offline tests” onpage 3-1. Re-adjust if necessary.

10. Check the thermal paper switch adjustment. Go to “Thermal paper switchadjustment” on page 5-10.



Shoulder Screws

Shoulder Screws


Latch Return Spring


Platen Latch

Thermal Printer Cover

Figure 5-6. Thermal printhead adjustment for customer receipt and journal stations



Thermal paper switch adjustment1. Loosen the bracket-mounting screw until the switch and the bracket assembly

slide smoothly into the switch mounting bracket slot. See Figure 5-7.

2. Slide the switch in the slot so that the switch is closest to the front of the printerand successively move the switch rearward until the printer passes the followingtest steps.

3. Test the printer by installing about 150 mm (6 in) of paper and closing the cover.The blinking CR light should go to a steady state. If the light does not, press theCR paper feed button to advance the receipt paper a few inches. The printerready LED should then go to a steady state.

4. With the paper cover still closed, feed the paper out of the printer. The printerready LED should start to blink, indicating an out-of-paper condition.

Document sensor threshold resetSet the document sensor threshold reset (adjustment), if the printer does not sensean inserted document.

To reset the sensor threshold values to the original default values:

1. Press and hold both buttons to enter offline mode.

2. While the printer is offline, open and close the customer receipt cover.

Figure 5-7. Thermal paper switch adjustment



Chapter 6. Operation

Indicators, controls, and stations – thermal/impact printers . . . . . . . . 6-1Check verification and printing (model TN4 only) . . . . . . . . . . . . 6-2Ribbon loading (Models with DI) . . . . . . . . . . . . . . . . . . 6-6Clearing jams in the check flipper area . . . . . . . . . . . . . . . . 6-8Cleaning the MICR reader read head . . . . . . . . . . . . . . . . 6-10Thermal printheads cleaning . . . . . . . . . . . . . . . . . . . 6-11

Note: All covers must be installed on the SureMark printer before and duringoperation.

Indicators, controls, and stations – thermal/impact printersThere are two LED indicators and three triangular-shaped buttons located on thetop of the printer. The indicators and buttons serve multiple functions.

When the Printer Ready LED indicator is on continuously, the printer is online(connected to the system) and ready for printing.

When the Printer Ready LED indicator blinks, one of the following conditions exists:v The printer is offline (offline testing is enabled).v The printer is out of thermal paper.v The document insert station cover and/or CR paper cover is open.v The journal station cover is open.v The printer has a nonrecoverable home error.

The second LED is the document present indicator. It lights when a document isinserted far enough into the Document Insert (DI) station to reach the DI sensor.When this LED blinks, the DI station is waiting for you to insert a document.

The topmost button is the Customer Receipt (CR) paper feed button. Press thisbutton to advance the CR paper. The lower button is the document insert stationfeed button. Press this feed button to advance a document.

Journal Feed Button

Customer ReceiptPrinter Station

Ribbon Cover(Document insert cover)

Document InsertPrinter Station

Printer Ready LED

Customer Receipt Feed Button

Document Present LED

Document Feed Button

CustomerReceiptPaper Cover

Journal papercover

Journal PrinterStation

Figure 6-1. Indicators, controls, and printing stations – Thermal/Impact SureMark Printers



|

||

If you simultaneously press both customer receipt and document feed buttonsmomentarily and then release them, the DI throat opens. The throat must be opento insert a document from the side. Press and then release both buttons again toclose the throat.

Both CR and DI buttons are also used to test the printer. See “Offline tests” onpage 3-1 for additional button functions.

The third button on the top of the printer is located on the journal station. Press thisbutton to advance the paper in the journal station.

Check verification and printing (model TN4 only)Model TN4 printers are capable of printing verification information on a check andprinting information on an inserted document. Figure 6-2 on page 6-3 shows thecorrect positioning of the check in a printer. It also shows how to side load adocument to align it exactly where you want it to be printed.

Attention: Do not pull the receipt paper out of the printer with the paper accesscover closed. Doing that will disengage the paper feed and the paper feed motormust catch up before the printer can feed the paper. The result will be missing linesor partial lines of print. Use the Customer Receipt Feed button to advance thereceipt and all lines will be printed.



Insertion of Checkfor MICR Readingand Franking

Insertion of Checkfor Printing the Face

Insertion of Document(Front Load)

Insertion of Document(Side Load)

Print Position

4001

19

Pay To TheOrder Of

Memo

$

Dollars

End

orse

Her

e

Do

Not

Sig

n / W

rite

/ Sta

mp

Bel

owT

his

Line

For

Fin

anci

al U

sage

Onl

y

Fede

ral R

eser

ve B

ank

Reg

ulat

ion

CC

041117847096 095867238671 4001

Figure 6-2. Positioning checks and documents for reading and printing

Check Verification and PrintingUpdated August 13, 2003

Chapter 6. Operation 6-3

Figure 6-3 and Figure 6-4 on page 6-5 show the printable area on an inserteddocument for both portrait and landscape.

Figure 6-3. Printable area of an inserted document (portrait)

Check Verification and Printing Updated August 13, 2003


Figure 6-4. Printable area of an inserted document (landscape)

Check Verification and PrintingUpdated August 13, 2003


Ribbon loading (Models with DI)1. Open the ribbon cover. As the cover is opened, the printhead moves to a

position where you can easily load a ribbon.

2. If there is already a ribbon cartridge installed, remove it by lifting it straight up.

Note: You might need to grab the body of the cartridge rather than the top toremove.

Figure 6-5. Opening the ribbon cover

Ribbon Loading Updated August 13, 2003


3. Maintain ribbon tension by turning the ribbon cartridge knob as shown inFigure 6-6. Lower the cartridge into position until notches on its sides snap intoplace on the printer guides. After the cartridge is in place, turn the knob until theribbon slides into place between the printhead and the ribbon shield. SeeFigure 6-7 for correct ribbon positioning.

4. Close the ribbon cover.

Figure 6-6. Ribbon cartridge loading

Correct Not Correct

Ribbon Shield

Print Head

Figure 6-7. Ribbon path around the printhead

Ribbon LoadingUpdated August 13, 2003


Clearing jams in the check flipper areaThis procedure is for the SureMark Model TN4 printer (MICR reader and checkflipper feature) only.

If a check jams in the check flipper mechanism:

1. Lift up the left front corner of the lower document insert cover and pull the coverfrom the printer. (See Figure 6-8.)

2. The action you take in this step depends on whether the document is visibleand can be removed:

v If you can remove the document, remove it, and replace the lower documentinsert cover.

v If you cannot remove the document, continue with step 3.

3. Lift up the tab on the left side of the check flipper cartridge and remove theassembly from the printer. (See Figure 6-9 on page 6-9.)

Figure 6-8. Removing the lower document insert (DI) cover

Clearing Jams in Check Flipper Updated August 13, 2003


4. Reach inside the document insert station and carefully remove the jammedcheck.

5. Remove any debris from the belts. Clean the belt surface with a brush or dampcloth. Dry the belts completely.

6. Reinstall the check flipper cartridge and the lower DI cover.

Figure 6-9. Removing the check flipper cartridge

Clearing Jams in Check FlipperUpdated August 13, 2003


Cleaning the MICR reader read headThe MICR reader read head should be cleaned after 10,000 checks are processedor every 3 months. Insert the MICR reader cleaning card through the documentinsert station several times.

If cleaning the MICR reader read head does not solve a problem you are having, itmight be that you are experiencing electromagnetic noise interference. Sources ofelectromagnetic noise (for example, displays, security towers, and other sources)can interfere with the MICR reader read head. The printer filters noise from manydevices. If the MICR reader does not function properly, rearranging the printerrelative to the device may improve MICR reader reading. The noise source shouldbe as far away as possible from the right side of the printer.

For additional information on troubleshooting MICR reader read problems, see“Offline tests” on page 3-1.

Cleaning MICR Read Head Updated August 13, 2003


Thermal printheads cleaningThe thermal printheads in both the customer receipt and journal station can becleaned whenever print quality deteriorates.

1. Open the paper or journal cover.

2. Using a cotton swab soaked in isopropyl alcohol, gently wipe the printheadseveral times on its print line and on the surrounding area. See Figure 6-10.

3. Wipe off any residual alcohol with a dry swab.

If print quality does not improve after cleaning the thermal printhead, call forservice.

Thermal Print Line

Detail View of Thermal Print Head

Paper Cover

Figure 6-10. Printhead and print line area

Thermal printerheads CleaningUpdated August 13, 2003


Thermal printerheads Cleaning Updated August 13, 2003


Chapter 7. Parts listing

Assembly 1: Printer assembly . . . . . . . . . . . . . . . . . . . 7-2Assembly 2: Journal station cover and button assembly . . . . . . . . . 7-4Assembly 3: Customer receipt station operator button assembly . . . . . . 7-6Assembly 4: Logic cards and shock mounts . . . . . . . . . . . . . . 7-8Assembly 5: Document insert station . . . . . . . . . . . . . . . . 7-10Assembly 6: Customer receipt thermal printhead assembly and cover . . . . 7-12Assembly 7: Printhead transport and ribbon drive assembly. . . . . . . . 7-14Assembly 8: Impact printhead assembly . . . . . . . . . . . . . . . 7-16Assembly 9: Document insert station platen and lever . . . . . . . . . . 7-18Assembly 10: Document insert drive shaft assembly . . . . . . . . . . 7-20Assembly 11: Document insert station gears and motor . . . . . . . . . 7-22Assembly 12: Customer receipt drive, cutter, and platen . . . . . . . . . 7-24Assembly 13: Models TN3, TN4, and TN5 interface assembly . . . . . . . 7-26Assembly 14: Model GRx (RS-485) fiscal interface assembly . . . . . . . 7-28Assembly 15: Model GBx and GEx (USB) fiscal interface assembly . . . . . 7-30Assembly 16: Journal assembly — both sides view . . . . . . . . . . . 7-32Assembly 17: Models GR3 and GE3 power supply assembly (Argentina only) 7-34Assembly 18: Hardware Kits . . . . . . . . . . . . . . . . . . . 7-36Assembly 19: Cable assemblies, filler panel, power supply . . . . . . . . 7-37Assembly 20: Complete printer replacement as a FRU . . . . . . . . . 7-38Assembly 21: Paper roll holder, (Argentina only) . . . . . . . . . . . . 7-40



||

Assembly 1: Printer assembly

4

23

15

2

10

87

1

20

14

6

12

519

22

31617

11

1520219

13



Asm–Index

PartNumber Units Description

1–1 - Interface Assembly BaseSee “Assembly 13: Models TN3, TN4, and TN5 interface assembly” on page 7-26

– - Interface Assembly (Fiscal RS-485) BaseSee “Assembly 14: Model GRx (RS-485) fiscal interface assembly” on page 7-28

– - Interface Assembly (Fiscal USB) BaseSee “Assembly 15: Model GBx and GEx (USB) fiscal interface assembly” on

page 7-30–2 NP Printer frame–3 NP Base Assembly–4 17P6232 1 JNL Cover FRU Assembly - Pear White– 49P6817 1 JNL Cover FRU Assembly - Iron Gray–5 17P6233 1 Journal Assembly–6 17P6242 1 Main Cover Top Assembly - Pearl White– 35P0165 1 Main Cover Top Assembly, Argentina only - Pearl White– 54P1669 1 Main Cover Top Assembly - Iron Gray– 54P1585 1 Main Cover Top Assembly, Argentina only - Iron Gray–7 17P6224 1 Main Logic Card Assembly–8 17P6223 1 Sub Logic Card Assembly–9 NP Label-Cover S/N–10 NP Label-Frame S/N–11 2 Base screw 6-32 X 2.5 inch (GR3 only), use miscellaneous hardware kit 17P6244

–12 42H1132 1 Cover, ribbon - Pearl White– 10J1573 1 Cover, ribbon - Iron Gray– 54P1625 1 Cover, ribbon (for integrated paper roll asembly), Argentina only - Pearl White– 13G2034 1 Cover, ribbon (for integrated paper roll asembly), Argentina only - Iron Gray

– 42H1139 v Button KitIncludes Assembly Index -13 and -14)

–13 2 v v Button, key–14 2 v v Key Pad Button

– 42H1140 v Shock KitIncludes Assembly Index -15, -16, and -17)

–15 2 v v Shock Mount–16 1 v v Plug, Shock MTG Base–17 1 v v Front Shock Mount Base

–19 NP Paper Bucket–20 42H1063 2 Stud, Cover Shock Mount–22 NP Main Card Shield–23 42H1136 1 Paper Cover Lens Assembly- Pearl White– 10J1568 1 Paper Cover Lens Assembly- Iron Gray

Assembly 1: (continued)Updated August 13, 2003

Chapter 7. Parts listing 7-3

||||

||||

||||||||

||||||||||||||||

|||||||||||||||||||||

||||||||||||||||||||||||||

||||

||||||||

Assembly 2: Journal station cover and button assembly

1

2

3

4

8 8

7

65

11

9



Asm–Index


2–1 NP v Cover Frame–2 NP v Print Head Shaft with e-clips–3 NP v Cover Support Frame–4 17P6245 1 v Print Head Cover (Thermal)–6 NP v Spring Thermal Latch–7 17P6235 1 v JNL Button Card–8 NP v M3X6 Double Sems (ZC) included in hardware kit–9 17P6236 1 v Print Head ASM–10 NP v M3X5 Double Sems (ZC) included in hardware kit–11 NP v Thermal Head Connector



Assembly 3: Customer receipt station operator button assembly

5

1

2

3

4



Asm–Index


3–1 42H1139 2 v Switch Button, Operator (2x)–2 42H1135 1 v Switch Asm, Operator

Includes Screw (Assembly Index -3) and Insulator (Assembly Index -4)–3 NP v v Screw (see kit 42H1063)–4 NP v v Insulator, Switch–5 NP Frame



Assembly 4: Logic cards and shock mounts

17

1

4

16

6

12

18

5

2

10

15

19



Asm–Index


4–1 NP Customer Receipt/Document Insert Frame– 42H1140 1 v Kit, Shock Mounts

(Includes Assembly Index -2, -3, -4 , and -5)–2 NP v v Shock, Front, Mount–3 NP v v Shock, Front–4 NP v v Shock, Rear (X2)–5 NP v v Support, Front–6 NP v Assembly Card Shield–10 NP Cover, Base–12 17P6224 1 Card Assembly, Main Logic–15 02L0816 1 Card Assembly, Interface (RS-232 and RS-485), Models TN3, TN4, and TN5–15 1 Fiscal Interface Assembly, Model GRx.

See “Assembly 14: Model GRx (RS-485) fiscal interface assembly” on page 7-28.Includes trap door

– - Interface Assembly, GBx and GEx.See “Assembly 15: Model GBx and GEx (USB) fiscal interface assembly” on

page 7-30–16 02L0769 1 Shield, Tray Spill Base–17 NP Journal Frame–18 17P6223 1 Sub Card Asm–19 54P1627 Security Shield, RS-485 (Argentina only)– 54P1629 Security Shield, USB (Argentina only)



||||||||||

||||||||

Assembly 5: Document insert station

1

2

3

5

4

6



Asm–Index


5–1 NP Frame–2 42H1133 1 DI Forms Entry, Upper - Pearl White– 10J1565 1 DI Forms Entry, Upper - Iron White–3 42H1115 1 Flipper Cover (Models xR4 Only), Includes - Pearl White– 10J1188 1 Flipper Cover (Models xB4 Only), Includes - Iron Gray

Rollers (Assembly Index -4) and roller shafts (Assembly Index -5)See “Assembly 10: Document insert drive shaft assembly” on page 7-20 for theDI Lower Forms Entry Cover for Models TN3 and Gx3

–4 NP Rollers (X4)–5 NP Shaft, roller (X2)–6 42H1116 1 Cartridge Asm, Flipper (Model xx4 Only)

Includes sample check (2x)



||||||||||||||||

|

Assembly 6: Customer receipt thermal printhead assembly and cover

2

3

4

11

56

10

7

8

1

9



Asm–Index


6–1 30L6442 1 Cable, Thermal, High Speed–2 42H1137 1 v Hinge

Includes Assembly Index -4, -5, and -6.–3 30L6441 1 v Thermal Printhead Assembly, High Speed– 42H1059 1 v v Thermal Latch Asm.–4 NP v v Spring, Thermal–5 NP v v Spring, Latch Return–6 NP v v Latch, Platen–7 42H1180 1 v Cover, Thermal Printhead

Includes Label.–8 42H1129 1 v Drag Strip

Includes E-clip–9 42H1128 1 v Sensor, Thermal Paper

Includes Screws and Mounting Bracket.–10 NP Frame–11 08L1843 1 Thermal Printhead FRU, High Speed (all models except TI1 and TI2)–11 42H1262 1 Thermal Printhead FRU, High Speed (Models TI1 and TI2 only)



||||

Assembly 7: Printhead transport and ribbon drive assembly

1

2

3

4

5

6

7

8

9

10

11

12



Asm–Index


7–1 42H1107 1 v Bushing, Gap Adjust (2X)–2 42H1106 1 v Shaft, Transport, Rear

Includes Gap Adjust Bushings (Assembly Index -1)–3 42H1044 1 v Shaft, Transport, Front

Includes Screw (Assembly Index -4)–4 NP v v Screw (see kit 42H1063)–5 42H1110 1 v Belt, Timing–6 42H1109 1 v Spring, Tensioner–7 42H1108 1 v Tensioner Asm.

Includes Tension Spring (Assembly Index -6)–8 42H1145 1 v Spacer, Printhead–9 NP Frame–10 42H1114 1 v Ribbon Drive Asm.–11 42H1045 1 v Motor, Transport

Includes Screws (Assembly Index -12)–12 1 v v Screws (2X)

See Hardware Kit, 42H1063, Miscellaneous Fasteners.)



Assembly 8: Impact printhead assembly

1

2

3

4

5

6

7

89

10



Asm–Index


8–1 42H1047 1 v Guide, RibbonIncludes Screws (Assembly Index -2)

–2 NP v v Screws (2X)Part of Hardware Kit, 42H1063, Miscellaneous Fasteners.

–3 42H1046 1 v Printhead Asm, ImpactIncludes Printhead, Screw (Assembly Index -4), Printhead Gap Gage

–4 NP v v Screw (see kit 42H1063)–5 42H1112 1 v Carriage Asm.–6 42H1111 1 v Cable, Printhead–7 42H1113 1 v Bearing, Carrier, Front–8 42H1048 1 v Sensor, Home

Includes Screw (Assembly Index -9)–9 NP v v Screw

Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.–10 NP Frame– 42H1190 1 Printhead Gap Gage



Assembly 9: Document insert station platen and lever



Asm–Index


9– 42H1062 1 v Platen Asm, DI StationIncludes Assembly Index -1, -2, -3, -4, and -5.

–1 NP v v E-Clips (2X) (part of 42H1063)–2 NP v v Shaft, Platen–3 NP v v Spring, Clip (2X) (part of 42H1144)–4 NP v v Platen–5 NP v v Spring, Platen (part of 42H1144)– 42H1051 1 v Pressure Pad Asm.

Includes Assembly Index -6, -7, and Sample Checks– 42H1052 1 v DI Sensor Asm.

Includes Assembly Index -6, -7, -8, -9, and Sample Checks–6 NP v v Holder, Pressure Pad–7 NP v v Pressure Pad–8 NP v v Spring, Sensor (part of 42H1144)–9 NP v v Sensor, DI Upper/Lower–12 NP v v Wear Plate–10 42H1121 1 v DI Lever Asm

Includes Bushing, E-clip, DI Lever–11 NP Frame



Assembly 10: Document insert drive shaft assembly



Asm–Index


10–1 NP Frame–2 38H7504 1 v Read Head, MICR (Model TN4 Only)

Includes Screw (Assembly Index -3) and Sample Check (2x)–3 NP v v Screw (part of 42H1063)– 42H1057 1 v DI Feedroller Assembly. (Model TN4 Only)

Includes Assembly Index -4, -5, and -6.–4 NP v v DI Feedroller (Model TN4 Only)–5 NP v v E-Clip (part of 42H1063)–6 NP v v Bearing, Feed, Left– 42H1119 1 v DI Feedroller Assembly. (Model TN3 and GR3 Only)

Includes Assembly Index -7, -8, and -9.–7 NP v v DI Feedroller (Model TN3 and GR3 Only)–8 NP v v E-Clip (part of 42H1063)–9 NP v v Bearing, Feed, Left–10 42H1117 1 v Bail, (Model TN4 Only)–11 42H1118 1 v Bail, (Model TN3 and GR3 Only)– 42H1050 1 v Flipper Assembly, DI lower Forms Entry (TN4 Only)

Includes Assembly Index -12, -13, -14, -15, -16, Drive Belt, Toggle Lever,Toggle Spring, Roller Shaft, Roller Spring, Roller (2x), Lower Gate,Gate Spring, Upper Gate, Gate Shaft, Support Shaft, C-Clip (2x),Flipper Frame, Flipper Drive Gear, Sample Check (2x)

–12 NP v v Gear, Drive–13 NP v v Shaft, Drive–14 NP v v E-Clip (2x)

Part of Hardware Kit, 42H1063, Miscellaneous Fasteners.–15 NP v v Clip, Toggle Actuator

(Also part of Hardware Kit, 42H1144, Miscellaneous Springs.)–16 NP v v Flipper Sub. Assembly. (Model TN4 Only)– 42H1134 1 v DI Lower Forms Entry (Model TN3 and GR3 Only)

Includes Assembly Index -17, -18, and -19.–17 NP v v Shaft–18 NP v v E-Clip (2x)

Part of Hardware Kit, 42H1063, Miscellaneous Fasteners.–19 NP v v Frame, Lower Forms Entry (Model TN3 and GR3 Only)– 73G2601 1 Sample Check (2x)



Assembly 11: Document insert station gears and motor

41

25

3

7

6

98

10

11

12

13



Asm–Index


11– 42H1053 1 Kit, DI GearsIncludes Assembly Index -1, -2, -3, -4, and -5

–1 NP v Gear, Motor–2 NP v Gear, Idler–3 NP v Gear, Shaft–4 NP v E-Clip

(Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.)–5 NP E-Clip (X2)– 42H1058 1 DI Backup Roll Shaft Asm

Includes Assembly Index -6, -7, -8, -9, and -10(Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.)

–6 NP v Right Shaft Bearing–7 NP v DI Back-up Roller–8 NP v E-Clip

(Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.)–9 NP v Bearing, Shaft Eccentric–8 NP v Left Shaft Bearing–10 NP v Spring

(Also part of Hardware Kit, 42H1144, Miscellaneous Springs.)–11 42H1120 1 Motor, DI Feed

Includes screws–12 NP v Screws (2X)

(Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.)–13 NP Frame



Assembly 12: Customer receipt drive, cutter, and platen

4

5

3

2

1

6

78

10

9

11

2320

191817

16

12

211413

2215

24



Asm–Index


12– 42H1065 1 v Thermal Cutter AssemblyIncludes Assembly Index -1, -2, -3, -4, -5, -6, -7, -8, and lubricant

–1 NP v v Guide, Thermal (also part of 42H1164)–2 NP v v Spring, Leaf or Lever/Spring–3 NP v v Stud–4 NP v v Blade, Stationary or Blade Asm, Stationary–5 NP v v Pin–6 NP v v Stud, Cutter–7 NP v v Blade Asm, Rotating–8 NP v v Pin– NP v v E-clip

Part of Hardware Kit, 42H1063, Miscellaneous Fasteners.– NP v v E-clip Stationary Blade

Part of Hardware Kit, 42H1063, Miscellaneous Fasteners.– NP v v Lubricant– 30L6443 1 v Platen Assembly, Thermal

Includes Assembly Index -9, -10, and -11.–9 NP v v Bearings, Thermal, Right–10 NP v v Platen, Thermal–11 NP v v Bearings, Thermal, Left–12 42H1164 1 v Stripper– 42H1060 1 v Kit, CR Cutter Gears

Includes Assembly Index -13, -14, -15, -16, -17, -18, 19, and -20.–13 NP v v E-Clip

Part of Hardware Kit, 42H1063, Miscellaneous Fasteners.–14 NP v v Gear, Pin–15 NP v v Pin, Lever Drive–16 NP v v E-Clip

Part of Hardware Kit, 42H1063, Miscellaneous Fasteners.–17 NP v v Spring, Cutter Stop–18 NP v v Gear, Cutter–19 NP v v Gear, Thermal Feed–20 NP v v Gear, Thermal Idler–22 NP v v Spiral Pin–21 30L6445 1 v Clutch Assembly, Cutter–23 30L6444 1 v Motor, CR

Includes Screws (2x)–24 NP Frame



Assembly 13: Models TN3, TN4, and TN5 interface assembly



Asm–Index


13–1 02L0816 1 Interface Assembly–1 NP Thumb Screw–1 NP 2 E Ring A-B (93F0233)–1 NP Hex Card Spacer



Assembly 14: Model GRx (RS-485) fiscal interface assembly

1

3

4

2

5

7

6

8

9



Asm–Index


14–1 NP Screw, included in index assembly -4

–2 Use the Country-specific Fiscal Processor Card Assembly for:– 33P0171 1 v Argentina GRx– 35P0175 1 v Greece GRx– 35P0170 1 v Italy GRx– 35P0174 1 v Turkey GRx

–3 NP 3X8 D_SM Small-ZC standoff, included in index assembly -4

–4 Use the Country-specific Fiscal Interface Logic Card for:– 17P6226 1 v All countries except Argentina and Greece– 35P0168 1 v Argentina GRx– 47P0293 1 v Greece GRx

–5 Use the Country-specific Fiscal Base and Memory Assembly for:– 35P0211 1 v Argentina GRx– 35P0215 1 v Greece GRx– 35P0210 1 v Italy GRx– 35P0214 1 v Turkey GRx

–6 NP v Card Insulator – included in index assembly -4–7 NP v Screws – included in index assembly -4–8 NP v Lock Washer – included in index assembly -4–9 NP v Flat Washer – included in index assembly -4



||||||||||||||||

||||||||

||||||||||||||||

Assembly 15: Model GBx and GEx (USB) fiscal interface assembly

1

3

4

2

5

7

6

8

9



|

|

Asm–Index


15–1 NP Screw, included in index assembly -4

–2 Use the Country-specific USB Fiscal Processor Card Assembly for:– 49P8998 1 v Argentina GEx– 49P9002 1 v Greece GBx– 49P9001 1 v Turkey GBx

–3 NP 3X8 D_SM Small-ZC standoff, included in index assembly -4

–4 Use the Country-specific USB Fiscal Interface Logic Card for:– 13G2002 1 v All GBx countries except Argentina– 35P0169 1 v Argentina GEx

–5 Use the Country-specific USB Fiscal Base and Memory Assembly for:– 49P6838 1 v Argentina GEx– 49P6842 1 v Greece GBx– 49P6841 1 v Turkey GBx

–6 NP v Card Insulator – included in index assembly -4–7 NP v Screws – included in index assembly -4–8 NP v Lock Washer – included in index assembly -4–9 NP v Flat Washer – included in index assembly -4



|||||||

||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||

Assembly 16: Journal assembly — both sides view

1514

1124481079

17

16

1220

22

19

151126

6

281

25

Left side view

31

32

2

30

6

Right side view



Asm–Index


16–0 17P6232 1 Complete Journal Assembly FRU–1 NP Left Frame Sub Assembly–2 NP M3X6 Double Sems (ZC)–4 NP 2 5 E Ring A (SUS)–6 NP M3X6 CSK ZC (30221300610)–7 2 Roller, see miscellaneous hardware kit 17P6244–8 NP Cover Lock Shaft–9 NP Guide Shaft–10 NP Right Frame SUB ASM–11 NP Front Guide SUB ASM–12 17P6237 1 Platen Assembly–14 17P6234 1 Spool Assembly–15 NP Cover Shaft–16 NP Cover Open Spring R–17 NP Cover Open Spring L–19 42H1129 1 Drag Strip–20 NP Rear Guide–22 NP Roller Shaft 1–24 NP Front Guide Shaft–25 NP Frame Shaft–26 NP Earth Plate 4–28 NP Earth Plate 3–30 17P6241 1 Gear Kit with Clutch–31 17P6240 1 Journal Paper Out Sensor–32 1 Journal Cover Switch Assembly



Assembly 17: Models GR3 and GE3 power supply assembly (Argentinaonly)

1

2



Asm–Index


17– Power Supply Assembly–1 35P0164 1 Y-cable and power switch–2 35P0162 1 Power supply module



Assembly 18: Hardware KitsAsm–Index


18–1 42H1063 1 Kit, Miscellaneous Fasteners– v Washer (2X)– v Nut, Hex, Transport, M3 (9X)– v Screw, M3X14– v Screw, Motor (3X)– v Screw, Shoulder (2X)– v Screw, Ribbon Shield (2X)– v Plug, Front Shock– v Stud, Front Shock– v Clip (4X)– v Clip– v Tie, Cable (2X)– v Clamp, Cable– v Screw (2X)– v Washer (1X)– v Screw (M3)– v Nut, M3 (2X)– v Washer, Lock (3X)– v Clip (3X)– v Screw, Lock (2X)– v Screw (4X)– v Washer, Lock (2X)– v Clip (4X)– v Washer– v Clip (6X)–2 42H1144 1 Kit, Miscellaneous Springs– v Spring, Tensioner– v Spring Toggle– v Spring, Sensor– v Actuator, Toggle– v Spring, Thermal Head– v Spring, DI– v Spring, Platen– v Spring, Ribbon Drive– v Spring, Cutter Clutch– v Spring, Cutter Stop– v Spring, Gate– v Spring, Thermal Latch– v Spring, Latch Return–3 17P6244 1 Kit, Miscellaneous Hardware for Journal Station



Assembly 19: Cable assemblies, filler panel, power supplyAsm–Index


19–1 42H1143 1 Cables, Logic CardIncludes Signal Cable, Power Cable, and Cable Clamp.

–2 42H1056 1 Cables, Thermal PrintheadIncludes Both Cables, Cable Tie, and Spiral Wrap.

–3 42H1111 1 Cable Asm, Impact Printhead–4 42H1157 1 Filler Panel–5 42H1176 1 Power Supply–80W for GBx Models (USB attached) and TNx Models (when RS-232

attached)–6 72H3802 1 Cash Drawer Cable, Short– 72H3803 1 Cash Drawer Cable, Long–7 86H2192 1 Models TNx Cable, RS-232 Interface, 2 m– 86H2195 1 Models TNx Cable, RS-232 Interface, 4 m–8 54P1626 Cable, RS-485 interface, 1 m– 47P0284 Cable, RS-485 interface, 1.8 m– 08L2014 9 USB interface cable– 13G2036 10 Cable, RS-232 Audit Port (Models GRx, GBx, and GEx only)



|||||

||||||||||||||||||||||||

Assembly 20: Complete printer replacement as a FRUAsm–Index


20– 35P0281 1 4610-TN3 Printer Assembly– 35P0279 1 4610-TN4 Printer Assembly– 35P0285 1 4610-TN5 Printer Assembly– 35P0280 1 4610-GR3 Printer Assembly (without fiscal interface assembly) (except Argentina)– 35P0277 1 4610-GR3 Printer Assembly for Argentina (without fiscal interface assembly)– 35P0278 1 4610-GR4 Printer Assembly (without fiscal interface assembly)– 35P0284 1 4610-GR5 Printer Assembly (without fiscal interface assembly)



||||

Assembly 21: Paper roll holder, (Argentina only)

4

2

3

1

5

5



Asm–Index


21–1 54P1625 1 v Cover, Ribbon (for integrated paper roll assembly) includes index assembly -2,(Argentina only)

–2 NP v v Integrated Paper Roll Assembly, (Argentina only)–3 42H1132 1 Cover, Ribbon, (for distributed paper roll assembly), (Argentina only)–4 54P1622 1 Distributed Paper Roll Assembly, (Argentina only)–5 54P1623 1 Tear Bar (Argentina Only)



|

|||||||||||||||||||||

Appendix A. Removal and replacements for Argentina ModelGR3 and GE3 printers

Remove the paper roll holder . . . . . . . . . . . . . . . . . . . A-1Remove the distributed paper roll holder . . . . . . . . . . . . . . A-2Remove the integrated paper roll holder . . . . . . . . . . . . . . A-3

Remove the security shield . . . . . . . . . . . . . . . . . . . . A-3Remove the interface assembly . . . . . . . . . . . . . . . . . . A-5Remove the power switch and/or cable . . . . . . . . . . . . . . . A-7Logic card procedures . . . . . . . . . . . . . . . . . . . . . A-10

Electrostatic discharge (ESD). . . . . . . . . . . . . . . . . . A-10Removing and replacing the main logic and sub-logic cards and

connector-attached interface card (models GR3 and GE3 for Argentina) . A-11Remove the power cable . . . . . . . . . . . . . . . . . . . . A-13Remove the power supply . . . . . . . . . . . . . . . . . . . . A-14

This chapter shows the removal procedures for the Argentina version of the IBM4610 SureMark Three-Station Printer Model GRx.

Remove the paper roll holderThe Paper Roll Holder is used to print additional copies of receipts. There are twotypes of Paper Roll Holders:v Distributed Paper Roll Holder is attached to the bottom of the Printer directly in

front of the document input station. See Figure A-1 for diagram and “Remove thedistributed paper roll holder” on page A-2 for removal instructions.

Tear-off bar

Clip

Spindle

Paper roll holder

Paper roll

Figure A-1. Distributed paper roll holder


© Copyright IBM Corp. 2001, 2003 A-1

v Integrated Paper Roll Holder is attached to the top of the Ribbon Cover with twoscrews. See Figure A-2 for diagram and “Remove the integrated paper rollholder” on page A-3 for removal instructions.

Remove the distributed paper roll holder1. Remove paper roll.

a. Push down on paper roll until paper spindle is below the clip indentation.

b. Pull clip out to disconnect from paper spindle.

c. Lift paper roll up and off distributed paper assembly.

2. Remove the paper roll holder.

a. Place the printer up on its end, as show in Figure A-3 on page A-3.

Tear-off bar

Clip

Ribbon cover Paper roll holder

screws

Paper roll

Figure A-2. Integrated paper roll holder


A-2 Three Station Printer: Service

b. Tilt and lift up on the distributed paper roll holder assembly to detach it fromthe three plastic tabs located on the bottom of the printer.

3. Reassemble.

Remove the integrated paper roll holder1. Remove paper roll.

a. Push down on paper roll until paper spindle is below the clip indentation.

b. Pull clip out to disconnect from paper spindle.

c. Lift paper roll up and off integrated paper assembly.

2. Remove the paper roll holder.

a.

Remove the two screws securing the integrated paper roll holder to theribbon cover, see Figure A-2 on page A-2 for screw locations.

Lift the integrated paper roll holder up and off of ribbon cover.

3. Reassemble.

Remove the security shield1. Power OFF the printer by unplugging the internal power source from the

electrical outlet.

2. Invert the printer.

3. Remove the printer seal from the secure screw at the back of the printer.

4. Remove the secure screw.

Paper roll holder

Figure A-3. Removing the distributed paper roll holder


Appendix A. Removal and replacements for Argentina Model GR3 and GE3 printers A-3

5. See Figure A-5. Note the orientation of the locking tabs on the security shield.

Figure A-4. Remove the security shield

Figure A-5. Security shield



6. Lift the rear edge of the security shield up about 25 mm (1 in.). Slide thesecurity shield forward slightly and lift it off of the printer.

Remove the interface assemblyThe interface assembly must be removed before the power supply module can beremoved, because the interface assembly covers the power supply module’s covertab and the screws that hold the top cover to the base. See Figure A-6 on page A-6for more details.

The secure seal is specified by country regulations, contact your local serviceplanner.



1. Remove the security shield, see “Remove the security shield” on page A-3

2. Loosen the interface assembly screw on the bottom of the printer.

3. Gently tilt and lift the interface assembly out of the printer from the left side ofthe assembly.

4. Remove the interface power cable from the interface assembly by pressing onthe tabs and pulling the connectors apart.


Powermodulecover

SecureScrew

Fiscalprinterseal

Figure A-6. Remove the printer seal and the secure screw from rear panel


Powermodulecover

Fiscal interfaceassembly

Screw

Figure A-7. Loosen the fiscal interface assembly screw and tilt the assembly to disconnectelectrical connector



Remove the power switch and/or cableEnsure that the printer is powered off by unplugging the printer’s power cable fromthe wall outlet.

The power on/off switch is located under the customer receipt cover in the right reartop behind the customer receipt feed button. Lift the customer receipt cover to viewthe power on/off switch.

Figure A-8. Disconnect the electrical connectors and remove the assembly



To remove, the power on/off switch, remove the covers. See “Removing andreplacing the printer covers” on page 4-3 for information about how to remove thecovers to remove the power switch.

With the covers removed, the power cable is visible. The power cable runs alongthe middle of the printer next to the logic card. It turns downward and terminates inthe bottom cavity where the power module is located. The following figures showthe route of the cable.

On/Offswitch

Figure A-9. Location of the power on/off switch



The bracket is attached by a screw to the right side of the customer receipt station.Unscrew the bracket and remove the switch and cable. The cable runs beside themain logic card and it is surrounded by other cables. The power cable is shown.

Figure A-10. Power switch and cable with bracket



Remove the main logic cards using the logic cards procedure described below.

Logic card procedures






Figure A-11. Power cable beside main logic card



Removing and replacing the main logic and sub-logic cards andconnector-attached interface card (models GR3 and GE3 for Argentina)

Note: The interface card attaches to the logic card through a connector.


2. Invert the fully assembled printer.

3. Loosen the screw that holds the interface card assembly. This releases themain logic card from the interface assembly.

4. Pull down on the interface card assembly at the end nearest to the screw.

5. Slide the interface card assembly out of the bottom cover.

6. Remove the top covers. Go to “Removing and replacing the printer covers” onpage 4-3.

7. Remove all cables from the main logic card.

8. Lift the main logic card out of the bottom cover.

Note: Before replacing the main logic card, verify that you have the correct path forthe new power cable to avoid cutting the cable when reassembling theprinter.

Logic Card ProceduresUpdated August 13, 2003


Main Logic Card

Screws

Nuts

Sub-logiccard

Plasticstandoffs

AssemblyCardShield

Figure A-12. Removing the Printer Logic Cards

Logic Card Procedures Updated August 13, 2003


Remove the power cableThe cable is exposed when the main logic card is removed. Unplug the cable fromthe bottom of the printer housing where it enters the interface assembly cavity.

With the document insert station removed, the printer cable junction is visible.

Figure A-13. Removing the Interface Card Assembly



Remove the power supply1. Remove the power cord.

2. Remove the fiscal screw on the back of the printer.

3. Loosen the screw that secures the interface assembly housing, and remove theinterface assembly.

4. Remove the two screws at the top of the power supply module cover where thecover attaches to the base, and remove the screw that secures the mountingtab of the power module to the printer.

5. Remove the screw that secures the mounting tab of the power module to theprinter.

6. Lower the power module.


Powermodulecover

Screws

Figure A-14. Loosen the screws and lower the power module cover assembly



7. Loosen the connectors by pressing on the middle tab and the two side tabs,and pull the connectors apart. Inspect the two wires that go into the connectorto ensure that they are making the proper contact. If either wire is broken andnot making good contact, you must remove the covers and replace the cable.

Figure A-15. Loosen the connectors and remove the power supply



Reassembly:

1. Install the power module assembly by reconnecting the power cable to thepower module’s cable. Insert the power module into the printer housing with thebottom end first. This step puts the right side tab in the groove in the base sothat the fiscal interface cover can secure the base of the printer.

2. Ensure that the power module tab is in the groove, and insert the screw throughthe tab.

3. Reconnect the power cable to the interface assembly connector.

4. Insert the left end of the interface assembly into the printer and tighten thesecure screw.


Powermodulecover

Screws

Figure A-16. Reassembly of the power module into the printer


PowermodulecoverFiscal interface

assembly

Figure A-17. Complete the insertion of the interface assembly housing into the printer



|||

5. The printer is ready to be tested and the fiscal seal should be applied if therepair was successful.



Appendix B. Notices

This information was developed for products and services offered in the U.S.A.

IBM may not offer the products, services, or features discussed in this document inother countries. Consult your local IBM representative for information on theproducts and services currently available in your area. Any reference to an IBMproduct, program, or service is not intended to state or imply that only that IBMproduct, program, or service may be used. Any functionally equivalent product,program, or service that does not infringe any IBM intellectual property right may beused instead. However, it is the user’s responsibility to evaluate and verify theoperation of any non-IBM product, program, or service.

IBM may have patents or pending patent applications covering the subject matter inthis document. The furnishing of this document does not give you any license tothese patents. You can send license inquiries, in writing, to:

IBM Director of LicensingIBM CorporationNorth Castle DriveArmonk, NY 10504-1785U.S.A.

For license inquiries regarding double-byte (DBCS) information, contact the IBMIntellectual Property Department in your country or send inquiries, in writing, to:

IBM World Trade Asia CorporationLicensing2-31 Roppongi 3-chome, Minato-kuTokyo 106, Japan

The following paragraph does not apply to the United Kingdom or any other countrywhere such provisions are inconsistent with local law: INTERNATIONAL BUSINESSMACHINES CORPORATION PROVIDES THIS PUBLICATION ″AS IS″ WITHOUTWARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUTNOT LIMITED TO, THE IMPLIED WARRANTIES OF NON-INFRINGEMENT,MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. Some statesdo not allow disclaimer of express or implied warranties in certain transactions,therefore, this statement may not apply to you.

This information could include technical inaccuracies or typographical errors.Changes are periodically made to the information herein; these changes will beincorporated in new editions of the publication. IBM may make improvements and/orchanges in the product(s) and/or program(s) described in this publication at anytime without notice.

IBM may use or distribute any of the information you supply in any way it believesappropriate without incurring any obligation to you.

Any references in this information to non-IBM Web sites are provided forconvenience only and do not in any manner serve as an endorsement of thoseWeb sites. The materials at those Web sites are not part of the materials for thisIBM product and use of those Web sites is at your own risk.


© Copyright IBM Corp. 2001, 2003 B-1

TrademarksThe following terms are trademarks of International Business Machines Corporationin the United States or other countries or both:

IBM, the IBM logo, OS/2, and SureMark are trademarks of the IBM Corporation inthe United States or other countries or both.

Microsoft, Windows, Windows NT, and the Windows logo are registered trademarksof Microsoft Corporation.

Pentium, MMX, ProShare, LANDesk and ActionMedia are trademarks or registeredtrademarks of Intel Corporation in the U.S. and other countries.

Other company, product, and service names may be trademarks or service marksof others.

Other company, product, and service names may be trademarks or service marksof others.


B-2 Three Station Printer: Service

Electronic emission notices

Federal communications commission (FCC) statementThis equipment has been tested and found to comply with the limits for a Class Adigital device, pursuant to Part 15 of the FCC Rules. These limits are designed toprovide reasonable protection against harmful interference when the equipment isoperated in a commercial environment. This equipment generates, uses, and canradiate radio frequency energy and, if not installed and used in accordance with theinstruction manual, may cause harmful interference to radio communications.Operation of this equipment in a residential area is likely to cause harmfulinterference, in which case the user will be required to correct the interference athis own expense.

Properly shielded and grounded cables and connectors must be used in order tomeet FCC emission limits. IBM is not responsible for any radio or televisioninterference caused by using other than recommended cables and connectors or byunauthorized changes or modifications to this equipment. Unauthorized changes ormodifications could void the user’s authority to operate the equipment.

This device complies with part 15 of the FCC Rules. Operation is subject to thefollowing two conditions: (1) this device may not cause harmful interference, and (2)this device must accept any interference received, including interference that maycause undesired operation.

Industry Canada class A emission compliance statementThis Class A digital apparatus complies with Canadian ICES-003.

Avis de conformité aux normes d’Industrie CanadaCet appareil numérique de la classe A est conforme à la norme NMB-003 duCanada.

European Union (EU) Mark of Conformity StatementThis product has been tested and found to comply with the limits for Class AInformation Technology Equipment according to European Standard EN 55022. Thelimits for Class A equipment were derived for commercial and industrialenvironments to provide reasonable protection against interference with licensedcommunication equipment.

Warning: This is a Class A product. In a domestic environment this product maycause radio interference in which case the user may be required to take adequatemeasures.

Properly shielded and grounded cables and connectors must be used in order toreduce the potential for causing interference to radio and TV communications andto other electrical or electronic equipment. Such cables and connectors areavailable from IBM authorized dealers. IBM cannot accept responsibility for anyinterference caused by using other than recommended cables and connectors.

GermanyZulassungsbescheinigung laut dem Deutschen Gesetz über die elektromagnetischeVerträglichkeit von Geräten (EMVG) vom 30. August 1995 (bzw. der EMC EGRichlinie 89/336).


Appendix B. Notices B-3

Dieses Gerät ist berechtigt in Übereinstimmung mit dem Deutschen EMVG dasEG-Konformitätszeichen - CE - zu führen.

Verantwortlich für die Konformitätserklärung nach Paragraph 5 des EMVG ist dieIBM Deutschland Informationssysteme GmbH, 70548 Stuttgart.

Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:

Das Gerät erfüllt die Schutzanforderungen nach EN 50082–1 und EN 55022 Klasse A.

EN 55022 Klasse A Geräte müssen mit folgendem Warnhinweis versehen werden:

″Warnung: dies ist eine Einrichtung der Klasse A. Diese Einrichtung kann imWohnbereich Funkstörungen verursachen; in diesem Fall kann vom betreiberverlangt werden, angemessene Maβnahmen durchzuführen und dafüraufzukommen.″

EN 50082–1 Hinweis:

″Wird dieses Gerät in einer industriellen Umgebung betrieben (wie in EN 50082–2festgelegt), dann kann es dabei eventuell gestört werden. In solch einem Fall ist derAbstand bzw. die Abschirmung zu der industriellen Störquelle zu vergröβern.″

Anmerkung:

Um die Einhaltung des EMVG sicherzustellen sind die Geräte, wie in den IBMHandbüchern angegeben, zu installieren und zu betreiben.

Australia / New ZealandAttention: This is a Class A product. In a domestic environment this product maycause radio interference, in which case the user may be required to take adequatemeasures.

Japanese voluntary control council for interference (VCCI) statementThis product is a Class A Information Technology Equipment and conforms to thestandards set by the Voluntary Control Council for Interference by TechnologyEquipment (VCCI). In a domestic environment this product may cause radiointerference in which case the user may be required to take adequate measures.



Taiwanese class A warning statement

Korean communications statementPlease note that this device has been approved for business purposes with regardto electromagnetic interference. If you find this is not suitable for your use, you mayexchange it for a non-business purpose one.

Electrostatic discharge (ESD)Attention: ESD damage can occur when there is a difference in charge betweenthe part, the product, and the service person. No damage will occur if the serviceperson and the part being installed are at the same charge level.

ESD Damage Prevention

Anytime a service action involves physical contact with logic cards, modules,back-panel pins, or other ESD sensitive (ESDS) parts, the service person must beconnected to an ESD common ground point on the product through the ESD wriststrap and cord.


Handling Removed Cards

Logic cards removed from a product should be placed in ESD protective containers.No other object should be allowed inside the ESD container with the logic card.Attach tags or reports that must accompany the card to the outside of the container.


Appendix B. Notices B-5

Part Number Index

PartNumber

Asm–Index Page

02L0769 4–16 7-902L0816 13–1 7-2702L0816 4–15 7-908L1843 6–11 7-1308L2014 19– 7-3710J1188 5– 7-1110J1565 5– 7-1110J1568 1– 7-310J1573 1– 7-313G2002 15– 7-3113G2034 1– 7-313G2036 19– 7-3717P6223 1–8 7-317P6223 4–18 7-917P6224 1–7 7-317P6224 4–12 7-917P6226 14– 7-2917P6232 1–4 7-317P6232 16–0 7-3317P6233 1–5 7-317P6234 16–14 7-3317P6235 2–7 7-517P6236 2–9 7-517P6237 16–12 7-3317P6240 16–31 7-3317P6241 16–30 7-3317P6242 1–6 7-317P6244 18–3 7-3617P6245 2–4 7-530L6441 6–3 7-1330L6442 6–1 7-1330L6443 12– 7-2530L6444 12–23 7-2530L6445 12–21 7-2533P0171 14– 7-2935P0162 17–2 7-3535P0164 17–1 7-3535P0165 1– 7-335P0168 14– 7-2935P0169 15– 7-3135P0170 14– 7-2935P0174 14– 7-2935P0175 14– 7-2935P0210 14– 7-2935P0211 14– 7-2935P0214 14– 7-2935P0215 14– 7-2935P0277 20– 7-3835P0278 20– 7-3835P0279 20– 7-38

PartNumber

Asm–Index Page

35P0280 20– 7-3835P0281 20– 7-3835P0284 20– 7-3835P0285 20– 7-3838H7504 10–2 7-2142H1044 7–3 7-1542H1045 7–11 7-1542H1046 8–3 7-1742H1047 8–1 7-1742H1048 8–8 7-1742H1050 10– 7-2142H1051 9– 7-1942H1052 9– 7-1942H1053 11– 7-2342H1056 19–2 7-3742H1057 10– 7-2142H1058 11– 7-2342H1059 6– 7-1342H1060 12– 7-2542H1062 9– 7-1942H1063 1–20 7-342H1063 18–1 7-3642H1065 12– 7-2542H1106 7–2 7-1542H1107 7–1 7-1542H1108 7–7 7-1542H1109 7–6 7-1542H1110 7–5 7-1542H1111 19–3 7-3742H1111 8–6 7-1742H1112 8–5 7-1742H1113 8–7 7-1742H1114 7–10 7-1542H1115 5–3 7-1142H1116 5–6 7-1142H1117 10–10 7-2142H1118 10–11 7-2142H1119 10– 7-2142H1120 11–11 7-2342H1121 9–10 7-1942H1128 6–9 7-1342H1129 16–19 7-3342H1129 6–8 7-1342H1132 1–12 7-342H1132 21–3 7-4142H1133 5–2 7-1142H1134 10– 7-2142H1135 3–2 7-742H1136 1–23 7-342H1137 6–2 7-13


© Copyright IBM Corp. 2001, 2003 C-1

|||

|||

PartNumber

Asm–Index Page

42H1139 1– 7-342H1139 3–1 7-742H1140 1– 7-342H1140 4– 7-942H1143 19–1 7-3742H1144 18–2 7-3642H1145 7–8 7-1542H1157 19–4 7-3742H1164 12–12 7-2542H1176 19–5 7-3742H1180 6–7 7-1342H1190 8– 7-1742H1262 6–11 7-1347P0284 19– 7-3747P0293 14– 7-2949P6817 1– 7-349P6838 15– 7-3149P6841 15– 7-3149P6842 15– 7-3149P8998 15– 7-3149P9001 15– 7-3149P9002 15– 7-3154P1585 1– 7-354P1622 21–4 7-4154P1623 21–5 7-4154P1625 1– 7-354P1625 21–1 7-4154P1626 19–8 7-3754P1627 4–19 7-954P1629 4– 7-954P1669 1– 7-372H3802 19–6 7-3772H3803 19– 7-3773G2601 10– 7-2186H2192 19–7 7-3786H2195 19– 7-37


C-2 Three Station Printer: Service

|||

|||

||||||||||||||||||

|||

Index

Numerics4610 fonts and logos utility diskette 2-44693 Terminal Reference and Diagnostic Diskette 2-14694/4695 Service Diagnostic Diskette 2-1

AArgentina power supply model 1-4Attended Update Diskette 2-1

Bbar codes 1-12button, journal station 4-71buttons, description 6-1buttons, how to use 6-1

Ccable, printhead 4-22cables resistance checks 4-46card handling 4-81card installation 4-47check verification, printing 6-2checks, clearing jams 6-8cleaning, thermal printhead 6-11clearing jams, DI station 6-8code pages 1-12communication interface baud rate 1-8communication interfaces 1-6Configure MCT Utility Diskette 2-1cover removal

latch tabs 4-4mounting posts 4-4

customer receipt cutter motor cable resistancechecks 4-46

customer receipt paper movement 4-60cutter blade run-in 5-7cutter problems 4-60

DDI forms compensation adjustment 5-2DI open lever adjustment 5-6DI throat, how to open 6-1DI-Less MCT Diskette 2-1DI-Less removing and replacing logic card procedure

main logic card 4-45reconfiguring MCT values 4-45resistance checks for failing FRUs 4-45

differences in the models 1-4diskette download support information 2-1diskette update of firmware 2-4document insert lower cover 4-9document insert motor cable resistance checks 4-46

document insert sensor assemblyinsert assembly 4-24sensor spring 4-24

Eelectrostatic discharge damage prevention 5-1electrostatic discharge prevention 4-43, A-10emulating the Model 3 or 4 printer 2-6emulation via utility diskettes 2-6emulation, limitations 2-6ESD prevention 4-81

Ffirmware

updating firmware 2-4firmware update diskette 2-4fiscal interface assembly, removing 4-82fiscal interface card, removing 4-85fiscal memory card, removing 4-88fiscal processor card, removing 4-84flipper cartridge 4-9front shock mount, removing and replacing 4-13FRU removal and replacement 4-3

GGR5 DI-Less MCT Diskette 2-1

Hhandling removed cards 4-81hardware requirements 1-11home sensor, removing and replacing 4-11

Iinformation, planning 1-6interface card assembly procedures 4-81Internet resources 1-12introduction 1-5

Jjournal button 4-71journal clutch, removing 4-79Journal cover removal 4-3journal cover sensor, removing 4-80journal gear kit, removing 4-79journal motor assembly, replacing 4-76journal optical paper sensor, removing 4-78journal paper movement 4-77journal platten assembly, removing 4-75journal printhead assembly, removing 4-73journal printhead cover, removing 4-72journal top cover, removing 4-71


© Copyright IBM Corp. 2001, 2003 X-1

Llatch tabs in cover removal 4-4LED, description of 6-1limitation model 4, bar code and check writing 1-11limitation on updating firmware 2-5limitations for emulation 2-6loading ribbon 6-6

Mmain logic cable connectors resistance checks 4-46main logic card procedure 4-43, A-10main logic card removal and reconfiguring 4-44, A-11MCT Utility Diskette 2-1MCT values for DI-Less printers 4-45messages 3-6MICR data parser sample code 2-7MICR reader and check flipper 3-4MICR reader read head cleaning 6-10Model 3 or 4 printer emulation 2-6model 4 bar code limitations 1-11model 4 check writing limitations 1-11model differences 1-4model GR3 interface assembly, removing 4-82mounting posts 4-5

Nnon-fiscal interface card, removing 4-81

Ooffline testing 3-1overview 1-5

Pplanning information 1-6posts, mounting 4-5printer adjustments 4-47printer resistance checks 4-45printhead cable 4-22printhead carriage assembly

bushing 4-16front transport bearing 4-16front transport shaft 4-16home sensor 4-16printhead carriage assembly 4-16rear transport shaft 4-16ribbon guide 4-16timing belt 4-16

printhead cleaning, thermal 6-11printhead platen gap adjustment 5-4printhead resistance checks 4-45printhead, removing and replacing 4-10Procedures, journal station 4-71publications, related xi

Rreconfiguring MCT values for DI-Less printers 4-45related publications and diskettes xiremoving and replacing

backup roller and insert assembly 4-37bail 4-30clip springs 4-26connector-attached interface card 4-43, A-11customer receipt motor 4-62customer receipt paper bucket 4-69customer receipt paper guide 4-67cutter clutch 4-66cutter gear 4-66cutter gears 4-66cutter stud 4-57document insert backup roller 4-34document insert feed motor 4-40document insert idler gear 4-40feed roller 4-37flipper assembly 4-30, 4-37hinge 4-57ideal gear 4-60idler gear 4-66insert lever assembly 4-34insert platten assembly 4-30insert sensor assembly 4-30journal cover 4-3leaf spring 4-57lower forms entry frame 4-30main logic card 4-43, A-11MICR 4-28MICR read head 4-37motor gear 4-40operator buttons 4-8paper cover 4-3paper switch 4-51pin gear 4-66platen 4-26platen springs 4-26printhead shaft 4-57printhead spacer 4-42ribbon cover 4-3rotating blade 4-60rotating cutter blade 4-64sensor assembly 4-37spiral pin 4-66stationary blade 4-57stop spring 4-66stripper 4-60switch card 4-42thermal cables 4-51thermal feed gear 4-60thermal guide 4-60thermal platen 4-60thermal platen assembly 4-60thermal printhead assembly 4-57thermal printhead drag strip 4-55thermal printhead latch 4-53thermal printhead latch spring 4-53top cover 4-3upper DI forms entry 4-30


X-2 Three Station Printer: Service

requirements for hardware 1-11resident code pages 1-12Retail Store Solutions Web site 1-12ribbon drive assembly, removing and replacing 4-13ribbon drive cable resistance checks 4-46ribbon loading 6-6RS-232 XON/XOFF 1-7RS485, RS232 reference diskettes 2-1RS485, RS232 service diskettes 2-1rubber shock mounts 4-6

Ssensor, journal cover 4-80shock mounts, rubber 4-6software requirements 1-11sub-logic card removal 4-43, A-11switch settings 4-47symptoms 3-6

Ttabs, latch 4-5tensioner spring 4-15tensioner, removing and replacing 4-15test

customer receipt 3-1document insert 3-2

testing, offline 3-1thermal paper switch adjustment 5-10thermal printhead adjustment 5-8thermal/impact printers

controls 6-1indicators 6-1

throat, DI station 6-1transport motor 4-20transport motor cable resistance checks 4-46

UUnattended Update Diskette 2-1Updating firmware

via RS-232 attachment 2-5

WWeb site, Retail Store Solutions 1-12

XXON/XOFF 1-7


Index X-3


X-4 Three Station Printer: Service

Readers’ Comments — We’d Like to Hear from You

4610 SureMark Three-Station Printer All ModelsHardware Service Manual

Publication No. GY27-0399-03

Overall, how satisfied are you with the information in this book?

Very Satisfied Satisfied Neutral Dissatisfied Very DissatisfiedOverall satisfaction h h h h h

How satisfied are you that the information in this book is:

Very Satisfied Satisfied Neutral Dissatisfied Very DissatisfiedAccurate h h h h h

Complete h h h h h

Easy to find h h h h h

Easy to understand h h h h h

Well organized h h h h h

Applicable to your tasks h h h h h

Please tell us how we can improve this book:

Thank you for your responses. May we contact you? h Yes h No

When you send comments to IBM, you grant IBM a nonexclusive right to use or distribute your comments in anyway it believes appropriate without incurring any obligation to you.

Name Address

Company or Organization

Phone No.

Readers’ Comments — We’d Like to Hear from YouGY27-0399-03

GY27-0399-03

��Cut or FoldAlong Line

Cut or FoldAlong Line

Fold and Tape Please do not staple Fold and Tape

Fold and Tape Please do not staple Fold and Tape

NO POSTAGENECESSARYIF MAILED IN THEUNITED STATES

BUSINESS REPLY MAILFIRST-CLASS MAIL PERMIT NO. 40 ARMONK, NEW YORK

POSTAGE WILL BE PAID BY ADDRESSEE

International Business Machines CorporationDesign & Information DevelopmentDept. CJMA/Bldg. 645PO BOX 12195Research Triangle Park NC27709-9990

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

__

_

��

Updated August 13, 2003Printed in U.S.A.

GY27-0399-03

4610 fru

Documents

round ground

pressure pad

coil short

provide reasonable

copyright

paper starts

esd wrist

gap setting