4610 Fru

4610 SureMark Three-Station Printer All Models
Hardware Service Manual
Updated August 13, 2003
GY27-0399-03
4610 SureMark Three-Station Printer All Models
Hardware Service Manual
GY27-0399-03
Note Before using this information and the product it supports, be sure to read Safety information on page xvii and the general information 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 and | GE3. | | | | | | | | | | | | | |
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 are not stocked at the address given below. A form for readers comments is also provided at the back of this publication. If the form has been removed, address your comments to: IBM Corporation, Information Development, Department CJMA PO Box 12195 Research 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 you supply 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 Contract with IBM Corp.
Contents
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Preface . . . . . . . . . . Who should read this manual . . Prerequisites to this manual . . How this manual is organized . . Related publications and diskettes Summary of changes . June 2003 . . . . . October 2002 . . . . May 2002 . . . . . . December 2001 . . . August 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi xi xi xi xi xiii xiii xiii xiii xiii xiii
Tell us what you think. . . . . . . . . . . . . . . . . . . . . . xv Safety information. . . . . . . . . . . . . . . . . . . . . . . xvii Chapter 1. Introduction . . Available model designations Printer overview . . . . . Communications overview . Physical requirements . . . Software requirements . . Miscellaneous information . Limitations . . . . . . . User responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-5 1-6 1-9 1-11 1-12 1-13 1-13 2-1 2-1 2-1 2-4 2-4 2-6 2-7 3-1 3-1 3-1 3-6
Chapter 2. Installation, service, and utility software adjustments . 4610 diskette download support information . . . . . . . . . . Software adjustments for document insert station . . . . . . . . 4610 fonts and logos utility diskette (Models TNx only) . . . . . . Firmware update (Models TNx only) . . . . . . . . . . . . . Emulating the IBM Model 3 or Model 4 printers (Models TNx only) . MICR data parser sample code (Model TN4 only) . . . . . . . . Chapter 3. Problem determination for Fiscal unit return codes . . . . . . Offline tests . . . . . . . . . . . Symptoms . . . . . . . . . . . the 4610 Three-Station . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
Printer . . . . . . . . .
Chapter 4. FRU removal and replacement . . . . . . Top covers procedures (Models TNx) . . . . . . . . Document insert station procedures (Models with DI only) . Logic cards procedure . . . . . . . . . . . . . Customer receipt station procedures . . . . . . . . Journal station procedures . . . . . . . . . . . . Interface Card Assembly Procedures . . . . . . . . Chapter 5. Hardware adjustment procedures
Copyright IBM Corp. 2001, 2003
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 4-1 . . . . 4-2 . . . . 4-9 . . . . 4-43 . . . . 4-49 . . . . 4-71 . . . . 4-81
. . . . . . . . . . . . 5-1
iii
Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . . 5-1 Mechanical adjustments . . . . . . . . . . . . . . . . . . . . . 5-2 Chapter 6. Operation . . . . . . . . . . . . . . Indicators, controls, and stations thermal/impact printers Check verification and printing (model TN4 only) . . . . Ribbon loading (Models with DI) . . . . . . . . . . Clearing jams in the check flipper area . . . . . . . . Cleaning the MICR reader read head . . . . . . . . Thermal printheads cleaning . . . . . . . . . . . . 6-1 . 6-1 . 6-2 . 6-6 . 6-8 . . . . . . . . 6-10 . . . . . . . . 6-11 . 7-1 . 7-2 . 7-4 . 7-6 . 7-8 . 7-10 . 7-12 . 7-14 . 7-16 . 7-18 . 7-20 . 7-22 . 7-24 . 7-26 . 7-28 . 7-30 . 7-32 7-34 . 7-36 . 7-37 . 7-38 . 7-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 7. Parts listing . . . . . . . . . . . . . . . . . . . . Assembly 1: Printer assembly . . . . . . . . . . . . . . . . . . Assembly 2: Journal station cover and button assembly . . . . . . . . Assembly 3: Customer receipt station operator button assembly . . . . . Assembly 4: Logic cards and shock mounts . . . . . . . . . . . . . Assembly 5: Document insert station . . . . . . . . . . . . . . . Assembly 6: Customer receipt thermal printhead assembly and cover . . . Assembly 7: Printhead transport and ribbon drive assembly. . . . . . . Assembly 8: Impact printhead assembly . . . . . . . . . . . . . . Assembly 9: Document insert station platen and lever . . . . . . . . . Assembly 10: Document insert drive shaft assembly . . . . . . . . . Assembly 11: Document insert station gears and motor . . . . . . . . Assembly 12: Customer receipt drive, cutter, and platen . . . . . . . . Assembly 13: Models TN3, TN4, and TN5 interface assembly . . . . . . Assembly 14: Model GRx (RS-485) fiscal interface assembly . . . . . . Assembly 15: Model GBx and GEx (USB) fiscal interface assembly . . . . Assembly 16: Journal assembly both sides view . . . . . . . . . . Assembly 17: Models GR3 and GE3 power supply assembly (Argentina only) Assembly 18: Hardware Kits . . . . . . . . . . . . . . . . . . Assembly 19: Cable assemblies, filler panel, power supply . . . . . . . Assembly 20: Complete printer replacement as a FRU . . . . . . . . Assembly 21: Paper roll holder, (Argentina only) . . . . . . . . . . . Appendix A. Removal and replacements for Argentina Model GR3 and GE3 printers . . . . . . . . . . . . . . . . . . . . . . . Remove the paper roll holder . . . . . . . . . . . . . . . . . . Remove the security shield . . . . . . . . . . . . . . . . . . . Remove the interface assembly . . . . . . . . . . . . . . . . . Remove the power switch and/or cable . . . . . . . . . . . . . . Logic card procedures . . . . . . . . . . . . . . . . . . . . Remove the power cable . . . . . . . . . . . . . . . . . . . Remove the power supply . . . . . . . . . . . . . . . . . . . Appendix B. Notices . . . . . . Trademarks . . . . . . . . . . Electronic emission notices . . . . Japanese voluntary control council for Taiwanese class A warning statement Korean communications statement . Electrostatic discharge (ESD) . . . Part Number Index . . . . . . . . . . . . . . . interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (VCCI) statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. A-1 . A-1 . A-3 . A-5 . A-7 . A-10 . A-13 . A-14 . . . . . . . B-1 B-2 B-3 B-4 B-5 B-5 B-5
. . . . . . . . . . . . . . . . . . . . . . C-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1
iv
Three Station Printer: Service
Figures
1-1. 1-2. 1-3. 2-1. 3-1. 3-2. 3-3. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4-19. 4-20. 4-21. 4-22. 4-23. 4-24. 4-25. 4-26. 4-27. 4-28. 4-29. 4-30. 4-31. 4-32. 4-33. 4-34. 4-35. 4-36. 4-37. 4-38. 4-39. 4-40. 4-41. 4-42. 4-43. 4-44. 4-45. 4-46. IBM 4610 SureMark point-of-sale printer . . . . . . . . . . . . . . . . . Cable Connectors and RS-232 Mode Switch for Thermal/Impact SureMark Printers SureMark Printer Dimensions . . . . . . . . . . . . . . . . . . . . Adjustment and Alignment Printouts . . . . . . . . . . . . . . . . . . Offline Printer Test Pattern (Thermal/Impact SureMark Printers) . . . . . . . . MICR Reader Test Results Good Noise Level . . . . . . . . . . . . . . MICR Reader Test Results Noise Level Needs Adjusting . . . . . . . . . . Removing the Paper and Ribbon Covers . . . . . . . . . . . . . . . . Release the Rear Latch Tabs . . . . . . . . . . . . . . . . . . . . . Mounting Posts on Front Face of Cover . . . . . . . . . . . . . . . . . Removing the Top Cover . . . . . . . . . . . . . . . . . . . . . . Removing the operator buttons in the top cover . . . . . . . . . . . . . . Removing the Document Insert Feed Cover and the Flipper Cartridge . . . . . . Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . Disconnecting the Home Sensor . . . . . . . . . . . . . . . . . . . Replacing the Home Sensor . . . . . . . . . . . . . . . . . . . . . Removing the Ribbon Drive Assembly . . . . . . . . . . . . . . . . . Removing the Tensioner . . . . . . . . . . . . . . . . . . . . . . Removing the Timing Belt. . . . . . . . . . . . . . . . . . . . . . Removing the Printhead/Home Sensor Cable . . . . . . . . . . . . . . Removing the Carriage Assembly, Front or Rear Transport Shafts . . . . . . . Removing the Front Transport Carrier Bearing . . . . . . . . . . . . . . Removing the Transport Motor . . . . . . . . . . . . . . . . . . . . Disconnecting the Printhead Cable and Home Sensor . . . . . . . . . . . Disconnecting the Sensor Spring and Removing the DI Insert Assembly . . . . Removing the Document Insert Platen Assembly . . . . . . . . . . . . . Removing the Front Shock Mount. . . . . . . . . . . . . . . . . . . Removing the MICR. . . . . . . . . . . . . . . . . . . . . . . . Disconnecting the MICR Cable . . . . . . . . . . . . . . . . . . . . Removing the Lower Forms Entry Frame . . . . . . . . . . . . . . . . Removing the Flipper Assembly . . . . . . . . . . . . . . . . . . . Removing the Bail . . . . . . . . . . . . . . . . . . . . . . . . Removing the DI Backup Roller . . . . . . . . . . . . . . . . . . . Removing the DI Lever Assembly . . . . . . . . . . . . . . . . . . . Removing the Front Shock Mount and Disconnecting the MICR Cable . . . . . Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Document Insert Feed Roller . . . . . . . . . . . . . . . Removing the Front Shock Mount and Disconnecting the MICR Cable . . . . . Removing the Motor Gear and Idler Gear . . . . . . . . . . . . . . . . Removing the Document Insert Feed Motor . . . . . . . . . . . . . . . Removing the Switch Card and Printhead Spacer . . . . . . . . . . . . . Removing the Interface Card Assembly. . . . . . . . . . . . . . . . . Printhead cable . . . . . . . . . . . . . . . . . . . . . . . . . Main logic cable connectors . . . . . . . . . . . . . . . . . . . . . Main logic cable connectors . . . . . . . . . . . . . . . . . . . . . Removing the receipt and ribbon covers . . . . . . . . . . . . . . . . Removing the Thermal Cover . . . . . . . . . . . . . . . . . . . . Removing the Spiral Wraps . . . . . . . . . . . . . . . . . . . . . Disconnecting the Thermal Printhead Cable from the Main Logic Card . . . . . Thermal Printhead Latch Assembly . . . . . . . . . . . . . . . . . . Removing the Thermal Printhead Latch Spring . . . . . . . . . . . . . . View of Drag Strip from Back of Printer. . . . . . . . . . . . . . . . . Removing the Drag Strip . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-7 . . . . 1-10 . . . . 2-3 . . . . 3-3 . . . . 3-4 . . . . 3-5 . . . . 4-4 . . . . 4-5 . . . . 4-5 . . . . 4-6 . . . . 4-8 . . . . 4-9 . . . . 4-10 . . . . 4-11 . . . . 4-12 . . . . 4-14 . . . . 4-15 . . . . 4-17 . . . . 4-17 . . . . 4-18 . . . . 4-19 . . . . 4-21 . . . . 4-23 . . . . 4-25 . . . . 4-27 . . . . 4-29 . . . . 4-29 . . . . 4-31 . . . . 4-32 . . . . 4-32 . . . . 4-33 . . . . 4-35 . . . . 4-36 . . . . 4-38 . . . . 4-38 . . . . 4-39 . . . . 4-40 . . . . 4-41 . . . . 4-41 . . . . 4-42 . . . . 4-44 . . . . 4-45 . . . . 4-46 . . . . 4-47 . . . . 4-50 . . . . 4-51 . . . . 4-52 . . . . 4-52 . . . . 4-53 . . . . 4-54 . . . . 4-55 . . . . 4-56
4-47. 4-48. 4-49. 4-50. 4-51. 4-52. 4-53. 4-54. 4-55. 4-56. 4-57. 4-58. 4-59. 4-60. 4-61. 4-62. 4-63. 4-64. 4-65. 4-66. 4-67. 4-68. 4-69. 4-70. 4-71. 4-72. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. | 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. A-1. A-2. A-3. A-4. A-5. A-6. A-7. A-8. A-9. A-10. A-11. A-12.
Thermal Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-58 Removing the Spiral Wraps . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 Removing the Cutter Stud, Stationary Blade, and Printhead Shaft (Model GR3 or TN3) 4-59 Removing the Cutter Stud, Stationary Blade, and Printhead Shaft (Model GR3 or TN4) 4-59 Removing the Thermal Platen Assembly . . . . . . . . . . . . . . . . . . . . 4-60 Removing the Customer Receipt Motor. . . . . . . . . . . . . . . . . . . . . 4-63 Removing the Rotating Blade and Thermal Guide (Model GR3 or TN3) . . . . . . . . . 4-64 Removing the Rotating Blade and Thermal Guide (Model TN4) . . . . . . . . . . . . 4-65 Removing the Cutter Gears . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 Removing the Customer Receipt Paper Guide . . . . . . . . . . . . . . . . . . 4-68 Removing the Front Shock Mount and Disconnecting the MICR Cable . . . . . . . . . 4-69 Customer Receipt Paper Bucket . . . . . . . . . . . . . . . . . . . . . . . 4-70 Journal station button . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71 Journal Station Thermal Printhead Assembly . . . . . . . . . . . . . . . . . . 4-73 Journal Station Thermal Printhead Cover Assembly . . . . . . . . . . . . . . . 4-74 Journal Station Platen Assembly . . . . . . . . . . . . . . . . . . . . . . 4-75 Journal Station Motor Assembly . . . . . . . . . . . . . . . . . . . . . . 4-76 Journal Station Motor Assembly . . . . . . . . . . . . . . . . . . . . . . 4-78 Journal Station Gear Kit with Clutch and E-clip Assembly . . . . . . . . . . . . . 4-79 Journal Station Top Cover Sensor switch Assembly . . . . . . . . . . . . . . . 4-80 Remove Printer Seal and the Secure Screw from Rear Panel . . . . . . . . . . . . 4-82 Loosen the Fiscal Interface Assembly Screw and Tilt and Remove Assembly . . . . . . . 4-83 Remove Processor Card . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84 Remove Interface Card from Assembly . . . . . . . . . . . . . . . . . . . . . 4-85 Release the Rear Latch Tabs . . . . . . . . . . . . . . . . . . . . . . . . 4-89 Mounting Posts on Front Face of base Cover . . . . . . . . . . . . . . . . . . 4-90 DI forms adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Placement of gap setting tool . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Platen gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 DI open lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Cutter blade run-In (Models TN3 and TN4) . . . . . . . . . . . . . . . . . . . . 5-7 Thermal printhead adjustment for customer receipt and journal stations . . . . . . . . . 5-9 Thermal paper switch adjustment . . . . . . . . . . . . . . . . . . . . . . . 5-10 Indicators, controls, and printing stations Thermal/Impact SureMark Printers . . . . . . . 6-1 Positioning checks and documents for reading and printing . . . . . . . . . . . . . . 6-3 Printable area of an inserted document (portrait) . . . . . . . . . . . . . . . . . . 6-4 Printable area of an inserted document (landscape) . . . . . . . . . . . . . . . . 6-5 Opening the ribbon cover . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Ribbon cartridge loading . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Ribbon path around the printhead . . . . . . . . . . . . . . . . . . . . . . . 6-7 Removing the lower document insert (DI) cover . . . . . . . . . . . . . . . . . . 6-8 Removing the check flipper cartridge . . . . . . . . . . . . . . . . . . . . . . 6-9 Printhead and print line area. . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Distributed paper roll holder . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Integrated paper roll holder . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Removing the distributed paper roll holder . . . . . . . . . . . . . . . . . . . . A-3 Remove the security shield . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Security shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Remove the printer seal and the secure screw from rear panel . . . . . . . . . . . . A-6 Loosen the fiscal interface assembly screw and tilt the assembly to disconnect electrical connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Disconnect the electrical connectors and remove the assembly . . . . . . . . . . . . A-7 Location of the power on/off switch . . . . . . . . . . . . . . . . . . . . . . A-8 Power switch and cable with bracket . . . . . . . . . . . . . . . . . . . . . . A-9 Power cable beside main logic card . . . . . . . . . . . . . . . . . . . . . . A-10 Removing the Printer Logic Cards . . . . . . . . . . . . . . . . . . . . . . A-12
vi
A-13. A-14. A-15. A-16. | A-17.
Removing the Interface Card Assembly . . . . . . . . . . . . Loosen the screws and lower the power module cover assembly . . . Loosen the connectors and remove the power supply . . . . . . . Reassembly of the power module into the printer . . . . . . . . . Complete the insertion of the interface assembly housing into the printer
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
A-13 A-14 A-15 A-16 A-16
Figures
vii
viii
Tables
| 1-1. 3-1. 4-1. SureMark Three-Station printer model numbers and the features . . . . . . . . . . . . 1-2 Printer Symptoms or Messages . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
ix
Preface
This manual provides information about problem determination, testing, field-replaceable unit (FRU) removal and replacement procedures, and parts listing for the IBM 4610 SureMark Three-Station Point-of-Sale Printers.
Who should read this manual

This manual is intended for use by trained service representatives.
Prerequisites to this manual

You should be familiar with the contents of the IBM 4610 SureMark Point-of-Sale Printers: Users Guide, GA27-4291
How this manual is organized

v 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 2-1 provides information on installation, service, and utility software. v Chapter 3, Problem determination for the 4610 Three-Station Printer, on page 3-1 provides information on testing, messages, and symptoms for determining any failing components of the 4610 printer. v Chapter 4, FRU removal and replacement, on page 4-1 provides information about procedures for removing and replacing printer components. provides information about procedures for removing and replacing components specific to the Model GR3 fiscal printer. v Chapter 5, Hardware adjustment procedures, on page 5-1 provides information about procedures for operation of the printer. v Chapter 6, Operation, on page 6-1 provides part numbers of the field replaceable units (FRUs) for the SureMark printer. v Appendix A, Removal and replacements for Argentina Model GR3 and GE3 printers, on page A-1 provides information about procedures for removing and replacing the internal power supply for the Model GR3 printer for Argentina. v Appendix B, Notices, on page B-1 contains electronic emission notices and other general information. v Safety Information on page 4-86 contains the lithium battery safety statement.
Related publications and diskettes

v v v v IBM IBM IBM IBM 4610 SureMark Point-of-Sale Printers: Users Guide, GA27-4291 4610 SureMark Point-of-Sale Printers Installation Utilities Diskette 4694/4695 Point-of-Sale Terminals Service Diskette 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 download from the internet.
xi
For information about ordering IBM publications not shipped with the 4610 SureMark Point-of-Sale Printers, contact your IBM representative or your place of purchase.
xii
Summary of changes
| | | |
June 2003
Added/Changed part numbers in the parts catalog. Modified table 11. Updated various graphics.
October 2002
Added: v New SureMark Three-Station printer USB Models GB3, GB5 and GE3 information has been added. v Table 1-1 on page 1-2 has been updated that shows the Printer Model Numbers and the main characteristics of the models. v Updated Assembly 14 in parts listing.
May 2002
Added information for: v The printer for Greece and Turkey v New security shield for Argentina v Argentina paper specification.
December 2001
Updates include: Corrections to parts catalog Model clarifications to chapter 1 Various minor changes throughout.
August 2001
Updates for Models TN3 and TN5 information and Models GR3 and GR5 information has been added. A table has been added that shows the Printer Model Numbers and the main characteristics of the various models. Includes information about how to service the Argentine printers power supply. Includes information about the utility service diskette and how to use it when you change the main logic card on the DI-less model.
xiii
xiv
Tell us what you think

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Safety information
Danger: Before you begin to install this product, read the safety information in IBM Safety Information Read This First, GA27-4004. This booklet describes safe procedures for cabling and plugging in electrical equipment.
Gevaar: Voordat u begint met de installatie van dit produkt, moet u eerst de veiligheidsinstructies lezen in de brochure VeiligheidsinstructiesLees dit eerst, GA27-4004. Hierin wordt beschreven hoe u electrische apparatuur op een veilige manier moet bekabelen en aansluiten.
Perigo: Antes de comear a instalar este produto, leia as informaes de segurana contidas em Informaes Sobre SeguranaaLeia Isto Primeiro, GA27-4004. Esse folheto descreve procedimentos de segurana para a instalao de cabos e conexes em equipamentos eltricos.
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Fare! Fr du installerer dette produkt, skal du lse sikkerhedsforskrifterne i SikkerhedsforskrifterLs dette frst GA27-4004. Vejledningen beskriver den fremgangsmde, du skal bruge ved tilslutning af kabler og udstyr.
Gevaar Voordat u begint met het installeren van dit produkt, dient u eerst de veiligheidsrichtlijnen te lezen die zijn vermeld in de publikatie IBM Safety Information Read This First, GA27-4004. In dit boekje vindt u veilige procedures voor het aansluiten van elektrische appratuur.
VAARA Ennen kuin aloitat tmn tuotteen asennuksen, lue julkaisussa TurvaohjeetLuetm ensin, GA27-4004, olevat turvaohjeet. Tss kirjasessa on ohjeet siit, miten shklaitteet kaapeloidaan ja kytketn turvallisesti.
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Danger Avant dinstaller le prsent produit, consultez le livret Informations pour la scuritLisez-moi dabord, GA27-4004, qui dcrit les procdures respecter pour effectuer les oprations de cblage et brancher les quipements lectriques en toute scurit.
Vorsicht Bevor mit der Installation des Produktes begonnen wird, die Sicherheitshinweise in SicherheitsinformationenBitte zuerst lesen, IBM Form GA27-4004. Diese Verffentlichung beschreibt die Sicherheitsvorkehrungen fr das Verkabeln und Anschlieen elektrischer Gerte.
Vigyzat Mieltt megkezdi a berendezs zembe helyezst, olvassa el a IBM Safety Information Read This First, GA27-4004 knyvecskben lert biztonsgi informcikat. Ez a knyv lerja, milyen biztonsgi intzkedseket kell megtenni az elektromos berendezs huzalozsakor illetve csatlakoztatsakor.
Pericolo prima di iniziare linstallazione di questo prodotto, leggere le informazioni relative alla sicurezza riportate nellopuscolo Informazioni di sicurezzaPrime informazioni da leggere in cui sono descritte le procedure per il cablaggio ed il collegamento di apparecchiature elettriche.
Safety information
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Fare Fr du begynner installere dette produktet, m du lese sikkerhetsinformasjonen i SikkerhetsinformasjonLes dette frst, GA27-4004 som beskriver sikkerhetsrutinene for kabling og tilkobling av elektrisk utstyr.
Perigo Antes de iniciar a instalao deste produto, leia as informaes de segurana Informaes de SeguranaLeia Primeiro, GA27-4004. Este documento descreve como efectuar, de um modo seguro, as ligaes elctricas dos equipamentos.
Peligro Antes de empezar a instalar este producto, lea la informacin de seguridad en Informacin de SeguridadLea Esto Primero, GA27-4004. Este documento describe los procedimientos de sequridad para cablear y enchufar equipos elctricos.
Varninglivsfara Innan du brjar installera den hr produkten br du lsa skerhetsinformationen i dikumentet SkerhetsfreskrifterLs detta frst, GA27-4004. Dr beskrivs hur du p ett skert stt ansluter elektrisk utrustning.
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IBM
IBM
GA27-4004
GA27-4004
Safety information
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Safety information
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Chapter 1. Introduction
Available model designations . . . . . . . . . . . . . . . . . . Model TNx non-fiscal printer application . . . . . . . . . . . . . Model GRx, GBx, and GE3 fiscal printer application . . . . . . . . . Features available for the 4610 Three-Station printer . . . . . . . . Differences in the Models TNx printers and the Model GRx, GBx and GE3 printers . . . . . . . . . . . . . . . . . . . . . . . . Printer overview . . . . . . . . . . . . . . . . . . . . . . . Communications overview . . . . . . . . . . . . . . . . . . . Communications requirements . . . . . . . . . . . . . . . . . Communication interfaces for Models TNx . . . . . . . . . . . . RS-232 XON/XOFF mode selection switch (Models TNx only) . . . . . RS-232/RS-485 connections for Models TNx . . . . . . . . . . . Communication interface baud rates . . . . . . . . . . . . . . . Physical requirements . . . . . . . . . . . . . . . . . . . . . Temperature and humidity limits for all models . . . . . . . . . . . Physical dimensions of all models . . . . . . . . . . . . . . . Hardware requirements . . . . . . . . . . . . . . . . . . . Software requirements . . . . . . . . . . . . . . . . . . . . Operating system levels for Models TNx . . . . . . . . . . . . . Operating system levels for Models GRx. . . . . . . . . . . . . Miscellaneous information . . . . . . . . . . . . . . . . . . . Resident code pages . . . . . . . . . . . . . . . . . . . . Bar codes . . . . . . . . . . . . . . . . . . . . . . . . Resources on the internet . . . . . . . . . . . . . . . . . . Limitations . . . . . . . . . . . . . . . . . . . . . . . . . User responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-3 1-3 1-3
1-4 1-5 1-6 1-6 1-6 1-7 1-7 1-8 1-9 1-9 1-9 1-11 1-11 1-11 1-11 1-12 1-12 1-12 1-12 1-13 1-13
Available model designations

The IBM SureMark Three-Station printers are available for fiscal and non-fiscal applications. The various models are shown below with the model number designations and the features that are included in each model. Refer to this chart for details of the model numbers and the features associated with each model. The references to the printers in this document that apply to all models of printers are designated as TNx (for models TN3, TN4, and TN5) or GRx (for models GR3 and GR5), GBx (for models GB3 and GB5) or model GE3.
1-1
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
Table 1-1. SureMark Three-Station printer model numbers and the features Model Number Top Cover Color Base Color Interface MICR (RS485, RS-232, or USB) RS-485 No & RS-232 RS-485 Yes & RS-232 RS-485 No & RS-232 RS-485 No Doc Insert POS Power Terminal Source
4610-TN3
Pearl White
Litho Gray
Yes
4694 POS Terminal (RS-485) or External supply (RS-232)
4610-TN4
Pearl White
Litho Gray
Yes
4694
4610-TN5
Pearl White
Litho Gray
No
4694
4610-GR3
Pearl White
Litho Gray
Yes
4694
POS Terminal (except Argentina supply internal to printer) POS Terminal
4610-GR5 4610-GB3
Pearl White Iron Gray
Litho Gray Iron Gray
RS-485 No USB No
No Yes
4694
External 4810 (SP300), Supply 4840 (SP500, & SP600) External 4810 (SP300), Supply 4840 (SP500, & SP600) Printer 4810 (SP300), Internal 4840 (SP500, & SP600)
4610GB5
Iron Gray
Iron Gray
USB
No
No
4610GE3
Iron Gray
Iron Gray
USB
No
Yes
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Model TNx non-fiscal printer application

This section lists the following non-fiscal 4610 Models: Model TN3 Model TN4 Standard Model that supports receipt, journal, and document printing. High-function Models that feature check handling. Check handling uses the MICR Reader and Check Flipper that are included in these Models. With one insertion of a check, the Model TN4 printer reads the magnetic-ink-character line on the check, franks the check, and prints the face of the check. While the printer is processing the check, the operator is free to attend to the customers needs, which shortens the total transaction time. Model TN5 A Model that supports receipt and journal printing. The TN5 does not have a document insert station.
Model GRx, GBx, and GE3 fiscal printer application

This section lists the following fiscal 4610 Models: Model GR3 (Fiscal Printer) An RS-485 printer Model that supports receipt, journal, and document printing. This printer Model contains special hardware and 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. This printer Model contains special hardware and microcode required by certain countries. Model GB3 (Fiscal Printer) A USB printer Model that supports receipt, journal, and document printing. This printer Model contains special hardware and microcode required by certain countries. Model GB5 (Fiscal Printer) A USB printer Model that supports receipt and journal printing. The Model GB5 does not have a document insert station. This printer Model contains special hardware and microcode required by certain countries. Model GE3 (Fiscal Printer) A USB printer Model that supports receipt, journal, and document printing, and includes an internal power supply. This printer Model contains special hardware and microcode required by certain countries.
Features available for the 4610 Three-Station printer

The following features are available: v 40-Character VFD Post Extension v 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)
1-3
| |
v v v v v v
Power Supply, P/N 42H1176 (RS-232 TNx, and USB GBx models only) Power Cords (country-specific) Journal Keylock POS Terminal Fiscal Fence (Gxx models only) Cash drawer (TN3 and TN4 only) 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 and GE3 printers
Differences between Models TNx of the 4610 printer and Models GRx, GBx and GE3 occur in three categories: v Hardware v Microcode v Compatibility Modes | | | | The Model GRx, GBx, and GE3 printers have a different trap door on the bottom of the printer with hardware supporting fiscal features including a fiscal seal and memory epoxied to the circuit board. The 4610 Models GR3 and GE3 for Argentina have 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.
Hardware
Microcode
Models TNx can download microcode loads. The microcode download feature is not available on the GRx, GBx and GE3 models due to the fiscal regulations limiting code changes.
Compatibility modes
Models TNx support Model 4 Emulation. Model 4 Emulation is not supported in all operating system environments. Models GRx, GBx and GE3 are generally compatible with 3F models. Application changes are required when printing inserted documents.
1-4
Printer overview
Customer Receipt Paper Cover Printer Ready LED Customer Receipt Feed Button Document Present LED Document Feed Button Journal paper cover Journal Printer Station Journal Feed Button Customer Receipt Printer Station Ribbon Cover (Document insert cover) Document Insert Printer Station
Figure 1-1. IBM 4610 SureMark point-of-sale printer
The IBM SureMark Point-of-Sale Printer is a high-performance, high-function printer that features a: v Thermal printer customer receipt station v Thermal printer journal station v Impact printer document insert station The dual thermal printheads enable quiet, fast printing of customer receipts and store journals. The printer also has the capability to print and frank checks and to print multipart forms through the document insert station. All SureMark printers provide: v Fast quiet receipt printing v Fast quiet journal printing with a take-up spool v Easy to load paper and easy-to-load ribbon cartridge v Bar code generation | The SureMark Model TNx printers provide: v Dual interface support: RS-232 (EIA 232) and RS-485 (EIA 485) v Downloadable microcode v Downloadable fonts and code pages v 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 USB v Conformance to fiscal printer regulations. Check the IBM Retail Store Solutions web site for availability in a specific fiscal country.
1-5
Communications overview
Communications overview contains requirements, interface information, baud rates, and mode selection.
Communications requirements
For Models TNx, with RS-232 communications, a 24 V DC power supply with a power 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. The RS-485 cable supplies power directly to the printer. Models TNx support both RS-232 and RS-485 interfaces. See the 4610 SureMark Three-Station Printer: Programming Guide for more information about the RS-232 interface. | | | | | Models GRx support the RS-485 interface. The RS-485 cable supplies power directly to the printer. Models GBx support the USB interface and require a 24V DC power supply with a power cord and a standard USB cable. Models GE3 support the USB interface and contains an internal ower supply.
Communication interfaces for Models TNx

These SureMark printer Models feature a standard RS-232 and an IBM RS-485 interface. RS-485 operates at a 187.5K baud rate. RS-232 (TN3, TN4, and TN5 only) 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 logic card and is accessible without removing the printer covers. See Figure 1-2 on page 1-7. Set the switch as follows: SW1-1 OFF - 9600 baud SW1-1 ON - 19,200 baud The card is normally factory-set with SW1-1 in the OFF position, which selects the 9600 baud rate. See Figure 1-2 on page 1-7 for thermal/impact SureMark printers.
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Figure 1-2. Cable Connectors and RS-232 Mode Switch for Thermal/Impact SureMark Printers. (View is from the bottom rear of the printer) (Models TNx only)
RS-232 XON/XOFF mode selection switch (Models TNx only)

The SureMark printer, Models TNx, support RS-232 protocol using DTR/DSR lines to control data transmission. It also supports XON/XOFF modes where system and printer software control the flow of data. Select these modes using SW1-2 on the main logic card. The switch is located on the lower left corner of the logic card and is accessible without removing the printer covers. Set the switch as follows: SW1-2 OFF - DTR/DSR Control SW1-2 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 selects DTR/DSR mode of operation. See Figure 1-2.
RS-232/RS-485 connections for Models TNx

The SureMark printer operates using either RS-232 or RS-485 communications protocol. RS-232 is typically associated with PC systems. The printer contains a 9-pin D-shell connector for RS-232 communications. This connector is located on the interface card and is accessible under the printer without the need to remove the printer covers. The connector has the following pin functions:
Pin 1 2 3 4 5 Signal Not Connected Transmit Receive DTR Signal Ground Pin 6 7 8 9 Signal DSR Not Connected Not Connected Not Connected
RS-485 mode of communication is obtained when attaching the appropriate cable to Port 7 on an IBM POS system. The RS-485 mode has a higher baud rate than RS-232.
OFF
RS 232 Mode Switch
Cash Drawer Port
Power Supply Port (RS 232 Only)
RS 232 Port
RS 485 Port
1-7
Communication interface baud rates

| | | The RS-485 interface operates at a 187.5K baud rate. RS-232 (TNx only) supports 9600 and 19,200 baud rates. Models GRx work on RS-485 only. Models GBx work with USB only.
1-8
Physical requirements Temperature and humidity limits for all models

Shipping Storage Operating 40 to 60 degrees C (-40 to 140 degrees F) with 5% to 100% relative humidity including condensation, but excluding rain. 0 to 60 degrees C (32 to 140 degrees F) 0 to 40 degrees C (32 to 104 degrees F) with 8% to 80% relative humidity.
To allow convection cooling, do not block the ventilation holes in the cover.
Physical dimensions of all models

Width Depth Height Weight 322 mm (12.68 in) 258.7 mm (10.19 in) Front: 140 mm (5.5 in) Rear: 190 mm (7.5 in) 6.89 kg (15.15 lb)
1-9
Front
7.48 inches (190.07 mm)
7.48 inches (190.07 mm) 12.67 inches (322 mm)
Top
12.68 inches (322 mm)
10.19 inches (259 mm)
Figure 1-3. SureMark Printer Dimensions
1-10
Power requirements for external power supply models

| | | | | | | | | | | | | With the exception of the Argentina GR3 and GE3 models, the SureMark printer does not contain a power supply. For the Models GBx and TNx, (operating in RS-232 or USB mode), an external power supply must be attached to the interface card of the printer. This connector is located under the printer and is accessible without removing the printer covers. The power connector has the following pin function: Pin Signal 1 +24 V dc 2 Not connected 3 Ground For the models GRx and TNx printers that are operating in RS-485 mode, power is supplied to the printer from the IBM POS terminal. The terminal supplies 38V dc and 5V dc to the printer.
Hardware requirements
SureMark printers work with the following terminals: v PC or other store controller with an RS-232 Models TNx only with power supply v 4683 (RS-485 connection only) v 4693 v 4694 v 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 requirements
The full function of Models TNx is supported only in native mode with RS-232 attachment. No unique driver is required. If you use the RS-232 interface, use the commands described in the 4610 SureMark Three-Station Printer: Programming Guide.
Operating system levels for Models TNx

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

Fiscal 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, and 3F2 fiscal printers. v 4690 OS V1 Level K010 or later v 4690 OS V2R2 Level 0020 or later v 4690 OS V2R3 Level 00A0 or later v POSS for Windows 1.42 or later v 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 the drivers.
1-11
POSS drivers can be downloaded from the Retail Store Solutions Web site. See Resources on the internet for more information.
Miscellaneous information Resident code pages

These code pages are resident in the Model TNx printers: v Generic v 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 is available 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 fiscal microcode.
Bar codes
SureMark printers can generate these bar codes: v UPC-A v UPC-E v JAN13 (EAN-13) v JAN8 (EAN-8) v Code 39 v ITF v Codabar v Code 128C v Code 93 v PDF 417 Note: The command to generate the above bar codes is not available in Model 4 emulation mode.
Resources on the internet

The 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 page under SurePOS Peripherals. Use the links for: v Peripheral Drivers folder, if you use RS-485 connections v IBM SureMark Printer v IBM Fiscal POS Printers v Peripheral Drivers Note: Published IBM manuals can be accessed using the Publications icon. Access diskettes, drivers, and miscellaneous documentation, such as README files and OEM paper certification information by using the Downloads icon. The Knowledgebase icon provides access to previously asked questions and their answers.
1-12
Limitations
The SureMark printer protects the hardware from potential damage if excessive duty cycles are used. This should not be noticeable during normal operation. Electromagnetic noise sources can interfere with the MICR read head. If the MICR reader does not function properly, rearranging the printer relative to the noise source may improve performance. The noise source should be as far away as possible from the right side of the printer. Damaged checks may not be readable or may not feed reliably.
User responsibilities
You are responsible for replenishing consumable supplies, such as roll paper for the thermal printer, forms, ribbon cartridges for the impact printer, and MICR head cleaner cards, if MICR is attached. You are responsible for understanding that the Model GRx fiscal printers are used in a legal manner, and for obtaining all of the software in a manner that is consistent with the regulations of your country. This may include requirements to attach certain displays to your POS terminal or for obtaining your POS software.
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1-14
Chapter 2. Installation, service, and utility software adjustments

4610 diskette download support information . . . . . . . . . . . Software adjustments for document insert station . . . . . . . . . Using the reference/service diskettes (RS-485 or RS-232). . . . . 4610 fonts and logos utility diskette (Models TNx only) . . . . . . . Firmware update (Models TNx only) . . . . . . . . . . . . . . Using a firmware update diskette . . . . . . . . . . . . . . Updating Models TNx firmware using temporary RS-232 attachment . Limitation on updating firmware on Models TNx . . . . . . . . Emulating the IBM Model 3 or Model 4 printers (Models TNx only) . . Enabling emulation using utility diskettes . . . . . . . . . . . Limitations for emulation . . . . . . . . . . . . . . . . . MICR data parser sample code (Model TN4 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-1 2-4 2-4 2-4 2-5 2-5 2-6 2-6 2-6 2-7
This chapter describes how to make software adjustments using the 4690 Operating System (4690 OS), IBM Point-of-Sale Device Diagnostics (POSS for Windows and RS-485), or diskettes and other resources that are available from the Retail Store Solutions Web site.
4610 diskette download support information

Service tools for the 4610 SureMark Printer can be downloaded from http://www.ibm.com/solutions/retail/store, which is the Retail Store Solutions Web site. After you select Support at the left side of the screen, select IBM SureMark 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 station

Depending on your operating system, you can use the following to make software adjustments 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 4610 Printer Test for an RS-232 connection. 4. If another system is attached, select the system whose printer you want to adjust. This is unnecessary when there is no other system attached. 5. Select Printer Utilities.
2-1
Software Adjustments
6. Select the adjustment you want to make from the menu. v Print current adjustment values v Character alignment procedure v DI front load print line adjustment v Document landscape adjustment v Engineering use only v Change 4610 Model Configuration v 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.
2-2
TL1
TL2
TL3 TL4
TL5
CURRENT ADJUSTMENT VALUES H 5 = Character alignment TL5 = Top line front insert BL3 = Bottom line top insert
TL6
TL7
TL8
TL9
Measure from the top edge of this paper to the top of each print line. Press the key (1-9) that corresponds to the print line that is closest to 5MM.
CHARACTER ALIGNMENT PROCEDURE
Press the key (1-9) that corresponds to the pair of H's that appear to be most aligned 5 = selected line
Figure 2-1. Adjustment and Alignment Printouts
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 utility from the Retail Store Solutions Web site. The utility program allows you to perform the following functions: v Configure the printer Model v Create, edit, and download user-defined character fonts, logo images, and messages v Convert fonts and logo files from impact to thermal From the same Web site, you can also download the following sample files for use with the utility program: v User-defined characters file v Message file v Logo file
Firmware update (Models TNx only)

The non-fiscal versions of the SureMark printer can receive SureMark firmware updates from the host system unit to which it is attached for either RS-485 attached, 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, after downloading the latest level software from the Retail Store Solutions Web site.
Using a firmware update diskette

Use a firmware update diskette to update the firmware in configurations when the SureMark printer is attached by either an RS-232 or RS-485 cable, and the system has 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 update methods, 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 an RS-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, also make 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).
2-4
Firmware Update (non-fiscal)

e. f. g. h. Select O (Operations). Select A (Advanced Options). Select U (Update Firmware). Press Enter twice to select the desired firmware image file (usually only the latest 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 not power off the host system or the SureMark printer after the update has 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 attachment

To use the firmware update diskettes to update SureMark printer firmware for configurations that do not have a diskette drive and PC display and keyboard, you must provide a temporary RS-232 attachment to a host PC that does have a diskette drive. Note: A 4610 firmware update diskette at V3.10 or greater is required to use this utility. 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 in length (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 not support a diskette drive, use the following procedure to temporarily connect the printer to a host PC that has a diskette drive, RS-232 port, PC keyboard and a display. 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 TNx

The following limitation must be considered when updating firmware on the SureMark printer: v SureMark printer firmware updates cannot be performed if the printer currently has Model 4 emulation enabled. If emulation is enabled, temporarily disable Model 4 emulation, then start the SureMark printer firmware update. After the
2-5
Firmware Update (non-fiscal)
firmware update is complete, re-enable Model 4 emulation. See Emulating the IBM 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 SureMark printer. You must change the configuration to enable the SureMark printer to emulate 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 the Configure MCT Utility Diskette. Download the latest-level diskette from the Retail Store Solutions Web site. v For medialess systems using the 4690 OS, use the 4690 OS Online Terminal Diagnostics (see Enabling emulation using utility diskettes in the next section).
Enabling emulation using utility diskettes

The following information is also available in the file named 4610MOD4.TXT on the diskette. Note: All SureMark printer firmware levels support emulation. To set up Model 3 or Model 4 emulation using the Font and Logos Utility Diskette or the 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 emulation

The following limitations must be considered when using the SureMark printer to emulate the Model 3 or Model 4 printer. v Printing the face of checks requires application changes (franking the back of checks should not). v Printing wide documents may require changes. The document station on the Model 4 printer supports 86 characters, the SureMark printer supports 47 characters. v There is no top document registration (documents must be inserted from the front). v User-defined special characters are not supported. v Emulation mode does not support the Model 4A double-byte character set.
2-6
Emulating Model 3 or 4 printers
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 a check. v An exception data file that is used with the parsing code. You can edit this file to add new check formats, if necessary. Refer to the README file in this download package for additional information.
2-7
Emulating Model 3 or 4 printers
2-8
Chapter 3. Problem determination for the 4610 Three-Station Printer

Fiscal unit return codes . . . . . . . . . . . . . . Offline tests . . . . . . . . . . . . . . . . . . . Customer receipt test . . . . . . . . . . . . . . Journal station test . . . . . . . . . . . . . . . Document insert test (except Models TN5, GR5 and GB5) MICR reader and check flipper test (Model TN4 only) . . Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-1 3-1 3-2 3-4 3-6
Fiscal unit return codes

Fiscal return codes vary by country. Refer to the Retail Store Solutions Electronic Support 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 Support publications. 4. Scroll down to IBM 4610 SureMark Printers.
Offline tests
Use the following offline tests as diagnostic tools to ensure the printer is operating correctly.
Customer receipt test

1. Press and hold both the customer receipt and document insert buttons/switches to enter offline mode. (Buttons and switches are used interchangably in this document.) When the Printer Ready indicator begins blinking, release both buttons. 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 correct information 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 test pattern you print, or if the solid line is missing, go to Symptoms on page 3-6.
Journal station test

1. Press and hold both the customer receipt and document insert buttons/switches to enter offline mode. When the Printer Ready indicator begins blinking, release both 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 correct information for your model and configuration: v MICR reader enabled and check flipper enabled (Model TN4)
3-1
Offline Test
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 test pattern you print, or if the solid line is missing, go to Symptoms on page 3-6.
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. If the Document Present indicator still does not come on, go to Document sensor 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 enter offline mode. When the Printer Ready indicator begins blinking, release both buttons. 3. Press and release the document feed button to print the test pattern. The test pattern includes all printable characters in the resident code page, printed in the default font. 4. See Figure 3-1 on page 3-3 and verify that your printer has printed correct information 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 applicable 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 test pattern you print, or if the solid line is missing, go to Symptoms on page 3-6.
3-2
Offline Test
The Printers S/N is 1234567 Microcode EC level is 30 Fiscal Microcode EC level is 16.01 Serial Interface: RS232 Serial Interface : 19.2K Baud, XON / XOFF MICR reader enabled Check Flipper enabled |"#$%&'()*+,-./0123456789:;<->?ABCDEFGHIKJK LMNOPQRSTUVWXYZ[\]^_ abcdefghijklmnopqrstuvw xyz{|}~.CcSs Gg I ^ ` ` ^` ` ` H I III OO UUUyY Cuts: 125850 CR Characters Printed: 142834 CR Motor Steps: 659340 CR Cover Openings: 593 DI 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:
1 2 3 4 6
,5
9
Figure 3-1. Offline Printer Test Pattern (Thermal/Impact SureMark Printers). This pattern is from the customer receipt (CR) station.
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 printers microcode. The fiscal microcode EC level information appears only in fiscal models of the printer. 3. The serial interface will be specified as RS232 or RS485, depending on which interface 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-232 switch settings. (See RS-232 XON/XOFF mode selection switch (Models TNx only) 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 interface is used. The value can be either DTR/DSR or XON/XOFF, depending on the RS-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 document insert (DI) station. 8. This section contains printer usage statistics that you can use for problem determination. (Some of this information is not printed on Model xx5 printers.) 9. The line across the bottom should be solid with no blank spaces.
Chapter 3. Problem Determination for All Models
| | | |
3-3
Offline Test
MICR reader and check flipper test (Model TN4 only)

Attention: If the printer is in Model 3 or 4 emulation mode, failure to perform these steps in the sequence shown will cause the entire electronic journal to print on the CR station. Printing the electronic journal erases the information from flash storage. 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 ready indicator 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 customer receipt 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 the customer 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 is not flipped. If the Model TN4 detects noise, it prints a message on the customer receipt below the magnetic characters from the check (Figure 3-2 and Figure 3-3 on page 3-5 are examples and actual numbers may vary). The message shows noise characteristics. You can use the noise level to position your printer to minimize outside interference with the MICR reader. Sources of electromagnetic noise (for example, displays, security towers, and other sources) can interfere with the MICR reader read head. If the printer shows an external noise source, rearrange the printer to make the noise source as far away as possible from the right side of the printer. This may eliminate the external noise.
Figure 3-2. MICR Reader Test Results Good Noise Level
3-4
Offline Test
Figure 3-3. MICR Reader Test Results Noise Level Needs Adjusting
3-5
Symptoms
Symptoms
Review the following symptoms or messages and take the suggested actions.
Table 3-1. Printer Symptoms or Messages Symptom Printer does not power ON (All LEDs are off). Repair actions listed in most likely order of failure 1. Check for a good connection and that the printer is plugged in. 2. Replace the printers external power supply or system unit. 3. Exchange the printer interface card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43. 4. Exchange the main logic card. Go to Removing and replacing the main 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 switch card and printhead spacer on page 4-42. 4. Exchange the main logic card. Go to Removing and replacing the main 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 loaded correctly. 3. Ensure that the covers are closed. 4. Adjust the thermal paper switch. Go to Thermal paper switch adjustment on page 5-10. 5. Run the printer offline tests. Go to Offline tests on page 3-1. Customer receipt (thermal) does not advance paper. 1. Check to see if the thermal paper is jammed or loaded incorrectly. 2. Go to Customer receipt paper movement and cutter problems on page 4-60 to isolate the problem. 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. 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 paper movement and cutter problems on page 4-60. Customer receipt (thermal) is missing character 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 on page 4-57. 3. Check and clean the printhead area, if contaminated. 4. Adjust the printhead. Go to Thermal printhead adjustment for customer 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.
Customer receipt (thermal) randomly missing rows of print, accompanied by one thin line on receipt. Customer receipt cutter does not work correctly.
3-6
Updated August 13, 2003 Table 3-1. Printer Symptoms or Messages (continued) Symptom Journal station (thermal) does not advance paper. Repair actions listed in most likely order of failure
Symptoms
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 the problem. Check for paper jams.
Journal station (thermal) randomly missing rows of print, accompanied by one thin line on journal paper. Journal station (thermal) is missing character 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 for customer 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 platen gap adjustment on page 5-4. 3. Check the printhead cable for continuity. Unplug the cable at the printhead 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 the printhead on page 4-10. 6. Exchange the logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43. 7. Exchange one or more of the following components: DI gears, DI feed roll shaft assembly, and feedroll assembly. Go to Removing and replacing the printhead carriage assembly on page 4-16 and Removing and replacing the cutter gears and cutter clutch on page 4-66.
DI station does not advance document/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 open lever adjustment on page 5-6. 4. Ensure that the DI forms compensation is correctly set. Go to DI forms compensation adjustment (Models with DI only) on page 5-2. 5. Exchange the DI motor. Go to Removing and replacing the document insert motor and gears (Models with DI) on page 4-40. 6. Exchange the DI gears, DI feed roll shaft assembly, and feedroll assembly. Go to Removing and replacing the printhead carriage assembly on page 4-16 and Removing and replacing the cutter gears and cutter clutch on page 4-66. 7. Replace the main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43.
3-7
Symptoms
Table 3-1. Printer Symptoms or Messages (continued) Symptom DI (impact) printhead does not move correctly.
Repair actions listed in most likely order of failure 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 on page 4-16. 4. Check the tensioner. If you need to exchange it, go to Removing and replacing the tensioner on page 4-15. 5. Check the home sensor cable for continuity. 6. Exchange the home sensor (see Removing and replacing the home sensor on page 4-11). 7. Exchange the transport motor. Go to Removing and replacing the transport motor on page 4-20. 8. Replace the main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43.
Ribbon does not advance.
1. Exchange the ribbon cartridge. Go to Ribbon loading (Models with DI) on page 6-6. 2. Ensure that the ribbon drive is connected to the main logic card (see Figure 4-17 on page 4-23). 3. Check the printhead gap and ribbon guide. Go to Printhead platen gap adjustment on page 5-4. 4. Exchange the ribbon drive assembly. Go to Removing and replacing the transport motor on page 4-20. 5. Exchange the main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43.
Printer Ready and/or Document Present LEDs 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 stations cover sensor switch 8. Verify that the journal stations sensor switch cable is seated properly to the logic card. 9. Verify that the journal stations sensor screw is tight. 10. Replace the journal stations sensor switch.
3-8
Updated August 13, 2003 Table 3-1. Printer Symptoms or Messages (continued) Symptom MICR does not read correctly. Repair actions listed in most likely order of failure
Symptoms
1. Clean the MICR head with cleaning card. Go to Cleaning the MICR reader 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 the MICR read head (Models with DI) on page 4-28. 5. Exchange the pressure pad. Go to Removing and replacing the document insert (DI) sensor assembly (Models with DI) on page 4-24. 6. Exchange the main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43.
Flipper is not working.
1. Check the cover for missing or incorrectly installed roller and spring shaft. 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 and replacing the document insert lower cover and flipper cartridge on page 4-9. 6. Exchange the flipper drive assembly. Go to Removing and replacing the lower forms entry frame or flipper assembly (TN4) on page 4-30.
DI not moving documents correctly. Uneven print on receipt. T7151 Printer card or cable is failing.
Perform the DI forms compensation adjustment procedure. Go to DI forms compensation adjustment (Models with DI only) on page 5-2. Go to Thermal printhead adjustment for customer receipt and journal station on page 5-8. 1. Check or exchange the printer interface cable. 2. Exchange the printer main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card 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 the printhead carriage assembly on page 4-16. 5. Exchange the logic card. 6. Exchange the transport motor. Go to Removing and replacing the transport 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 printer covers on page 4-3. 3. Exchange the main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43.
3-9
Symptoms
Table 3-1. Printer Symptoms or Messages (continued) Symptom
Repair actions listed in most likely order of failure
T7156 Document is inserted in the printer 1. Check for obstructions. and printer fails. 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 threshold reset on page 5-10. T7157 Document was not removed when 1. Exchange the document and run the test again. expected or DI sensor is failing. 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 threshold reset on page 5-10. T7159 EEPROM error. Exchange the main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43. An invalid command was sent to the printer. See Flipper is not working symptom. 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 DI station then back while reading the MICR. T7165 CR paper is empty or cover is open. 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 receipt station. 4. Open the customer receipt cover and manually press the switch. 5. Adjust the switch. Go to Thermal paper switch adjustment on page 5-10. 6. Exchange the main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43. T7166 Firmware error. 1. Update the SureMark printer firmware by downloading a new image from the utility diskette. 2. Exchange the main logic card. Go to Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43.
T7161 Command reject. T7163 Flipper error. T7164 MICR check movement error.
3-10
Chapter 4. FRU removal and replacement

Top covers procedures (Models TNx) . . . . . . . . . . . . . . . . 4-2 Removing and replacing the printer covers . . . . . . . . . . . . . 4-3 Removing and replacing the top cover operator buttons . . . . . . . . 4-8 Document insert station procedures (Models with DI only) . . . . . . . . . 4-9 Removing the Document Insert Station Cover . . . . . . . . . . . . 4-9 Removing and replacing the document insert lower cover and flipper cartridge . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Removing and replacing the printhead . . . . . . . . . . . . . . 4-10 Removing and replacing the home sensor . . . . . . . . . . . . . 4-11 Removing and replacing the ribbon drive assembly . . . . . . . . . . 4-13 Removing and replacing the tensioner . . . . . . . . . . . . . . 4-15 Removing and replacing the printhead carriage assembly . . . . . . . 4-16 Removing and replacing the transport motor . . . . . . . . . . . . 4-20 Removing and replacing the printhead cable . . . . . . . . . . . . 4-22 Removing and replacing the document insert (DI) sensor assembly (Models with DI) . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Removing and replacing the document insert platen assembly (Models with DI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Removing and replacing the MICR read head (Models with DI) . . . . . 4-28 Removing and replacing the lower forms entry frame or flipper assembly (TN4) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Removing and replacing the document insert backup roller and insert lever assembly (Models with DI) . . . . . . . . . . . . . . . . . . 4-34 Removing and replacing the document insert (DI) feed roller (Models with DI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Removing and replacing the document insert motor and gears (Models with DI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Removing and replacing the switch card and printhead spacer . . . . . 4-42 Logic cards procedure . . . . . . . . . . . . . . . . . . . . . 4-43 Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . 4-43 Removing and replacing the main logic and sub-logic cards and connector-attached interface card . . . . . . . . . . . . . . . 4-43 Customer receipt station procedures . . . . . . . . . . . . . . . . 4-49 Removing the customer receipt station cover . . . . . . . . . . . . 4-49 Removing and replacing the thermal cables and paper switch . . . . . . 4-51 Removing and replacing the thermal printhead latch . . . . . . . . . 4-53 Removing and replacing the thermal printhead drag strip. . . . . . . . 4-55 Removing and replacing the thermal printhead assembly. . . . . . . . 4-57 Removing and replacing the thermal platen assembly . . . . . . . . . 4-60 Customer receipt paper movement and cutter problems . . . . . . . . 4-60 Removing and replacing the customer receipt motor . . . . . . . . . 4-62 Removing and replacing the rotating cutter blade and thermal guide . . . 4-64 Removing and replacing the cutter gears and cutter clutch . . . . . . . 4-66 Removing and replacing the customer receipt paper guide . . . . . . . 4-67 Removing and replacing the customer receipt paper bucket. . . . . . . 4-69 Journal station procedures . . . . . . . . . . . . . . . . . . . . 4-71 Removing the journal station cover . . . . . . . . . . . . . . . . 4-71 Removing and replacing the journal station button . . . . . . . . . . 4-71 Removing and replacing the journal printhead cover assembly . . . . . 4-72 Removing and replacing thermal printhead assembly . . . . . . . . . 4-73 Removing and replacing the platen assembly . . . . . . . . . . . . 4-75 Removing and replacing the journal motor assembly . . . . . . . . . 4-76 Journal station paper movement . . . . . . . . . . . . . . . . . 4-77
4-1
Removing and replacing the optical paper sensor . . . . . . . . . Removing the gear kit with clutch and E-clip . . . . . . . . . . . Removing and replacing the journal cover sensor switch . . . . . . . Interface Card Assembly Procedures . . . . . . . . . . . . . . . Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . Removing and replacing the Interface card Assembly (models TNx). . . Removing and replacing fiscal interface assembly for model Gxx printers
. . . . . .
4-78 4-79 4-80 4-81 4-81 4-81 4-82
This section includes removal and replacement procedures for the SureMark printer top covers and base cover. The base cover is attached to the printer base, and it covers the major printer and journal station internal structures. The top covers cover the user accessible parts of the printer, such as the paper for the customer receipt and summary journal station and the document insert printer ribbon.
For the Model GRx You must remove the fiscal interface assembly in order to remove the two top cover retention screws. Removal of the two screws is essential to the removal of the top cover. See Removing the Model GRx fiscal printer cover on page 4-89.
Top covers procedures (Models TNx)

The paper cover refers to the cover for the customer receipt station. The ribbon cover refers to the cover for the document insert station. These terms are used interchangeably. 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 customer receipt station, the cover for the document insert station, and the cover for the journal station.
4-2
Top Covers
Removing and replacing the printer covers

Important This procedure shows you how to remove the printer covers (FRUs). Stop when you get to the failing FRUs, exchange the FRUs, and reassemble. The FRUs are highlighted.
Removing the printer cover

1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. See Figure 4-2 on page 4-5. 2. Open the journal station cover by unlocking the keylock on the front of the cover. You can use a screwdriver point to place between the bottom corner tab of the journal station cover and the printer and pull down on the top front part of the cover. Repeat for the left side if necessary. Slide the journal cover up and out. Set the journal cover aside. 3. Open the customer receipt paper cover. Place the top of a screwdriver handle between the side of the printer and the top cover. Then close the top cover on the 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 the document insert cover towards the left side while pressing the lock tab, and remove the cover. Note: When reassembling, be sure that the clear plastic paper guide is inserted through the slot in the paper cover.
Chapter 4. Cover removal and replacement
4-3
Top Covers
Figure 4-1. Removing the Paper and Ribbon Covers
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 the printer top cover. Lift the top cover up high enough to permit removal of the rubber grommet from the binding post. 7. Release the latch tabs by placing your finger against the inside of the left side of the cover and push down until your finger reaches the plastic latch tab. Pull the latch tab forward away from the cover and lift the left side of the section up until it is free from the cover. Do this on the right side by releasing the latch tab and 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 binding posts. Pull the left side of the top cover out and up to clear the tab from the track guide on the base. Pull out slightly on both the left and right sides. Lift the top cover up and away from the printer. 9. Reassemble.
4-4
Top Covers
Latch tabs
Figure 4-2. Release the Rear Latch Tabs
Mounting post
Impact printer cover
Figure 4-3. Mounting Posts on Front Face of Cover
4-5
Top Covers
Notes: 1. Ensure that the rubber front shock mount is correctly seated in the top cover before installing the top cover. 2. Ensure that the clear plastic paper guide is inserted through the slot in the paper cover.
Latch
Top Cover
Mounting Post Gasket
Figure 4-4. Removing the Top Cover
After completing this procedure, return to the procedure you were performing from the following list: v Removing and replacing the top cover operator buttons on page 4-8 v Removing and replacing the printhead on page 4-10 v Removing and replacing the home sensor on page 4-11 v Removing and replacing the ribbon drive assembly on page 4-13 v Removing and replacing the tensioner on page 4-15 v Removing and replacing the printhead carriage assembly on page 4-16 v Removing and replacing the transport motor on page 4-20 v Removing and replacing the printhead cable on page 4-22 v Removing and replacing the document insert (DI) sensor assembly (Models with DI) on page 4-24 v Removing and replacing the document insert platen assembly (Models with DI) on page 4-26 v Removing and replacing the MICR read head (Models with DI) on page 4-28
4-6
Top Covers
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 lever assembly (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 4-42 v Removing and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43 v Removing and replacing the thermal cables and paper switch on page 4-51 v Removing and replacing the thermal printhead latch on page 4-53 v Removing and replacing the thermal printhead drag strip on page 4-55 v Removing and replacing the thermal printhead assembly on page 4-57 v Removing and replacing the thermal platen assembly on page 4-60 v Removing and replacing the customer receipt motor on page 4-62 v Removing and replacing the rotating cutter blade and thermal guide on page 4-64 v Removing and replacing the cutter gears and cutter clutch on page 4-66 v Removing and replacing the customer receipt paper guide on page 4-67 v Removing and replacing the customer receipt paper bucket on page 4-69 v Removing and replacing the journal station button on page 4-71 v Removing and replacing the journal printhead cover assembly on page 4-72 v Removing and replacing thermal printhead assembly on page 4-73 v Removing and replacing the platen assembly on page 4-75 v Removing and replacing the journal motor assembly on page 4-76 v Journal station paper movement on page 4-77 v Removing and replacing the optical paper sensor on page 4-78 v Removing the gear kit with clutch and E-clip on page 4-79 v Removing and replacing the journal cover sensor switch on page 4-80
4-7
Top Covers
Removing and replacing the top cover operator buttons

Important This procedure shows you how to remove the top cover and the operator buttons (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 or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. On the under side of the base cover, press both sides of the key switch latch inward and lift the button out. See Figure 4-5. 4. Reassemble.
Hex Screw
Switch Card
Insulator
Printhead Spacer
Figure 4-5. Removing the operator buttons in the top cover
4-8
Document Insert Station Procedures
Document insert station procedures (Models with DI only) Removing the Document Insert Station Cover
This procedure does not apply to a Model TN5 or GR5 printer. Open the document insert cover using the lift tab. From the right side, push the document insert cover towards the left side while pressing the lock tab, and remove the cover. Note: When reassembling, be sure that the clear plastic paper guide is inserted through the slot in the paper cover.
Removing and replacing the document insert lower cover and flipper cartridge
Important This procedure shows you how to remove the flipper cover and the flipper cartridge (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 or unplugging the printers power source from the wall outlet. 2. Remove the flipper cover. Lift up and outward to remove the flipper cover. See Figure 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
4-9
Removing and replacing the printhead

Important This procedure shows you how to remove the printhead FRU. Stop when you get to the failing FRU, exchange the FRU, and reassemble. The FRUs are highlighted.
After completing this procedure, return to the procedure you were performing from the following list: v Removing and replacing the lower forms entry frame or flipper assembly (TN4) on page 4-30. 1. Ensure that the printer is powered OFF by either powering off the system or unplugging the printers power source from the wall outlet. 2. Open the ribbon cover. Go to Removing and replacing the printer covers on page 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 5-4 and then return to this procedure. 9. When you replace the impact printhead, run the service diskette and select Reset Statistics for the FRU. See Software adjustments for document insert station on page 2-1.
Figure 4-7. Replacing the Printhead
4-10
Removing and replacing the home sensor

Important This procedure shows you how to remove the home sensor FRU. Stop when you get to the failing FRU, exchange the FRU, and reassemble. The FRUs are highlighted. 1. Ensure that the printer is powered OFF by either powering off the system or unplugging the printers power source from the wall outlet. 2. Open the document insert ribbon cover. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Remove the ribbon cartridge. 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 (see Figure 4-15 on page 4-19 and then return to this procedure). 8. Reassemble.
Figure 4-8. Disconnecting the Home Sensor
4-11
Figure 4-9. Replacing the Home Sensor
4-12
Removing and replacing the ribbon drive assembly

Important This procedure shows you how to remove the ribbon drive 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 from the following list: v Removing and replacing the transport motor on page 4-20 v Removing and replacing the printhead cable on page 4-22 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Remove the front shock mount by turning the front shock mount 1/4 turn counterclockwise (end rib will be horizontal), then pull it out. See Figure 4-10 on page 4-14. 4. Disconnect the ribbon drive assembly cable from the main logic card. See Figure 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 out the 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 when reassembling. 8. Reassemble. 9. Ensure cables are seated properly on the logic card.
4-13
Front Shock Mount
Printer Assembly Main Logic
Ribbon Drive Assembly
Ribbon Drive Assembly Cable
Figure 4-10. Removing the Ribbon Drive Assembly
4-14
Removing and replacing the tensioner

Important This procedure shows you how to remove the tensioner 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 or unplugging the printers power source from the wall outlet. 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 motor pulley. 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 Software adjustments for document insert station on page 2-1 for additional information and return here.
Tensioner
Tensioner Spring
Timing Belt
Transport Motor
Figure 4-11. Removing the Tensioner
4-15
Removing and replacing the printhead carriage assembly

Important This procedure shows you how to remove the printhead carriage 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 from the following list: v Removing and replacing the home sensor on page 4-11 v Removing and replacing the printhead carriage assembly on page 4-16 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing and replacing the printer covers on page 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 transport motor pulley. See Figure 4-12 on page 4-17. 5. Disconnect the printhead/home sensor cable from the printhead and home sensor. Thread the cable through the printhead carrier. See Figure 4-13 on page 4-17. 6. Turn the bushing on the right side of the printer transport shaft counterclockwise until the locking tabs align with the release slots, which are visible on the inside of the frame. Remove the rear transport shaft. If necessary, 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 can remove each FRU separately without removing the other FRUs. Choose one or all of these steps to remove the failing FRUs, and then proceed with step 11. 8. Remove the screw holding the home sensor to the printhead carriage assembly. 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 the rear, and remove the ribbon guide. See Figure 4-13 on page 4-17. 10. Remove the timing belt from the printhead carriage assembly. See Figure 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 left side. See Figure 4-14 on page 4-18. 12. 13. 14. 15. Remove the front transport carrier bearing. See Figure 4-14 on page 4-18. Reassemble. Adjust the printhead. Run one of the 4610 diagnostic and adjustment utilities. See Software adjustments for document insert station on page 2-1 and then return to this procedure.
4-16
Tensioner
Tensioner Spring
Timing Belt
Transport Motor
Figure 4-12. Removing the Timing Belt
Figure 4-13. Removing the Printhead/Home Sensor Cable
4-17
Upper Feed Roller
Backup Roller Screw
Ribbon Guide Printer Carriage Assembly Right Eccentric Rear Transport Shaft Front Carrier Bearing Front Transport Shaft Left Printhead Gap Eccentric
Printhead Gap Eccentric Detail
Slot
Figure 4-14. Removing the Carriage Assembly, Front or Rear Transport Shafts
4-18
Figure 4-15. Removing the Front Transport Carrier Bearing
4-19
Removing and replacing the transport motor

Important This procedure shows you how to remove the transport motor FRU. 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 or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing and replacing the printer covers on page 4-3 and return to this procedure. 3. Remove the ribbon drive assembly. Go to Removing and replacing the ribbon drive assembly on page 4-13. 4. Disconnect the printhead cable from the main logic card. Go to Removing and replacing the printhead cable on page 4-22. 5. Position the carriage assembly to the right side of the printer. Push the tensioner inward and remove the timing belt from the transport motor pulley. 6. Turn the bushing on the right side of the printer transport shaft counterclockwise until locking tabs align with the release slots. Remove the rear transport shaft. If necessary, replace the bushing. Note: This step can be omitted if the rear transport motor screw can be removed 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. Remove the 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 Printhead platen gap adjustment on page 5-4. 12. When you replace the transport motor, run the service diskette and select Reset Statistics for the FRU. See Software adjustments for document insert station on page 2-1.
4-20
Transport Motor
Figure 4-16. Removing the Transport Motor
4-21
Removing and replacing the printhead cable

Important This procedure shows you how to remove the printhead cable FRU. 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 from the following list: v Removing and replacing the transport motor on page 4-20 v Removing and replacing the MICR read head (Models with DI) on page 4-28 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Remove the ribbon drive assembly. Go to Removing and replacing the ribbon drive 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 and pull it through and out of the carriage assembly (see Figure 4-17 on page 4-23). 6. Make an alignment mark across the edge of the cable, partly on the cable and partly 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 the upper document guide, by pressing forward and down with a screwdriver to loosen 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 is affixed to the frame with adhesive. 10. Lay the old and new printhead cables side by side. Copy the alignment mark from 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 the adhesive strip to affix the cable to the frame. Use the alignment mark to position the printhead cable.
4-22
Figure 4-17. Disconnecting the Printhead Cable and Home Sensor
4-23
Removing and replacing the document insert (DI) sensor assembly (Models with DI)
Important This procedure shows you how to remove the document insert (DI) 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 from the following list: v Removing and replacing the MICR read head (Models with DI) on page 4-28 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 lever assembly (Models with DI) on page 4-34 v Removing and replacing the document insert (DI) feed roller (Models with DI) on page 4-37 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover and the ribbon cartridge. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Remove the ribbon cartridge. 4. Disconnect the document sensor assembly cable (red five-pin connector) from the 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 next step. v If the DI sensor does not rotate forward past the carriage assembly, remove the pressure pad holder and the wear plate to provide the required clearance. 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 it forward to remove. 8. Reassemble. 9. Perform the document threshold reset procedure. Go to Document sensor threshold reset on page 5-10. 10. Run one of the 4610 diagnostic and adjustment utilities. See Software adjustments for document insert station on page 2-1.
4-24
Wear Plate Sensor Spring DI Sensor
Pressure Pad Holder Pressure Pad
Figure 4-18. Disconnecting the Sensor Spring and Removing the DI Insert Assembly
4-25
Removing and replacing the document insert platen assembly (Models with DI)
Important This procedure shows you how to remove the platen 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 from the following list: v Removing and replacing the MICR read head (Models with DI) on page 4-28 v Removing and replacing the lower forms entry frame or flipper assembly (TN4) on page 4-30 v Removing and replacing the document insert (DI) feed roller (Models with DI) on page 4-37 v Removing and replacing the cutter gears and cutter clutch on page 4-66 v Removing and replacing the customer receipt paper guide on page 4-67 v Removing and replacing the customer receipt paper bucket on page 4-69 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Open the thermal printhead assembly. 4. Disconnect the clip springs on both sides of the platen shaft. See Figure 4-19 on page 4-27. Note: The clip spring on the right side is installed reversed from the clip spring on the left side. 5. Disengage the platen spring and remove the platen assembly and the platen spring. 6. Reassemble. 7. Check the printhead gap. Go to Printhead platen gap adjustment on page 5-4.
4-26

E-Clips
Platen Shaft Clip Spring
Platen Platen with Scanner (Model Ti8) Platen Spring
Figure 4-19. Removing the Document Insert Platen Assembly
4-27
Removing and replacing the MICR read head (Models with DI)
Important This procedure shows you how to remove the MICR FRUs. Removing and Replacing 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 from the following list: v Removing and replacing the lower forms entry frame or flipper assembly (TN4) on page 4-30 v Removing and replacing the document insert (DI) feed roller (Models with DI) on page 4-37 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers and the ribbon cartridge. Go to Removing and replacing the 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 and replacing the printhead cable on page 4-22. 5. Lift the front of the frame high enough to reach in and disconnect the MICR reader cable. 6. Remove the document insert platen assembly. Go to Removing and replacing the 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 (Models with DI) on page 4-24. 8. Remove the screw holding the MICR to the lower form entry frame. See Figure 4-21 on page 4-29. 9. Move the printhead carrier to the full right position. Rotate the DI sensor toward the front of the printer. 10. Slide the MICR over towards the right side of the printer until it clears the mounting post, and remove it. Note the cable routing. See Figure 4-21 on page 4-29. 11. Reassemble. Note: Polarity of the connector is important. Do not force the connector. 12. Run one of the 4610 diagnostic and adjustment utilities. See Software adjustments for document insert station on page 2-1.
4-28
Main Logic Card Printer Assembly
MICR Cable
Frame
Bottom Cover
Front Shock Mount
Figure 4-20. Removing the Front Shock Mount
Toggle Actuator Screw Mounting Post MICR Bail
Figure 4-21. Removing the MICR
4-29
Removing and replacing the lower forms entry frame or flipper assembly (TN4)
Important This 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 performing from the following: v Removing and replacing the document insert (DI) feed roller (Models with DI) on page 4-37 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Depending on the printer model, gently remove the cables connected to the main logic card. 4. Twist the front shock mount to the horizontal position and pull it out. See Figure 4-22 on page 4-31. 5. Lift the front of the printer frame high enough to reach in and disconnect the MICR reader cable. 6. If you need to replace the upper DI forms entry, do so at this point, instead of disconnecting 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 front transport shaft. See Figure 4-7 on page 4-10. 7. Lift the frame out of the bottom cover. 8. Remove the document insert platen assembly. Go to Removing and replacing the document insert platen assembly (Models with DI) on page 4-26. 9. Remove the document insert sensor spring. Go to Removing and replacing the document 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 lower the 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 the drive shaft. See Figure 4-23 on page 4-32. 12. For Models TN3 and TN4 only, remove the toggle actuator clip. See Figure 4-23 on page 4-32. 13. For Model TN3 only, remove the document insert lower forms entry frame by maneuvering the bail through the DI backup roller and the feed roller and unsnapping the document insert sensor from the right side of the forms entry frame . See Figure 4-23 on page 4-32. 14. For Models TN3 and TN4 only, remove the flipper assembly by maneuvering the bail through the DI backup roller and the feed roller. See Figure 4-24 on page 4-32. Note: It is important to note the position of the drive gear for reassembling. See Figure 4-25 on page 4-33.
4-30
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 posts and pull outward. See Figure 4-25 on page 4-33. 16. Reassemble. 17. Adjust the printhead gap. Go to Printhead platen gap adjustment on page 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). If you 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.
MICR Cable
Frame
Bottom Cover
Front Shock Mount
Figure 4-22. Disconnecting the MICR Cable
4-31
Toggle Actuator
DI Feed Roller
DI Backup Roller
Upper Document Insert Forms Entry E Clip Flipper Drive Gear Bail E Clip Flipper
Drive Shaft
Figure 4-23. Removing the Lower Forms Entry Frame
Bail
Flipper Assembly
Flipper Drive Gear Flipper Drive Belt
Figure 4-24. Removing the Flipper Assembly
4-32
Bail
Hooked Tabs
Flipper Assembly
Figure 4-25. Removing the Bail
4-33
Removing and replacing the document insert backup roller and insert lever assembly (Models with DI)
Important This procedure shows you how to remove the document insert backup roller 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 from the following list: v Removing and replacing the document insert (DI) feed roller (Models with DI) on page 4-37 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the document insert sensor assembly. Go to Removing and replacing the document insert (DI) sensor assembly (Models with DI) on page 4-24 and then 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 to remove. 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 4-27 on page 4-36. 8. Remove the document insert lever assembly. 9. Reassemble. 10. Reset the pressure shaft eccentric bushing. Go to DI forms compensation adjustment (Models with DI only) on page 5-2. 11. Reset the DI open lever adjustment. Go to Document insert open lever adjustment on page 5-6. 12. Adjust the printhead gap. Go to Printhead platen gap adjustment on page 5-4. 13. Run one of the 4610 diagnostic and adjustment utilities. See Software adjustments for document insert station on page 2-1.
4-34
Figure 4-26. Removing the DI Backup Roller
4-35
Figure 4-27. Removing the DI Lever Assembly
4-36
Removing and replacing the document insert (DI) feed roller (Models with DI)
Important This procedure shows you how to remove the DI feed roller FRU. 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 or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 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. See Figure 4-28 on page 4-38. 6. Lift the front of the printer frame high enough to reach in and disconnect the MICR reader cable. 7. Remove the document insert platen assembly. Go to Removing and replacing the document insert platen assembly (Models with DI) on page 4-26. 8. Remove the document insert sensor assembly. Go to Removing and replacing the 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 read head (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 entry frame or flipper assembly (TN4) on page 4-30. 11. Remove the document insert backup roller. Go to Removing and replacing the document insert backup roller and insert lever assembly (Models with DI) on page 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. See Figure 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 in the frame and remove the feed roller. 16. Reassemble. 17. Adjust the printhead gap. Go to Printhead platen gap adjustment on page 5-4. 18. Run one of the 4610 diagnostic and adjustment utilities. See Software adjustments for document insert station on page 2-1.
4-37
MICR Cable
Frame
Bottom Cover
Front Shock Mount
Figure 4-28. Removing the Front Shock Mount and Disconnecting the MICR Cable
DI Gear E-Clip Flipper Assembly
DI Motor
DI Motor Gear E-Clip Idler Gear
E-Clip
Figure 4-29. Gear Removal
4-38
Figure 4-30. Removing the Document Insert Feed Roller
4-39
Removing and replacing the document insert motor and gears (Models with DI)
Important This procedure shows you how to remove the document insert motor and gear 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 or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Remove the customer receipt paper guide. Go to Removing and replacing the customer receipt paper guide on page 4-67. 4. Gently remove the cables connected to the main logic card, except the cable that 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 the MICR reader cable. See Figure 4-31. 7. Lift the frame out of the bottom cover. 8. Remove the E-clip that is holding the motor gear to the motor. See Figure 4-32 on 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 Reset Statistics for the FRU. See Software adjustments for document insert station on page 2-1.
MICR Cable
Frame
Bottom Cover
Front Shock Mount
4-40

Screw E-Clips
Screw Idler Gear
Motor Gear
Figure 4-32. Removing the Motor Gear and Idler Gear
Document Insert Feed Motor
Screws
Figure 4-33. Removing the Document Insert Feed Motor
4-41
Removing and replacing the switch card and printhead spacer

Important This procedure shows you how to remove the switch card and printhead spacer. 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 from the following list: v Removing and replacing the ribbon drive assembly on page 4-13 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 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.
Hex Screw
Switch Card
Insulator
Printhead Spacer
Figure 4-34. Removing the Switch Card and Printhead Spacer
4-42
Logic Cards Procedure
Logic cards procedure Electrostatic discharge (ESD)

Attention: Electrostatic discharge (ESD) damage can occur when there is a difference in charge between the part, the product, and the service person. No damage occurs if the service person and the part being installed are at the same charge level as the product.
ESD damage prevention

Whenever a service action involves physical contact with logic cards, modules, back-panel pins, or other ESD-sensitive (ESDS) parts, the service person must be connected to an ESD common ground point on the product through the ESD wrist strap and cord. The ESD ground clip can be attached to any frame ground, ground braid, green wire ground, or the round ground prong on the AC power plug. Coax or connector outside shells can also be used.
Handling removed cards

Logic 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 ESD container.
Removing and replacing the main logic and sub-logic cards and connector-attached interface card
Note: The interface card attaches to the logic card through a connector.
Important This procedure shows you how to remove the logic 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 from the following list: v Customer receipt paper movement and cutter problems on page 4-60 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Invert the fully assembled printer. 3. Loosen the screw that holds the interface card assembly. This releases the main 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 on page 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-logic card for reattachment to the new main logic card. The sub-logic card is
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removed by gently pulling on the sub-logic card where the two plastic standoff tabs are located at the top on each side of the card. To reassemble the sub-logic card on the new logic card, simply align the plastic standoff tabs with the 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 card associated with your model.
Plastic standoffs Sub-logic card
Screws Main Logic Card
Nuts
Assembly Card Shield
Figure 4-35. Removing the Interface Card Assembly
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Logic card replacement verifications for all models

Prior to replacing the logic card, perform the following steps: 1. Resistance checks must be performed prior to installing the new card. This ensures that there are no existing shorts that can damage the new logic card. 2. Make sure all the following procedures are performed and completed in sequence. 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 applicable FRUs: Note: Disconnect the cable from the logic card and measure for resistance at the cable connector. Following are the symptoms indicating a resistances check.
Table 4-1. Resistance Check Symptom Missing wire due to coil short Jitter (hear or see) due to coil short Ribbon motor does not turn Jitter (hear or see) due to coil short Jitter (hear or see) due to coil short FRU/Cable Resistance Check Print head Transport motor Ribbon motor Document insert (DI) feed (if present) 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 4-36. Printhead cable
Figure Figure 4-37 on page 4-46 shows the position of all of the connectors on the main logic card.
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Figure 4-37. Main logic cable connectors
Customer receipt cutter motor cable: Measure resistance per Figure 4-38 on page 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 4-38 on page 4-47. Replace the document insert motor if the resistance is not within the range of 68 92 ohms. Ribbon drive motor cable: Measure resistance between pins 1 and 3 per Figure 4-38 on page 4-47. Replace the ribbon drive assembly if the resistance is not within the range of 15 52 ohms.
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Figure 4-38. Main logic cable connectors
Switch settings, card installation, and printer adjustments: Perform the following steps: 1. Ensure that the dip switch settings on the new card are the same as the setting on the old card. 2. Install the printer main logic card. 4610 DI-Less (Model TN5 only): After replacing the 4610 Planar FRU in a 4610 DI-Less printer, you must run the 4610 Configure MCT Utility Diskette. Running the 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 left side 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 port 7, For RS-232 communication, use the COM1 port. 5. Boot the diskette and follow the menus to set 4610 MCT values to enable the 4610 for DI-Less operation. 4610 DI-Less (Model GR5 only): After replacing the 4610 Planar FRU in a 4610 DI-Less printer, you must run the 4610 GR5 DI-Less MCT Utility Diskette. Running the 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 left side 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.
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5. Attach the 4610 to a PC or 469x terminal. For RS-485 communication, use port 7. 6. Boot the diskette. The diskette will run by itself. It will sound the beeper five times consecutively, and then it will reboot. 7. Whenever you exchange the main logic card, you must configure the printer model and then update the firmware. Make a note of the printer model and serial number, which are located on the label that is either on or under the front cover of the printer, then go to Software adjustments for document insert station 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 for document insert station on page 2-1. 10. Only for the RG5 printer, load the reference/service diskette. Set the model and serial number when prompted.
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Customer Receipt Station Procedures
Customer receipt station procedures Removing the customer receipt station cover
Open the customer receipt cover. Place the top of the screwdriver handle between the side of the printer and the top cover. Then close the top cover on the screwdriver, one side at a time. This frees the pivots on both sides. Slide the receipt cover forward and out. See Figure 4-39 on page 4-50 The receipt cover refers to the cover for the customer receipt station. The ribbon cover refers to the cover for the document insert station. These terms are used interchangeably. These covers are shown below in figure Figure 4-39 on page 4-50.
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Paper Cover Lift Tab Ribbon Cover
Clear Plastic Guide
Top Cover
Lock Tab
Top Cover Ribbon Cover
Paper Cover
Screwdriver
Top Cover
Figure 4-39. Removing the receipt and ribbon covers
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Removing and replacing the thermal cables and paper switch

Important This 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. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 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 on page 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.
Shoulder Screws
Printhead Mounting Bracket Rear Tabs
Front Tabs Latch Return Spring
Thermal Latch Spring
Platen Latch
Thermal Cover
Figure 4-40. Removing the Thermal Cover

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Figure 4-41. Removing the Spiral Wraps
Thermal Paper-Out Sensor Connector (Green) Document Insert Sensor Connector (Red) Thermal Printhead Connector Document Insert Motor Connector (Green) Cutter Motor Connector (White) Switch Card Connector (Yellow)
OCR Scanner (White) Model TI8 only) Powered Flipper (White) (Model TI8 only) Future Use (White) (Model TI8 only) Interface Card Connector
Impact Ribbon Drive Connector (Yellow) Transport Motor Connector (Red) Impact Printhead Connector
MICR Head Connector
Figure 4-42. Disconnecting the Thermal Printhead Cable from the Main Logic Card
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Removing and replacing the thermal printhead latch

Important This 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. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the paper cover. Go to Removing and replacing the printer covers on page 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 the printhead mounting bracket. 7. Slide the thermal printhead latch spring to one side and remove it. See Figure 4-44 on page 4-54. 8. Reassemble.
Shoulder Screws
Printhead Mounting Bracket Rear Tabs
Front Tabs Latch Return Spring
Thermal Latch Spring
Platen Latch
Thermal Cover
Figure 4-43. Thermal Printhead Latch Assembly
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Figure 4-44. Removing the Thermal Printhead Latch Spring
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Removing and replacing the thermal printhead drag strip

Important This procedure shows you how to remove the thermal printhead drag strip 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 from the following list: v Removing and replacing the thermal printhead assembly on page 4-57 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 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. See Figure 4-46 on page 4-56. 4. Remove the drag strip by pulling it through the drag shaft housing. Make note of 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
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E-clip Drag Strip
Locking Post Paper Guide Locking Post
Figure 4-46. Removing the Drag Strip
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Removing and replacing the thermal printhead assembly

Important This procedure shows you how to remove the thermal printhead 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 from the following list: v Removing and replacing the customer receipt motor on page 4-62 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 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 drag strip on page 4-55. 5. Cut the tie wraps securing the thermal cables to the thermal frame. See Figure 4-48 on page 4-58. 6. Remove the hinge by rotating it approximately 45 and squeezing the hinge post 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 thermal printhead 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 of the blade from the frame. 10. Remove the stationary blade. See Figure 4-49 on page 4-59 or Figure 4-50 on page 4-59. 11. Remove the thermal cover. 12. Remove the E-clips from the left side of the printhead shaft. Remove the printhead shaft by sliding it through the printhead bracket. See Figure 4-49 on page 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 thermal printhead 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 select Reset Statistics for the FRU. See Software adjustments for document insert station on page 2-1.
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Figure 4-47. Thermal Printhead Assembly
Figure 4-48. Removing the Spiral Wraps
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Figure 4-49. Removing the Cutter Stud, Stationary Blade, and Printhead Shaft (Model GR3 or TN3)
Figure 4-50. Removing the Cutter Stud, Stationary Blade, and Printhead Shaft (Model GR3 or TN4)
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Removing and replacing the thermal platen assembly

Important This 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 from the following list: v Removing and replacing the customer receipt motor on page 4-62 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Open the thermal printhead assembly. 4. Rotate the right thermal platen bearing 90 and lift the right side of the platen so that the locating tab on the platen stripper is above the locating notch in the right 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 and thermal drive gear. 7. Lift the right side of the thermal platen and slide the left side of the platen out of the frame. 8. Reassemble.
Thermal Platen Bearing E-Clip Thermal Paper Guide Stripper
Thermal Feed Gear Cutter Gear Thermal Idler Gear Spiral Pin
Figure 4-51. Removing the Thermal Platen Assembly
Customer receipt paper movement and cutter problems

This procedure helps isolate customer receipt (thermal) paper movement or paper-cutting problems. If paper is accordian or wrapped around the platen, the paper guide may be caught under the main cover or something may have blocked the paper from freely exiting the printer.
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1. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 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 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 the gear 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 (Models with 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 on page 4-66. 4. Turn the thermal idler gear counterclockwise 1-1/4 rotations, and then clockwise 1-1/4 rotations. All four gears should turn and the two gears on the inside of the frame 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-point during 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 cover open, press the customer receipt feed button to ensure that the motor rotates the platen. Remove power from the printer by either unplugging it from 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. Ensure that the thermal paper is loaded and the paper cover is latched. c. If the platen still does not rotate, exchange the main logic card. Depending on how the main logic card is attached, seeRemoving and replacing the main logic and sub-logic cards and connector-attached interface card on page 4-43.
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Removing and replacing the customer receipt motor

Important This 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 from the following list: v Customer receipt paper movement and cutter problems on page 4-60 v Removing and replacing the cutter gears and cutter clutch on page 4-66 v Journal station paper movement on page 4-77 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 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 on the tabs that latch to the bottom of the guide. 6. Remove the two screws from the customer receipt motor and remove the motor by sliding it under the edge of the paper guide and then out through the paper bucket 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 on the tabs that latch to the bottom of the guide. 9. When you replace the customer receipt motor, run the service diskette and select Reset Statistics for the FRU. See Software adjustments for document insert station on page 2-1.
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Figure 4-52. Removing the Customer Receipt Motor
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Removing and replacing the rotating cutter blade and thermal guide
Important This procedure shows you how to remove the rotating cutter blade 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 from the following: v Removing and replacing the cutter gears and cutter clutch on page 4-66 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Remove the rotating cutter blade and the thermal guide by prying outward on the right side of the frame with a screwdriver. See Figure 4-53 or Figure 4-54 on page 4-65. 4. Reassemble.
Rotating Blade E-Clip Stud
Thermal Paper Guide
Pin
Figure 4-53. Removing the Rotating Blade and Thermal Guide (Model GR3 or TN3)
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Figure 4-54. Removing the Rotating Blade and Thermal Guide (Model TN4)
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Removing and replacing the cutter gears and cutter clutch

Important This procedure shows you how to remove the cutter gear 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 from the following list: v Customer receipt paper movement and cutter problems on page 4-60 v Journal station paper movement on page 4-77 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 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 rotating cutter 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
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Removing and replacing the customer receipt paper guide

Important This procedure shows you how to remove the customer receipt paper guide 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 from the following list: v Removing and replacing the document insert motor and gears (Models with DI) on page 4-40 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Remove the rotating cutter blade. Go to Removing and replacing the rotating cutter blade and thermal guide on page 4-64. 4. Remove the thermal printhead assembly. Go to Removing and replacing the thermal printhead assembly on page 4-57. 5. Remove the thermal platen. Go to Removing and replacing the thermal platen assembly on page 4-60. 6. Remove the document insert platen. Go to Removing and replacing the document insert platen assembly (Models with DI) on page 4-26. 7. Release the two locking posts from the frame and remove the customer receipt paper guide. See Figure 4-56 on page 4-68. Attention: Be careful that you do not break the locking posts. 8. Reassemble.
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Old Style
New Style
Locking Post Paper Guide Locking Post
Paper Guide/Bucket
Figure 4-56. Removing the Customer Receipt Paper Guide
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Removing and replacing the customer receipt paper bucket

Important This procedure shows you how to remove the customer receipt paper bucket 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 or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 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. See Figure 4-57. 5. Lift the front of the printer frame high enough to reach in and disconnect the MICR reader cable. See Figure 4-57. Return to this procedure. 6. Lift the frame out of the bottom cover. 7. Unlock the locking tabs from the underside of the frame and remove the customer 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 rib on the paper guide. 9. Reassemble.
MICR Cable
Frame
Bottom Cover
Front Shock Mount
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Figure 4-58. Customer Receipt Paper Bucket
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Journal Station Procedures
Journal station procedures Removing the journal station cover

1. 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 and toward the rear of the printer until the cover is released from the tabs on each side of the cover. 4. Set the journal cover aside.
Removing and replacing the journal station button
Switch assembly
Thermal print-head cover
Figure 4-59. Journal station button
The journal station button is housed on the journal cover in the rectangular cutout in the front of the cover. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 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.
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Removing and replacing the journal printhead cover assembly

1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the covers. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Remove the two screws and washers (one on each side) from the bushing at the top rear of the housing. 4. Bend the tension rods on each side far enough to unhook them from the housing. 5. Lift up on the top and gently guide the black plastic tab out of the tabs holder on the inside left of the housing.
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Removing and replacing thermal printhead assembly

Cable
Latch Thermal print head Journal switch card Cover
Figure 4-60. Journal Station Thermal Printhead Assembly
The thermal printhead is located near the middle of the journal cover. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing the journal station cover on page 4-71 and then return to this procedure. 3. Remove the black plastic printhead cover by gently straightening the bend tabs on the rear of the cover. 4. Slide the cover forward over the metal tabs that are located on the front of the cover. 5. Remove the two cable connectors that are located on each side of the thermal printhead. 6. Remove the two screws holding the thermal printhead to the journal cover.
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Screws
Figure 4-61. Journal Station Thermal Printhead Cover 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 select Reset Statistics for the FRU. See Software adjustments for document insert station on page 2-1.
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Removing and replacing the platen assembly
Platen gear
Writing plate
Spring E-clips Platen Bushings Optical paper sensor
Figure 4-62. Journal Station Platen Assembly
The platen assembly is located in the middle top portion of the journal housing. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Disconnect the cable from the logic card, and remove the journal station from the 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 brass bushings. 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.
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Removing and replacing the journal motor assembly
Slip clutch
Motor
Figure 4-63. Journal Station Motor Assembly
The journal motor assembly is located on the right side of the journal housing in the middle lower portion. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Disconnect the cable from the logic card, and remove the journal station from the printer. 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 journal housing. 8. Pull down on the gear and motor and slide the motor and gear out through the hole in the journal housing. 9. Reassemble.
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Journal station paper movement

This procedure helps isolate customer receipt (thermal) paper movement. If paper is accordiion or wrapped around the platen, the paper guide may be caught under the main cover or something may have blocked the paper from freely exiting the printer. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 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 turn and 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 the gear 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 clockwise 1-1/4 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 the platen. Remove power from the printer by either unplugging it from the wall outlet 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. Ensure that 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.
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Removing and replacing the optical paper sensor
Optical paper sensor
Figure 4-64. Journal Station Motor Assembly
The optical paper sensor is located below the platen assembly in the middle portion of the journal housing. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Disconnect the cable from the logic card, and remove the journal station from the printer. 4. Remove the screw immediately to the left of the journal cover switch located on the 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 the bottom of the housing. 7. Reassemble.
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Removing the gear kit with clutch and E-clip
Slip clutch
Figure 4-65. Journal Station Gear Kit with Clutch and E-clip Assembly
The gear kit is located on the right side of the journal housing. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Disconnect the cable from the logic card, and remove the journal station from the printer. 4. Remove the E-clips from the spindles for the four larger gears. Remove the gears. 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.
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Removing and replacing the journal cover sensor switch
Top cover sensor switch

Figure 4-66. Journal Station Top Cover Sensor switch Assembly
The journal cover switch is on the left side of the journal housing assembly. When the cover is open the switch is open. The cover must be closed to activate the switch and permit printing of the journal. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Remove the cover. Go to Removing and replacing the printer covers on page 4-3 and then return to this procedure. 3. Disconnect the cable from the logic card, and remove the journal station from the printer. 4. Remove the sensor switch cable. 5. Remove the screw holding the sensor switch to the frame. 6. Reassemble.
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Interface Card Assembly Procedures

| | | | | The first procedure listed below is for the Models TNx. These models do not have the securing locks and seals featured on the Model Gxx printers. The second procedure 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 for Argentina Model GR3 and GE3 printers, on page A-1.
Electrostatic discharge (ESD)



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 interface assembly card 3. Remove the two screws from the journal station access panel and lift up and pivot the cover out of the slot at the rear 4. Remove the two screws for the interface assembly 5. Reassemble.
4-81
Removing and replacing fiscal interface assembly for model Gxx printers
| | | | | This section describes removal and replacement procedures for the following field-replaceable units (FRUs) in the 4610 SureMark Three-Station Printer, Model GRx 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 assembly

The secure seal is specified by country regulations, contact your local service planner. See Appendix A, Removal and replacements for Argentina Model GR3 and GE3 printers, on page A-1 for information on powering off the Argentina Model GR3 and GE3 printers.
Power module cover
Bottom view of printer
Fiscal printer seal
Secure Screw
Figure 4-67. Remove Printer Seal and the Secure Screw from Rear Panel
1. Power OFF the printer by either powering off the terminal or unplugging the external power source from the electrical outlet. 2. 3. 4. 5. 6. 7. Remove the printer seal from the secure screw at the back of the printer. Remove the secure screw. Invert the printer. Loosen the interface assembly screw on the bottom of the printer. Gently tilt and lift the interface assembly out of the printer. Make a note of the printer model, which is located on the label that is on the front of the cover.
4-82

Screw Fiscal interface assembly
Figure 4-68. Loosen the Fiscal Interface Assembly Screw and Tilt and Remove Assembly
4-83
Processor card
1. Remove the interface assembly from the printer. 2. Remove the four screws in the four standoffs that are attached to the processor card. 3. Gently pull the card upward.
Screws
Fiscal Processor Card
Standoffs
Figure 4-69. Remove Processor Card
4-84
Interface card
| | | See Appendix A, Removal and replacements for Argentina Model GR3 and GE3 printers, on page A-1 for information on removing the interface assembly from the Argentina 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 avoid bending the nearby connector pins on the interface card. 4. On the vertical part of the base of the interface assembly, remove the two hex nuts, 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 card assembly. Attention: The main logic card incorporates a lithium battery. You do not replace this battery. See the safety notice below.
Standoff
Memory card
Fiscal interface card
Figure 4-70. Remove Interface Card from Assembly
6. Reassemble. Note: After the repair, reinstall the interface card and follow the local procedures to reseal (if applicable) the machine, and put the machine back into service. Additional procedures or paperwork may apply.
4-85
Safety Information
Before you begin to install or service this product, read the following safety information. The main logic card incorporates a lithium battery. Refer to IBM Safety Information - Read This First, GA27-4004 for proper handling procedures Safety Information-Brazilian Portuguese: Cuidado: Uma bateria de ltio pode causar incndio, exploso ou queimaduras graves. No recarregue, desmonte ou aquea acima de 100C (212F), no utilize solda diretamente na clula, nem incinere ou exponha o contedo da clula gua. Mantenha longe do alcance de crianas. Substitua apenas pelo nmero de pea especificado para este produto IBM. A utilizao de uma bateria diferente representa risco de incndio ou exploso. O conector da bateria polarizado; no tente reverter a polaridade. Descarte a bateria de acordo com as regulamentaes locais. Safety Information-French: Attention: Prenez garde aux risques dincendie, dexplosion ou de brlures graves lis lutilisation dune pile au lithium. Ne la rechargez pas et ne la damontez pas. Ne lexposez pas une temprature superiure 100 C, ne la soudez pas, ne la faites pas brler et nen exposez pas le contenu leau. Gardez la pile hors de porte des enfants. Si vous la remplacez, commandez une pile de rechange de e. mme rfrence. Toute autre pile risquerait de prendre feu ou dexploser. Le connecteur de la pile est polaris. Nessayez pas dinverser la polarit. Pour le recyclage ou la mise au rebut, reportez-vous . la r.glementation en vigueur. Safety Information-Italian: Attenzione: Una batteria al litio pu incendiarsi, esplodere o causare ustioni. Non ricaricarla, non smontarla, non riscaldarla ad una temperatura superiore a 100 C, non saldarla, non incenerirla, non gettarla in acqua. Tenere la batteria lontano dalla portata dei bambini.
4-86
Sostituirla soltanto con una batteria contrassegnata dal numero parte specifico per questo prodotto IBM. Lutilizzo di un altro tipo di batteria pu determinare rischi di incendio o di esplosione. Il connettore della batteria polarizzata; non tentare di invertire la polarit. Smaltire la batteria secondo la normativa in vigore (D.Lgs. 22 del 5/2/97) e successive disposizioni nazionali e disposizioni locali. Safety Information-Spanish: Caution: Una batera de litio puede causar un incendio, una explosin 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. Mantngala alejada de los nios. Sustityala slo con el nmero de pieza que se especifica para este producto IBM. El uso de una batera distinta puede causar riesgos de incendio o explosin. El conector de batera est polarizado; no intente invertir la polaridad. Deseche la batera se acuerdo con la normativa local. Safety Information-German: Achtung: Lithiumbatterien sind feuergefhrlich, explosiv und knnen schwere Verbrennungen verursachen. Batterie nicht wiederaufladen, ffnen oder ber 100 Grad Celsius erhitzen; die Zelle nicht direkt anlten, verbrennen oder den Inhalt der Zelle mit Wasser in Berhrung bringen. Batterie nicht in Reichweite von Kindern aufbewahren. Eine verbrauchte Batterie nur durch eine Batterie mit der fr dieses IBM Produkt spezifizierten Teilenummer ersetzen. Andere Batterien knnen sich entznden oder explodieren. Der Batterieanschlu hat zwei verschiedene Pole; beim Anschlieen die Pole nicht vertauschen. Batterie gem den rtlichen Richtlinien fr Sondermll entsorgen.
4-87
Memory card
1. 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 to local regulations. 4. Using a new interface housing with the bonded memory card, reassemble the interface 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 regulations may require storing the failed memory.
| |
4-88
Removing the Model GRx fiscal printer cover

1. 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 electrical outlet. 2. Remove the interface assembly (see Removing and replacing the fiscal interface assembly on page 4-82). 3. Remove the two screws from the bottom of the printer. The screws are located behind the fiscal interface assembly, note that they are inaccessible until the fiscal interface assembly is removed. See Appendix A, Removal and replacements for Argentina Model GR3 and GE3 printers, on page A-1 for how to remove the printer power supply module from the Model GR3 Argentina printer. 4. With the bottom screws removed, begin removing the components by removing the document insert station/ribbon cover, the journal-station cover, the customer receipt paper cover, and the entire printer base cover from the printer. See Removing and replacing the printer covers on page 4-3. 5. Release the latch tabs by placing your finger against the inside of the left side of the cover and push down until your finger reaches the plastic latch tab. Pull the latch tab forward away from the cover and lift the left side of the section up until it is free from the cover. Do this on the right side by releasing the latch tab and lifting up on the right side of the printer cover.
Latch tabs
Figure 4-71. Release the Rear Latch Tabs
4-89
Mounting post
Impact printer cover
Figure 4-72. Mounting Posts on Front Face of base Cover
6. Remove the two screws from the mounting posts located on the right side of the front of the printer top cover. Lift the top cover up high enough to permit removal of the rubber grommet from the binding post. 7. With both the paper cover and the journal station cover upright, the latch tabs inside the printer cover are visible. 8. Release the latch tabs by placing your finger against the inside of the left side of the cover and push down until your finger reaches the plastic latch tab. Pull the latch tab forward away from the cover and lift the left side of the section up until it is free from the cover. Do this on the right side by releasing the latch tab and lifting up on the right side of the printer cover. 9. Lift the front of the top cover outward and upward until it clears the binding posts. Pull the left side of the top cover out and up to clear the tab from the track guide on the base. Pull out slightly on both the left and right sides. Lift the top 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 top cover before installing the top cover. b. When reassembling, ensure that the clear plastic paper guide is inserted through the slot in the paper cover.
4-90
Chapter 5. Hardware adjustment procedures

Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . ESD damage prevention . . . . . . . . . . . . . . . . . . Handling removed cards . . . . . . . . . . . . . . . . . . Mechanical adjustments . . . . . . . . . . . . . . . . . . . DI forms compensation adjustment (Models with DI only) . . . . . . Printhead platen gap adjustment . . . . . . . . . . . . . . . Document insert open lever adjustment . . . . . . . . . . . . Cutter blade run-in . . . . . . . . . . . . . . . . . . . . Thermal printhead adjustment for customer receipt and journal station . Thermal paper switch adjustment . . . . . . . . . . . . . . Document sensor threshold reset . . . . . . . . . . . . . . DANGER Never work on equipment or connect or disconnect signal cables during periods of lightning activity. . 5-1 . 5-1 . 5-1 . 5-2 . 5-2 . 5-4 . 5-6 . 5-7 . 5-8 . . 5-10 . . 5-10 . . . . . . . . .
CAUTION: For your safety, connect equipment requiring electrical power to a correctly wired 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 between the part, the product, and the service person. No damage will occur if the service person, the product, and the part being installed are at the same charge level.

Anytime a service action involves physical contact with logic cards, modules, back-panel pins, or other ESD sensitive (ESDS) parts, the service person must be connected to an ESD common ground point on the product through the ESD wrist strap and cord. The ESD ground clip can be attached to any frame ground, ground braid, green wire ground, or the round ground prong on the AC power plug. Coax or connector outside shells can also be used.

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.
5-1
Mechanical Adjustments
Mechanical adjustments
The following adjustment procedures are included in this section. Important: Procedures 1 through 3 must be done in sequence. 1. DI forms compensation adjustment 2. Printhead/platen gap adjustment 3. DI open lever adjustment 4. Cutter blade run in 5. Thermal printhead adjustment 6. Thermal switch adjustment 7. Document sensor threshold reset
DI forms compensation adjustment (Models with DI only)

Before making this adjustment, make sure the printhead is not pushed against the platen. 1. Turn the printhead gap adjustment bushings away from the platen (clockwise when looking at the left side of the printer). Ensure that the printhead is not in the 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 DI feed roll shaft (clockwise). A single sheet of paper should be able to slip between the backup roll and the feed roll. 3. Rotate the shaft eccentric bearing counterclockwise so that the backup roll moves toward the feed roll. Make sure that the paper is removed before continuing the adjustment. 4. Rotate the shaft eccentric bearing until the feed roll shaft end nearest to the eccentric moves away from the pressure roll shaft 0.05 mm (0.002 in). You can measure this by using a feeler gauge between the frame and the left feed roll bearing. 5. Run one of the 4610 diagnostic and adjustment utilities. See Software adjustments for document insert station on page 2-1. 6. Continue with Printhead platen gap adjustment on page 5-4.
5-2
Figure 5-1. DI forms adjustment
Chapter 5. Hardware Adjustments
5-3
Printhead platen gap adjustment

The printhead platen gap needs to be adjusted to 0.508 mm (0.02 in) nominally across the length of the platen. This is accomplished by adjusting the printhead gap bushings located at the left and right ends of the carriage shaft. The gap setting tool FRU part number is 42H1190. A sealant might be required to reseal the SureMark cover set. 1. The printer mechanism must be installed in the printer base and resting on a flat 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 does not have to be in place. 2. Remove the ribbon from the printer (see Ribbon loading (Models with DI) on page 6-6). 3. Move the printhead carriage to the left. Check the printhead gap by sliding the gap setting tool between the printhead and the ribbon guide. See Figure 5-2 on page 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 as described in step 3. 5. If both adjustments are correct, no further action is required. If either adjustment is incorrect, return the printhead carriage to the left. 6. Adjust the left printhead gap eccentric using a screwdriver. The gap between the ribbon guide and the print wires on the printhead should be 0.388 +/- 0.02 mm (0.0153 +/- 0.0008 in). Adjust it with the printhead gap setting tool that is provided 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 gap eccentric 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 appear snug during the adjustment phase, apply a small amount of an appropriate sealant (nail polish or a sealant from Glyptal, Inc.) across the original seals. If the 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 introduce variations. 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 CR print test.
5-4
Figure 5-2. Placement of gap setting tool
Upper Feed Roller
Backup Roller Screw
Ribbon Guide Printer Carriage Assembly Right Eccentric Rear Transport Shaft Front Carrier Bearing Front Transport Shaft Left Printhead Gap Eccentric
Printhead Gap Eccentric Detail
Slot
Figure 5-3. Platen gap adjustment
5-5
Document insert open lever adjustment

1. 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 left end of the backup roll shaft has moved 2.5 mm (0.098 in or 0.1 in) from the closed position. This can be measured by the distance the left backup roll bearing moves back relative to the frame (see Figure 5-4). 3. Run one of the 4610 diagnostic and adjustment utilities. See Software adjustments for document insert station on page 2-1.
Figure 5-4. DI open lever adjustment
5-6
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 operating additional cycles.
Figure 5-5. Cutter blade run-In (Models TN3 and TN4)
5-7
Thermal printhead adjustment for customer receipt and journal station

Note: The thermal printhead should be adjusted prior to adjusting the thermal switch. The thermal printhead adjustment procedure is the same for both the printer station and the journal station only the cover information differs. The thermal printhead must be mounted in the printer and the respective cover removed. With the thermal bracket open, loosen both of the shoulder screws until the thermal printhead and the shoulder screws slide smoothly within the thermal printhead mounting bracket slots. See Figure 5-6 on page 5-9. Close the thermal bracket. Use a small screwdriver to press on the shaft of the shoulder screw, between the mounting bracket and the printhead bracket. Slide the printhead to the end of the slots, towards the back of the printer. Run the CR offline test (see Customer receipt test on page 3-1). Observe the thermal print density as it prints. Slide the thermal printhead using steps 4 and 5, one side at a time, towards the front of the printer. As you move the printhead, the printing will become darker. When the print is most dense and uniform across the entire print line, the thermal printhead adjustment is complete. Tighten the two shoulder screws until they are snug. Do not overtighten the shoulder screws.
1. 2.
3. 4. 5. 6. 7.
8.
9. Test the printer to ensure continued print quality. Go to Offline tests on page 3-1. Re-adjust if necessary. 10. Check the thermal paper switch adjustment. Go to Thermal paper switch adjustment on page 5-10.
5-8
Shoulder Screws
Printhead Mounting Bracket
Latch Return Spring Thermal Latch Spring Platen Latch
Thermal Printer Cover
Shoulder Screws
Figure 5-6. Thermal printhead adjustment for customer receipt and journal stations
5-9
Thermal paper switch adjustment

1. 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 printer and successively move the switch rearward until the printer passes the following test 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 the CR paper feed button to advance the receipt paper a few inches. The printer ready LED should then go to a steady state. 4. With the paper cover still closed, feed the paper out of the printer. The printer ready LED should start to blink, indicating an out-of-paper condition.
Figure 5-7. Thermal paper switch adjustment
Document sensor threshold reset

Set the document sensor threshold reset (adjustment), if the printer does not sense an 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.
5-10
Chapter 6. Operation
Indicators, controls, and stations thermal/impact printers Check verification and printing (model TN4 only) . . . . Ribbon loading (Models with DI) . . . . . . . . . . Clearing jams in the check flipper area . . . . . . . . Cleaning the MICR reader read head . . . . . . . . Thermal printheads cleaning . . . . . . . . . . . . 6-1 . 6-2 . 6-6 . 6-8 . . . . . . . . 6-10 . . . . . . . . 6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Note: All covers must be installed on the SureMark printer before and during operation.
Indicators, controls, and stations thermal/impact printers

There are two LED indicators and three triangular-shaped buttons located on the top of the printer. The indicators and buttons serve multiple functions. |
Customer Receipt Paper Cover Printer Ready LED Customer Receipt Feed Button Document Present LED Document Feed Button Journal paper cover Journal Printer Station Journal Feed Button Customer Receipt Printer Station Ribbon Cover (Document insert cover) Document Insert Printer Station
| |
Figure 6-1. Indicators, controls, and printing stations Thermal/Impact SureMark Printers
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 is inserted 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 this button to advance the CR paper. The lower button is the document insert station feed button. Press this feed button to advance a document.
6-1
If you simultaneously press both customer receipt and document feed buttons momentarily and then release them, the DI throat opens. The throat must be open to insert a document from the side. Press and then release both buttons again to close the throat. Both CR and DI buttons are also used to test the printer. See Offline tests on page 3-1 for additional button functions. The third button on the top of the printer is located on the journal station. Press this button 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 and printing information on an inserted document. Figure 6-2 on page 6-3 shows the correct positioning of the check in a printer. It also shows how to side load a document 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 access cover closed. Doing that will disengage the paper feed and the paper feed motor must catch up before the printer can feed the paper. The result will be missing lines or partial lines of print. Use the Customer Receipt Feed button to advance the receipt and all lines will be printed.
6-2
Check Verification and Printing
Insertion of Check for MICR Reading and Franking
Insertion of Check for Printing the Face
Do Not Sign / Write / Stamp Below This Line For Financial Usage Only
Federal Reserve Bank Regulation CC
4001
19
Pay To The Order Of
$ Dollars
Endorse Here
Memo
041117847096
095867238671
4001
Insertion of Document (Front Load)
Insertion of Document (Side Load)
Print Position
Figure 6-2. Positioning checks and documents for reading and printing
6-3
Figure 6-3 and Figure 6-4 on page 6-5 show the printable area on an inserted document for both portrait and landscape.
Figure 6-3. Printable area of an inserted document (portrait)
6-4
Figure 6-4. Printable area of an inserted document (landscape)
6-5
Ribbon Loading
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.
Figure 6-5. Opening the ribbon cover
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 to remove.
6-6
Ribbon Loading
Figure 6-6. Ribbon cartridge loading
3. Maintain ribbon tension by turning the ribbon cartridge knob as shown in Figure 6-6. Lower the cartridge into position until notches on its sides snap into place on the printer guides. After the cartridge is in place, turn the knob until the ribbon slides into place between the printhead and the ribbon shield. See Figure 6-7 for correct ribbon positioning.
Ribbon Shield Print Head
Correct
Figure 6-7. Ribbon path around the printhead
Not Correct
4. Close the ribbon cover.
6-7
Clearing Jams in Check Flipper
Clearing jams in the check flipper area

This procedure is for the SureMark Model TN4 printer (MICR reader and check flipper 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 cover from the printer. (See Figure 6-8.) 2. The action you take in this step depends on whether the document is visible and can be removed: v If you can remove the document, remove it, and replace the lower document insert cover. v If you cannot remove the document, continue with step 3.
Figure 6-8. Removing the lower document insert (DI) cover
3. Lift up the tab on the left side of the check flipper cartridge and remove the assembly from the printer. (See Figure 6-9 on page 6-9.)
6-8
Clearing Jams in Check Flipper
Figure 6-9. Removing the check flipper cartridge
4. Reach inside the document insert station and carefully remove the jammed check. 5. Remove any debris from the belts. Clean the belt surface with a brush or damp cloth. Dry the belts completely. 6. Reinstall the check flipper cartridge and the lower DI cover.
6-9
Cleaning MICR Read Head
Cleaning the MICR reader read head

The MICR reader read head should be cleaned after 10,000 checks are processed or every 3 months. Insert the MICR reader cleaning card through the document insert station several times. If cleaning the MICR reader read head does not solve a problem you are having, it might be that you are experiencing electromagnetic noise interference. Sources of electromagnetic noise (for example, displays, security towers, and other sources) can interfere with the MICR reader read head. The printer filters noise from many devices. If the MICR reader does not function properly, rearranging the printer relative to the device may improve MICR reader reading. The noise source should be 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.
6-10
Thermal printerheads Cleaning
Thermal printheads cleaning

The thermal printheads in both the customer receipt and journal station can be cleaned whenever print quality deteriorates. 1. Open the paper or journal cover. 2. Using a cotton swab soaked in isopropyl alcohol, gently wipe the printhead several 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 for service.
Detail View of Thermal Print Head
Thermal Print Line
Paper Cover
Figure 6-10. Printhead and print line area
6-11
Thermal printerheads Cleaning
6-12
Chapter 7. Parts listing

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

4
23 14 13 6 15 20 21 9 12 5 19 2 10 8 7 22
15 20
3 16 17
1 11
7-2
Assembly 1: (continued)
Asm Index 11
Part Number
Units Description - Interface Assembly Base See Assembly 13: Models TN3, TN4, and TN5 interface assembly on page 7-26 - Interface Assembly (Fiscal RS-485) Base See Assembly 14: Model GRx (RS-485) fiscal interface assembly on page 7-28 - Interface Assembly (Fiscal USB) Base See Assembly 15: Model GBx and GEx (USB) fiscal interface assembly on page 7-30 NP Printer frame NP Base Assembly 1 JNL Cover FRU Assembly - Pear White 1 JNL Cover FRU Assembly - Iron Gray 1 Journal Assembly 1 Main Cover Top Assembly - Pearl White 1 Main Cover Top Assembly, Argentina only - Pearl White 1 Main Cover Top Assembly - Iron Gray 1 Main Cover Top Assembly, Argentina only - Iron Gray 1 Main Logic Card Assembly 1 Sub Logic Card Assembly NP Label-Cover S/N NP Label-Frame S/N 2 Base screw 6-32 X 2.5 inch (GR3 only), use miscellaneous hardware kit 17P6244 1 1 1 1 Cover, Cover, Cover, Cover, ribbon ribbon ribbon ribbon - Pearl White - Iron Gray (for integrated paper roll asembly), Argentina only - Pearl White (for integrated paper roll asembly), Argentina only - Iron Gray
| |
| | | | | |
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 22 23
17P6232 49P6817 17P6233 17P6242 35P0165 54P1669 54P1585 17P6224 17P6223
| | | | | | | | | | | | | |
42H1132 10J1573 54P1625 13G2034 42H1139
v Button Kit Includes Assembly Index -13 and -14) 2 v v Button, key 2 v v Key Pad Button v Shock Kit Includes Assembly Index -15, -16, and -17) 2 v v Shock Mount 1 v v Plug, Shock MTG Base 1 v v Front Shock Mount Base NP 2 NP 1 1 Paper Bucket Stud, Cover Shock Mount Main Card Shield Paper Cover Lens Assembly- Pearl White Paper Cover Lens Assembly- Iron Gray
42H1140
| | |
42H1063 42H1136 10J1568
7-3
Assembly 2: Journal station cover and button assembly
8 9 2 3
8 7 6 5 11
7-4
Asm Index 21 2 3 4 6 7 8 9 10 11
Part Number
Units Description NP NP NP 1 NP 1 NP 1 NP NP v v v v v v v v v v Cover Frame Print Head Shaft with e-clips Cover Support Frame Print Head Cover (Thermal) Spring Thermal Latch JNL Button Card M3X6 Double Sems (ZC) included in hardware kit Print Head ASM M3X5 Double Sems (ZC) included in hardware kit Thermal Head Connector
17P6245 17P6235 17P6236
7-5
Assembly 3: Customer receipt station operator button assembly
3 2 4
7-6
Asm Index 31 2 3 4 5
Part Number 42H1139 42H1135
Units Description 2 v Switch Button, Operator (2x) 1 v Switch Asm, Operator Includes Screw (Assembly Index -3) and Insulator (Assembly Index -4) NP v v Screw (see kit 42H1063) NP v v Insulator, Switch NP Frame
7-7
Assembly 4: Logic cards and shock mounts
18
12
17
5 2
10
16
19
15
7-8
Asm Index 41 2 3 4 5 6 10 12 15 15
Part Number 42H1140
Units Description NP Customer Receipt/Document Insert Frame 1 v Kit, Shock Mounts (Includes Assembly Index -2, -3, -4 , and -5) NP v v Shock, Front, Mount NP v v Shock, Front NP v v Shock, Rear (X2) NP v v Support, Front NP v Assembly Card Shield NP Cover, Base 1 Card Assembly, Main Logic 1 Card Assembly, Interface (RS-232 and RS-485), Models TN3, TN4, and TN5 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 1 Shield, Tray Spill Base NP Journal Frame 1 Sub Card Asm Security Shield, RS-485 (Argentina only) Security Shield, USB (Argentina only)
17P6224 02L0816
| | | |
| |
16 17 18 19
02L0769 17P6223 54P1627 54P1629
7-9
Assembly 5: Document insert station
4 5
7-10
Asm Index
Part Number 42H1133 10J1565 42H1115 10J1188
Units Description NP 1 1 1 1 Frame DI Forms Entry, Upper - Pearl White DI Forms Entry, Upper - Iron White Flipper Cover (Models xR4 Only), Includes - Pearl White 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 the DI Lower Forms Entry Cover for Models TN3 and Gx3 NP Rollers (X4) NP Shaft, roller (X2) 1 Cartridge Asm, Flipper (Model xx4 Only) Includes sample check (2x)
| | | |
51 2 3
|
4 5 6
42H1116
7-11
Assembly 6: Customer receipt thermal printhead assembly and cover
11 8 4 5 6
10
7-12
Asm Index 61 2 3 4 5 6 7
Part Number 30L6442 42H1137 30L6441 42H1059
Units Description 1 Cable, Thermal, High Speed 1 v Hinge Includes Assembly Index -4, -5, and -6. 1 v Thermal Printhead Assembly, High Speed 1 v v Thermal Latch Asm. NP v v Spring, Thermal NP v v Spring, Latch Return NP v v Latch, Platen 1 v Cover, Thermal Printhead Includes Label. 1 v Drag Strip Includes E-clip 1 v Sensor, Thermal Paper Includes Screws and Mounting Bracket. NP Frame 1 Thermal Printhead FRU, High Speed (all models except TI1 and TI2) 1 Thermal Printhead FRU, High Speed (Models TI1 and TI2 only)
42H1180 42H1129 42H1128
8 9 10 11 11
08L1843 42H1262
7-13
Assembly 7: Printhead transport and ribbon drive assembly

1 2
4 3
6 7
10
12 11
7-14
Asm Index 71 2 3 4 5 6 7 8 9 10 11 12
Part Number 42H1107 42H1106 42H1044
Units Description 1 v Bushing, Gap Adjust (2X) 1 v Shaft, Transport, Rear Includes Gap Adjust Bushings (Assembly Index -1) 1 v Shaft, Transport, Front Includes Screw (Assembly Index -4) NP v v Screw (see kit 42H1063) 1 v Belt, Timing 1 v Spring, Tensioner 1 v Tensioner Asm. Includes Tension Spring (Assembly Index -6) 1 v Spacer, Printhead NP Frame 1 v Ribbon Drive Asm. 1 v Motor, Transport Includes Screws (Assembly Index -12) 1 v v Screws (2X) See Hardware Kit, 42H1063, Miscellaneous Fasteners.)
42H1110 42H1109 42H1108 42H1145 42H1114 42H1045
7-15
Assembly 8: Impact printhead assembly
2 1 4 3
7 9 8
10
7-16
Asm Index 81 2 3 4 5 6 7 8 9 10
Part Number 42H1047
Units Description 1 v Guide, Ribbon Includes Screws (Assembly Index -2) NP v v Screws (2X) Part of Hardware Kit, 42H1063, Miscellaneous Fasteners. 1 v Printhead Asm, Impact Includes Printhead, Screw (Assembly Index -4), Printhead Gap Gage NP v v Screw (see kit 42H1063) 1 v Carriage Asm. 1 v Cable, Printhead 1 v Bearing, Carrier, Front 1 v Sensor, Home Includes Screw (Assembly Index -9) NP v v Screw Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners. NP Frame 1 Printhead Gap Gage
42H1046
42H1112 42H1111 42H1113 42H1048
42H1190
7-17
Assembly 9: Document insert station platen and lever
7-18
Asm Index 9 1 2 3 4 5 6 7 8 9 12 10 11
Part Number 42H1062
Units Description 1 v Platen Asm, DI Station Includes Assembly Index -1, -2, -3, -4, and -5. NP v v E-Clips (2X) (part of 42H1063) NP v v Shaft, Platen NP v v Spring, Clip (2X) (part of 42H1144) NP v v Platen NP v v Spring, Platen (part of 42H1144) 1 v Pressure Pad Asm. Includes Assembly Index -6, -7, and Sample Checks 1 v DI Sensor Asm. Includes Assembly Index -6, -7, -8, -9, and Sample Checks NP v v Holder, Pressure Pad NP v v Pressure Pad NP v v Spring, Sensor (part of 42H1144) NP v v Sensor, DI Upper/Lower NP v v Wear Plate 1 v DI Lever Asm Includes Bushing, E-clip, DI Lever NP Frame
42H1051 42H1052
42H1121
7-19
Assembly 10: Document insert drive shaft assembly
7-20
Asm Index 101 2 3 4 5 6 7 8 9 10 11
Part Number 38H7504
Units Description NP Frame 1 v Read Head, MICR (Model TN4 Only) Includes Screw (Assembly Index -3) and Sample Check (2x) NP v v Screw (part of 42H1063) 1 v DI Feedroller Assembly. (Model TN4 Only) Includes Assembly Index -4, -5, and -6. NP v v DI Feedroller (Model TN4 Only) NP v v E-Clip (part of 42H1063) NP v v Bearing, Feed, Left 1 v DI Feedroller Assembly. (Model TN3 and GR3 Only) Includes Assembly Index -7, -8, and -9. NP v v DI Feedroller (Model TN3 and GR3 Only) NP v v E-Clip (part of 42H1063) NP v v Bearing, Feed, Left 1 v Bail, (Model TN4 Only) 1 v Bail, (Model TN3 and GR3 Only) 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) NP v v Gear, Drive NP v v Shaft, Drive NP v v E-Clip (2x) Part of Hardware Kit, 42H1063, Miscellaneous Fasteners. NP v v Clip, Toggle Actuator (Also part of Hardware Kit, 42H1144, Miscellaneous Springs.) NP v v Flipper Sub. Assembly. (Model TN4 Only) 1 v DI Lower Forms Entry (Model TN3 and GR3 Only) Includes Assembly Index -17, -18, and -19. NP v v Shaft NP v v E-Clip (2x) Part of Hardware Kit, 42H1063, Miscellaneous Fasteners. NP v v Frame, Lower Forms Entry (Model TN3 and GR3 Only) 1 Sample Check (2x)
42H1057
42H1119
42H1117 42H1118 42H1050
12 13 14 15 16 17 18 19
42H1134
73G2601
7-21
Assembly 11: Document insert station gears and motor
4 1
6 7
8 9 10
12
11
13
7-22
Asm Index 11 1 2 3 4 5
Part Number 42H1053
Units Description 1 Kit, DI Gears Includes Assembly Index -1, -2, -3, -4, and -5 NP v Gear, Motor NP v Gear, Idler NP v Gear, Shaft NP v E-Clip (Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.) NP E-Clip (X2) 1 DI Backup Roll Shaft Asm Includes Assembly Index -6, -7, -8, -9, and -10 (Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.) NP v Right Shaft Bearing NP v DI Back-up Roller NP v E-Clip (Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.) NP v Bearing, Shaft Eccentric NP v Left Shaft Bearing NP v Spring (Also part of Hardware Kit, 42H1144, Miscellaneous Springs.) 1 Motor, DI Feed Includes screws NP v Screws (2X) (Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.) NP Frame
42H1058
6 7 8 9 8 10 11 12 13 42H1120
7-23
Assembly 12: Customer receipt drive, cutter, and platen
3 4 5 6 7 8 9 10 11 12 15 22 13 14 21 17 18 19 20 23
16
24
7-24
Asm Index 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 21 23 24
Part Number 42H1065
Units Description 1 v Thermal Cutter Assembly Includes Assembly Index -1, -2, -3, -4, -5, -6, -7, -8, and lubricant NP v v Guide, Thermal (also part of 42H1164) NP v v Spring, Leaf or Lever/Spring NP v v Stud NP v v Blade, Stationary or Blade Asm, Stationary NP v v Pin NP v v Stud, Cutter NP v v Blade Asm, Rotating 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 1 v Platen Assembly, Thermal Includes Assembly Index -9, -10, and -11. NP v v Bearings, Thermal, Right NP v v Platen, Thermal NP v v Bearings, Thermal, Left 1 v Stripper 1 v Kit, CR Cutter Gears Includes Assembly Index -13, -14, -15, -16, -17, -18, 19, and -20. NP v v E-Clip Part of Hardware Kit, 42H1063, Miscellaneous Fasteners. NP v v Gear, Pin NP v v Pin, Lever Drive NP v v E-Clip Part of Hardware Kit, 42H1063, Miscellaneous Fasteners. NP v v Spring, Cutter Stop NP v v Gear, Cutter NP v v Gear, Thermal Feed NP v v Gear, Thermal Idler NP v v Spiral Pin 1 v Clutch Assembly, Cutter 1 v Motor, CR Includes Screws (2x) NP Frame
30L6443
42H1164 42H1060
30L6445 30L6444
7-25
Assembly 13: Models TN3, TN4, and TN5 interface assembly
7-26
Asm Index 131 1 1 1
Part Number 02L0816
Units Description 1 NP NP NP Interface Assembly Thumb Screw 2 E Ring A-B (93F0233) Hex Card Spacer
7-27
Assembly 14: Model GRx (RS-485) fiscal interface assembly
7-28
Asm Index 141 2 3 4 5 6 7 8 9
Part Number
Units Description NP Screw, included in index assembly -4 Use the Country-specific Fiscal Processor Card Assembly for: v Argentina GRx v Greece GRx v Italy GRx v Turkey GRx
| | | |
33P0171 35P0175 35P0170 35P0174
1 1 1 1
NP 3X8 D_SM Small-ZC standoff, included in index assembly -4 Use the Country-specific Fiscal Interface Logic Card for: 1 v All countries except Argentina and Greece 1 v Argentina GRx 1 v Greece GRx Use the Country-specific Fiscal Base and Memory Assembly for: v Argentina GRx v Greece GRx v Italy GRx v Turkey GRx v v v v Card Insulator included in index assembly -4 Screws included in index assembly -4 Lock Washer included in index assembly -4 Flat Washer included in index assembly -4
| |
17P6226 35P0168 47P0293
| | | |
35P0211 35P0215 35P0210 35P0214
1 1 1 1 NP NP NP NP
7-29
| |
Assembly 15: Model GBx and GEx (USB) fiscal interface assembly
7-30
| | | | | | | | | | | | | | | | | | | | | | | | | |
Asm Index 151 2 3 4 5 6 7 8 9
Part Number
Units Description NP Screw, included in index assembly -4 Use the Country-specific USB Fiscal Processor Card Assembly for: 1 v Argentina GEx 1 v Greece GBx 1 v Turkey GBx NP 3X8 D_SM Small-ZC standoff, included in index assembly -4 Use the Country-specific USB Fiscal Interface Logic Card for: 1 v All GBx countries except Argentina 1 v Argentina GEx Use the Country-specific USB Fiscal Base and Memory Assembly for: 1 v Argentina GEx 1 v Greece GBx 1 v Turkey GBx NP NP NP NP v v v v Card Insulator included in index assembly -4 Screws included in index assembly -4 Lock Washer included in index assembly -4 Flat Washer included in index assembly -4
49P8998 49P9002 49P9001
13G2002 35P0169
49P6838 49P6842 49P6841
7-31
Assembly 16: Journal assembly both sides view

Left side view
19 15 11 26 32 6 28 1 31
15 14 11 24 4 8 10 7 9
25 12 20 22
17
Right side view
16 2
30 6
7-32
Asm Index 160 1 2 4 6 7 8 9 10 11 12 14 15 16 17 19 20 22 24 25 26 28 30 31 32
Part Number 17P6232
Units Description 1 NP NP NP NP 2 NP NP NP NP 1 1 NP NP NP 1 NP NP NP NP NP NP 1 1 1 Complete Journal Assembly FRU Left Frame Sub Assembly M3X6 Double Sems (ZC) 2 5 E Ring A (SUS) M3X6 CSK ZC (30221300610) Roller, see miscellaneous hardware kit 17P6244 Cover Lock Shaft Guide Shaft Right Frame SUB ASM Front Guide SUB ASM Platen Assembly Spool Assembly Cover Shaft Cover Open Spring R Cover Open Spring L Drag Strip Rear Guide Roller Shaft 1 Front Guide Shaft Frame Shaft Earth Plate 4 Earth Plate 3 Gear Kit with Clutch Journal Paper Out Sensor Journal Cover Switch Assembly
17P6237 17P6234
42H1129
17P6241 17P6240
7-33
Assembly 17: Models GR3 and GE3 power supply assembly (Argentina only)
7-34
Asm Index 17 1 2
Part Number 35P0164 35P0162
Units Description Power Supply Assembly 1 Y-cable and power switch 1 Power supply module
7-35
Assembly 18: Hardware Kits

Asm Index 181 2 3 Part Number 42H1063 Units Description 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) 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 1 Kit, Miscellaneous Hardware for Journal Station
42H1144
17P6244
7-36
Assembly 19: Cable assemblies, filler panel, power supply

Asm Index 191 2 3 4 5 6 7 8 Part Number 42H1143 42H1056 42H1111 42H1157 42H1176 72H3802 72H3803 86H2192 86H2195 54P1626 47P0284 08L2014 13G2036 Units Description 1 Cables, Logic Card Includes Signal Cable, Power Cable, and Cable Clamp. 1 Cables, Thermal Printhead Includes Both Cables, Cable Tie, and Spiral Wrap. 1 Cable Asm, Impact Printhead 1 Filler Panel 1 Power Supply80W for GBx Models (USB attached) and TNx Models (when RS-232 attached) 1 Cash Drawer Cable, Short 1 Cash Drawer Cable, Long 1 Models TNx Cable, RS-232 Interface, 2 m 1 Models TNx Cable, RS-232 Interface, 4 m Cable, RS-485 interface, 1 m Cable, RS-485 interface, 1.8 m 9 USB interface cable 10 Cable, RS-232 Audit Port (Models GRx, GBx, and GEx only)
| |
| | | | | |
7-37
Assembly 20: Complete printer replacement as a FRU

Asm Index 20 Part Number 35P0281 35P0279 35P0285 35P0280 35P0277 35P0278 35P0284 Units Description 1 1 1 1 1 1 1 4610-TN3 Printer Assembly 4610-TN4 Printer Assembly 4610-TN5 Printer Assembly 4610-GR3 Printer Assembly 4610-GR3 Printer Assembly 4610-GR4 Printer Assembly 4610-GR5 Printer Assembly
(without fiscal interface assembly) (except Argentina) for Argentina (without fiscal interface assembly) (without fiscal interface assembly) (without fiscal interface assembly)
7-38
7-39
Assembly 21: Paper roll holder, (Argentina only)
7-40
| | | | | | |
Asm Index 211 2 3 4 5
Part Number 54P1625
Units Description 1 v Cover, Ribbon (for integrated paper roll assembly) includes index assembly -2, (Argentina only) NP v v Integrated Paper Roll Assembly, (Argentina only) 1 Cover, Ribbon, (for distributed paper roll assembly), (Argentina only) 1 Distributed Paper Roll Assembly, (Argentina only) 1 Tear Bar (Argentina Only)
42H1132 54P1622 54P1623
7-41
7-42
Appendix A. Removal and replacements for Argentina Model GR3 and GE3 printers
Remove the paper roll holder . . . . . . . . . . . . . . . . . . Remove the distributed paper roll holder . . . . . . . . . . . . . Remove the integrated paper roll holder . . . . . . . . . . . . . Remove the security shield . . . . . . . . . . . . . . . . . . . Remove the interface assembly . . . . . . . . . . . . . . . . . Remove the power switch and/or cable . . . . . . . . . . . . . . Logic card procedures . . . . . . . . . . . . . . . . . . . . Electrostatic discharge (ESD). . . . . . . . . . . . . . . . . Removing and replacing the main logic and sub-logic cards and connector-attached interface card (models GR3 and GE3 for Argentina) Remove the power cable . . . . . . . . . . . . . . . . . . . Remove the power supply . . . . . . . . . . . . . . . . . . . . A-1 . A-2 . A-3 . A-3 . A-5 . A-7 . A-10 . A-10 . A-11 . A-13 . A-14
This chapter shows the removal procedures for the Argentina version of the IBM 4610 SureMark Three-Station Printer Model GRx.
Remove the paper roll holder

The Paper Roll Holder is used to print additional copies of receipts. There are two types 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 the distributed paper roll holder on page A-2 for removal instructions.
Paper roll Tear-off bar
Clip Spindle
Paper roll holder
Figure A-1. Distributed paper roll holder
A-1
v Integrated Paper Roll Holder is attached to the top of the Ribbon Cover with two screws. See Figure A-2 for diagram and Remove the integrated paper roll holder on page A-3 for removal instructions.
Paper roll
Tear-off bar
Clip Ribbon cover

Figure A-2. Integrated paper roll holder
screws Paper roll holder
Remove the distributed paper roll holder

1. 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.
A-2
Paper roll holder
Figure A-3. Removing the distributed paper roll holder
b. Tilt and lift up on the distributed paper roll holder assembly to detach it from the three plastic tabs located on the bottom of the printer. 3. Reassemble.
Remove the integrated paper roll holder

1. 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 the ribbon 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 shield

1. 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.
A-3
Figure A-4. Remove the security shield
5. See Figure A-5. Note the orientation of the locking tabs on the security shield.
Figure A-5. Security shield
A-4
6. Lift the rear edge of the security shield up about 25 mm (1 in.). Slide the security shield forward slightly and lift it off of the printer.
Remove the interface assembly

The interface assembly must be removed before the power supply module can be removed, because the interface assembly covers the power supply modules cover tab and the screws that hold the top cover to the base. See Figure A-6 on page A-6 for more details. The secure seal is specified by country regulations, contact your local service planner.
A-5
Power module cover
Fiscal printer seal
Secure Screw
Figure A-6. Remove the printer seal and the secure screw from rear panel
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.
Screw
Fiscal interface assembly Power module cover
Figure A-7. Loosen the fiscal interface assembly screw and tilt the assembly to disconnect electrical connector
3. Gently tilt and lift the interface assembly out of the printer from the left side of the assembly. 4. Remove the interface power cable from the interface assembly by pressing on the tabs and pulling the connectors apart.
A-6
Figure A-8. Disconnect the electrical connectors and remove the assembly
Remove the power switch and/or cable

Ensure that the printer is powered off by unplugging the printers power cable from the wall outlet. The power on/off switch is located under the customer receipt cover in the right rear top behind the customer receipt feed button. Lift the customer receipt cover to view the power on/off switch.
A-7
On/Off switch
Figure A-9. Location of the power on/off switch
To remove, the power on/off switch, remove the covers. See Removing and replacing the printer covers on page 4-3 for information about how to remove the covers to remove the power switch. With the covers removed, the power cable is visible. The power cable runs along the middle of the printer next to the logic card. It turns downward and terminates in the bottom cavity where the power module is located. The following figures show the route of the cable.
A-8
Figure A-10. Power switch and cable with bracket
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 the main logic card and it is surrounded by other cables. The power cable is shown.
A-9
Figure A-11. Power cable beside main logic card
Remove the main logic cards using the logic cards procedure described below.
Logic card procedures Electrostatic discharge (ESD)



A-10
Logic Card Procedures
Removing and replacing the main logic and sub-logic cards and connector-attached interface card (models GR3 and GE3 for Argentina)
Note: The interface card attaches to the logic card through a connector. 1. Ensure that the printer is powered off by either powering off the system or unplugging the printers power source from the wall outlet. 2. Invert the fully assembled printer. 3. Loosen the screw that holds the interface card assembly. This releases the main 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 on page 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 for the new power cable to avoid cutting the cable when reassembling the printer.
A-11
Plastic standoffs Sub-logic card
Screws Main Logic Card
Nuts
Assembly Card Shield
Figure A-12. Removing the Printer Logic Cards
A-12
Remove the power cable

The cable is exposed when the main logic card is removed. Unplug the cable from the 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
A-13
Remove the power supply

1. 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 the interface assembly. 4. Remove the two screws at the top of the power supply module cover where the cover attaches to the base, and remove the screw that secures the mounting tab of the power module to the printer.
Screws
Power module cover Bottom view of printer
Figure A-14. Loosen the screws and lower the power module cover assembly
5. Remove the screw that secures the mounting tab of the power module to the printer. 6. Lower the power module.
A-14
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 connector to ensure that they are making the proper contact. If either wire is broken and not making good contact, you must remove the covers and replace the cable.
Figure A-15. Loosen the connectors and remove the power supply
A-15
Reassembly: 1. Install the power module assembly by reconnecting the power cable to the power modules cable. Insert the power module into the printer housing with the bottom end first. This step puts the right side tab in the groove in the base so that the fiscal interface cover can secure the base of the printer.
Screws
Power module cover Bottom view of printer
Figure A-16. Reassembly of the power module into the printer
| | |
2. Ensure that the power module tab is in the groove, and insert the screw through the 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 the secure screw.
Power module cover
Fiscal interface assembly
Figure A-17. Complete the insertion of the interface assembly housing into the printer
A-16
5. The printer is ready to be tested and the fiscal seal should be applied if the repair was successful.
A-17
A-18
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 in other countries. Consult your local IBM representative for information on the products and services currently available in your area. Any reference to an IBM product, program, or service is not intended to state or imply that only that IBM product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any IBM intellectual property right may be used instead. However, it is the users responsibility to evaluate and verify the operation of any non-IBM product, program, or service. IBM may have patents or pending patent applications covering the subject matter in this document. The furnishing of this document does not give you any license to these patents. You can send license inquiries, in writing, to: IBM Director of Licensing IBM Corporation North Castle Drive Armonk, NY 10504-1785 U.S.A. For license inquiries regarding double-byte (DBCS) information, contact the IBM Intellectual Property Department in your country or send inquiries, in writing, to: IBM World Trade Asia Corporation Licensing 2-31 Roppongi 3-chome, Minato-ku Tokyo 106, Japan The following paragraph does not apply to the United Kingdom or any other country where such provisions are inconsistent with local law: INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. Some states do 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 be incorporated in new editions of the publication. IBM may make improvements and/or changes in the product(s) and/or program(s) described in this publication at any time without notice. IBM may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. Any references in this information to non-IBM Web sites are provided for convenience only and do not in any manner serve as an endorsement of those Web sites. The materials at those Web sites are not part of the materials for this IBM product and use of those Web sites is at your own risk.
B-1
Trademarks
The following terms are trademarks of International Business Machines Corporation in the United States or other countries or both: IBM, the IBM logo, OS/2, and SureMark are trademarks of the IBM Corporation in the United States or other countries or both. Microsoft, Windows, Windows NT, and the Windows logo are registered trademarks of Microsoft Corporation. Pentium, MMX, ProShare, LANDesk and ActionMedia are trademarks or registered trademarks of Intel Corporation in the U.S. and other countries. Other company, product, and service names may be trademarks or service marks of others. Other company, product, and service names may be trademarks or service marks of others.
B-2
Electronic emission notices Federal communications commission (FCC) statement

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. IBM is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the users authority to operate the equipment. This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
Industry Canada class A emission compliance statement

This Class A digital apparatus complies with Canadian ICES-003.
Avis de conformit aux normes dIndustrie Canada

Cet appareil numrique de la classe A est conforme la norme NMB-003 du Canada.
European Union (EU) Mark of Conformity Statement

This product has been tested and found to comply with the limits for Class A Information Technology Equipment according to European Standard EN 55022. The limits for Class A equipment were derived for commercial and industrial environments to provide reasonable protection against interference with licensed communication equipment. Warning: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. Properly shielded and grounded cables and connectors must be used in order to reduce the potential for causing interference to radio and TV communications and to other electrical or electronic equipment. Such cables and connectors are available from IBM authorized dealers. IBM cannot accept responsibility for any interference caused by using other than recommended cables and connectors.
Germany
Zulassungsbescheinigung laut dem Deutschen Gesetz ber die elektromagnetische Vertrglichkeit von Gerten (EMVG) vom 30. August 1995 (bzw. der EMC EG Richlinie 89/336).
Appendix B. Notices
B-3
Dieses Gert ist berechtigt in bereinstimmung mit dem Deutschen EMVG das EG-Konformittszeichen - CE - zu fhren. Verantwortlich fr die Konformittserklrung nach Paragraph 5 des EMVG ist die IBM Deutschland Informationssysteme GmbH, 70548 Stuttgart. Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gert erfllt die Schutzanforderungen nach EN 500821 und EN 55022 Klasse A.
EN 55022 Klasse A Gerte mssen mit folgendem Warnhinweis versehen werden: Warnung: dies ist eine Einrichtung der Klasse A. Diese Einrichtung kann im Wohnbereich Funkstrungen verursachen; in diesem Fall kann vom betreiber verlangt werden, angemessene Manahmen durchzufhren und dafr aufzukommen. EN 500821 Hinweis: Wird dieses Gert in einer industriellen Umgebung betrieben (wie in EN 500822 festgelegt), dann kann es dabei eventuell gestrt werden. In solch einem Fall ist der Abstand bzw. die Abschirmung zu der industriellen Strquelle zu vergrern. Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Gerte, wie in den IBM Handbchern angegeben, zu installieren und zu betreiben.
Australia / New Zealand

Attention: This is a Class A product. In a domestic environment this product may cause radio interference, in which case the user may be required to take adequate measures.
Japanese voluntary control council for interference (VCCI) statement

This product is a Class A Information Technology Equipment and conforms to the standards set by the Voluntary Control Council for Interference by Technology Equipment (VCCI). In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.
B-4
Taiwanese class A warning statement
Korean communications statement

Please note that this device has been approved for business purposes with regard to electromagnetic interference. If you find this is not suitable for your use, you may exchange it for a non-business purpose one.

Attention: ESD damage can occur when there is a difference in charge between the part, the product, and the service person. No damage will occur if the service person 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 be connected to an ESD common ground point on the product through the ESD wrist strap and cord. The ESD ground clip can be attached to any frame ground, ground braid, green wire ground, or the round ground prong on the AC power plug. Coax or connector outside shells can also be used. 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
B-6
Part Number Index

Part Number 02L0769 02L0816 02L0816 08L1843 08L2014 10J1188 10J1565 10J1568 10J1573 13G2002 13G2034 13G2036 17P6223 17P6223 17P6224 17P6224 17P6226 17P6232 17P6232 17P6233 17P6234 17P6235 17P6236 17P6237 17P6240 17P6241 17P6242 17P6244 17P6245 30L6441 30L6442 30L6443 30L6444 30L6445 33P0171 35P0162 35P0164 35P0165 35P0168 35P0169 35P0170 35P0174 35P0175 35P0210 35P0211 35P0214 35P0215 35P0277 35P0278 35P0279 Asm Index 416 131 415 611 19 5 5 1 1 15 1 19 18 418 17 412 14 14 160 15 1614 27 29 1612 1631 1630 16 183 24 63 61 12 1223 1221 14 172 171 1 14 15 14 14 14 14 14 14 14 20 20 20 Page 7-9 7-27 7-9 7-13 7-37 7-11 7-11 7-3 7-3 7-31 7-3 7-37 7-3 7-9 7-3 7-9 7-29 7-3 7-33 7-3 7-33 7-5 7-5 7-33 7-33 7-33 7-3 7-36 7-5 7-13 7-13 7-25 7-25 7-25 7-29 7-35 7-35 7-3 7-29 7-31 7-29 7-29 7-29 7-29 7-29 7-29 7-29 7-38 7-38 7-38 Part Number 35P0280 35P0281 35P0284 35P0285 38H7504 42H1044 42H1045 42H1046 42H1047 42H1048 42H1050 42H1051 42H1052 42H1053 42H1056 42H1057 42H1058 42H1059 42H1060 42H1062 42H1063 42H1063 42H1065 42H1106 42H1107 42H1108 42H1109 42H1110 42H1111 42H1111 42H1112 42H1113 42H1114 42H1115 42H1116 42H1117 42H1118 42H1119 42H1120 42H1121 42H1128 42H1129 42H1129 42H1132 42H1132 42H1133 42H1134 42H1135 42H1136 42H1137 Asm Index 20 20 20 20 102 73 711 83 81 88 10 9 9 11 192 10 11 6 12 9 120 181 12 72 71 77 76 75 193 86 85 87 710 53 56 1010 1011 10 1111 910 69 1619 68 112 213 52 10 32 123 62 Page 7-38 7-38 7-38 7-38 7-21 7-15 7-15 7-17 7-17 7-17 7-21 7-19 7-19 7-23 7-37 7-21 7-23 7-13 7-25 7-19 7-3 7-36 7-25 7-15 7-15 7-15 7-15 7-15 7-37 7-17 7-17 7-17 7-15 7-11 7-11 7-21 7-21 7-21 7-23 7-19 7-13 7-33 7-13 7-3 7-41 7-11 7-21 7-7 7-3 7-13
C-1
Updated August 13, 2003 Part Number Asm Index 1 31 1 4 191 182 78 194 1212 195 67 8 611 19 14 1 15 15 15 15 15 15 1 214 215 1 211 198 419 4 1 196 19 10 197 19
Page 7-3 7-7 7-3 7-9 7-37 7-36 7-15 7-37 7-25 7-37 7-13 7-17 7-13 7-37 7-29 7-3 7-31 7-31 7-31 7-31 7-31 7-31 7-3 7-41 7-41 7-3 7-41 7-37 7-9 7-9 7-3 7-37 7-37 7-21 7-37 7-37
| |
| | | | | |
42H1139 42H1139 42H1140 42H1140 42H1143 42H1144 42H1145 42H1157 42H1164 42H1176 42H1180 42H1190 42H1262 47P0284 47P0293 49P6817 49P6838 49P6841 49P6842 49P8998 49P9001 49P9002 54P1585 54P1622 54P1623 54P1625 54P1625 54P1626 54P1627 54P1629 54P1669 72H3802 72H3803 73G2601 86H2192 86H2195
C-2
Index Numerics
4610 fonts and logos utility diskette 2-4 4693 Terminal Reference and Diagnostic Diskette 4694/4695 Service Diagnostic Diskette 2-1 2-1 document insert sensor assembly insert assembly 4-24 sensor spring 4-24
E A
Argentina power supply model 1-4 Attended Update Diskette 2-1 electrostatic discharge damage prevention 5-1 electrostatic discharge prevention 4-43, A-10 emulating the Model 3 or 4 printer 2-6 emulation via utility diskettes 2-6 emulation, limitations 2-6 ESD prevention 4-81
B
bar codes 1-12 button, journal station 4-71 buttons, description 6-1 buttons, how to use 6-1
F
firmware updating firmware 2-4 firmware update diskette 2-4 fiscal interface assembly, removing 4-82 fiscal interface card, removing 4-85 fiscal memory card, removing 4-88 fiscal processor card, removing 4-84 flipper cartridge 4-9 front shock mount, removing and replacing FRU removal and replacement 4-3
C
cable, printhead 4-22 cables resistance checks 4-46 card handling 4-81 card installation 4-47 check verification, printing 6-2 checks, clearing jams 6-8 cleaning, thermal printhead 6-11 clearing jams, DI station 6-8 code pages 1-12 communication interface baud rate 1-8 communication interfaces 1-6 Configure MCT Utility Diskette 2-1 cover removal latch tabs 4-4 mounting posts 4-4 customer receipt cutter motor cable resistance checks 4-46 customer receipt paper movement 4-60 cutter blade run-in 5-7 cutter problems 4-60
4-13
G
GR5 DI-Less MCT Diskette 2-1
H
handling removed cards 4-81 hardware requirements 1-11 home sensor, removing and replacing 4-11
I
information, planning 1-6 interface card assembly procedures Internet resources 1-12 introduction 1-5 4-81
D
DI forms compensation adjustment 5-2 DI open lever adjustment 5-6 DI throat, how to open 6-1 DI-Less MCT Diskette 2-1 DI-Less removing and replacing logic card procedure main logic card 4-45 reconfiguring MCT values 4-45 resistance checks for failing FRUs 4-45 differences in the models 1-4 diskette download support information 2-1 diskette update of firmware 2-4 document insert lower cover 4-9 document insert motor cable resistance checks 4-46
J
journal button 4-71 journal clutch, removing 4-79 Journal cover removal 4-3 journal cover sensor, removing 4-80 journal gear kit, removing 4-79 journal motor assembly, replacing 4-76 journal optical paper sensor, removing 4-78 journal paper movement 4-77 journal platten assembly, removing 4-75 journal printhead assembly, removing 4-73 journal printhead cover, removing 4-72 journal top cover, removing 4-71
X-1
L
latch tabs in cover removal 4-4 LED, description of 6-1 limitation model 4, bar code and check writing limitation on updating firmware 2-5 limitations for emulation 2-6 loading ribbon 6-6 1-11
R
reconfiguring MCT values for DI-Less printers 4-45 related publications and diskettes xi removing and replacing backup roller and insert assembly 4-37 bail 4-30 clip springs 4-26 connector-attached interface card 4-43, A-11 customer receipt motor 4-62 customer receipt paper bucket 4-69 customer receipt paper guide 4-67 cutter clutch 4-66 cutter gear 4-66 cutter gears 4-66 cutter stud 4-57 document insert backup roller 4-34 document insert feed motor 4-40 document insert idler gear 4-40 feed roller 4-37 flipper assembly 4-30, 4-37 hinge 4-57 ideal gear 4-60 idler gear 4-66 insert lever assembly 4-34 insert platten assembly 4-30 insert sensor assembly 4-30 journal cover 4-3 leaf spring 4-57 lower forms entry frame 4-30 main logic card 4-43, A-11 MICR 4-28 MICR read head 4-37 motor gear 4-40 operator buttons 4-8 paper cover 4-3 paper switch 4-51 pin gear 4-66 platen 4-26 platen springs 4-26 printhead shaft 4-57 printhead spacer 4-42 ribbon cover 4-3 rotating blade 4-60 rotating cutter blade 4-64 sensor assembly 4-37 spiral pin 4-66 stationary blade 4-57 stop spring 4-66 stripper 4-60 switch card 4-42 thermal cables 4-51 thermal feed gear 4-60 thermal guide 4-60 thermal platen 4-60 thermal platen assembly 4-60 thermal printhead assembly 4-57 thermal printhead drag strip 4-55 thermal printhead latch 4-53 thermal printhead latch spring 4-53 top cover 4-3 upper DI forms entry 4-30
M
main logic cable connectors resistance checks 4-46 main logic card procedure 4-43, A-10 main logic card removal and reconfiguring 4-44, A-11 MCT Utility Diskette 2-1 MCT values for DI-Less printers 4-45 messages 3-6 MICR data parser sample code 2-7 MICR reader and check flipper 3-4 MICR reader read head cleaning 6-10 Model 3 or 4 printer emulation 2-6 model 4 bar code limitations 1-11 model 4 check writing limitations 1-11 model differences 1-4 model GR3 interface assembly, removing 4-82 mounting posts 4-5
N
non-fiscal interface card, removing 4-81
O
offline testing 3-1 overview 1-5
P
planning information 1-6 posts, mounting 4-5 printer adjustments 4-47 printer resistance checks 4-45 printhead cable 4-22 printhead carriage assembly bushing 4-16 front transport bearing 4-16 front transport shaft 4-16 home sensor 4-16 printhead carriage assembly 4-16 rear transport shaft 4-16 ribbon guide 4-16 timing belt 4-16 printhead cleaning, thermal 6-11 printhead platen gap adjustment 5-4 printhead resistance checks 4-45 printhead, removing and replacing 4-10 Procedures, journal station 4-71 publications, related xi
X-2
Updated August 13, 2003 requirements for hardware 1-11 resident code pages 1-12 Retail Store Solutions Web site 1-12 ribbon drive assembly, removing and replacing ribbon drive cable resistance checks 4-46 ribbon loading 6-6 RS-232 XON/XOFF 1-7 RS485, RS232 reference diskettes 2-1 RS485, RS232 service diskettes 2-1 rubber shock mounts 4-6
4-13
S
sensor, journal cover 4-80 shock mounts, rubber 4-6 software requirements 1-11 sub-logic card removal 4-43, A-11 switch settings 4-47 symptoms 3-6
T
tabs, latch 4-5 tensioner spring 4-15 tensioner, removing and replacing 4-15 test customer receipt 3-1 document insert 3-2 testing, offline 3-1 thermal paper switch adjustment 5-10 thermal printhead adjustment 5-8 thermal/impact printers controls 6-1 indicators 6-1 throat, DI station 6-1 transport motor 4-20 transport motor cable resistance checks 4-46
U
Unattended Update Diskette 2-1 Updating firmware via RS-232 attachment 2-5
W
Web site, Retail Store Solutions 1-12
X
XON/XOFF 1-7
Index
X-3
X-4
Readers Comments Wed Like to Hear from You

4610 SureMark Three-Station Printer All Models Hardware Service Manual Publication No. GY27-0399-03 Overall, how satisfied are you with the information in this book? Very Satisfied h Satisfied h Neutral h Dissatisfied h Very Dissatisfied h
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4610 SureMark Three-Station Printer All Models

Hardware Service Manual

Updated August 13, 2003

4610 SureMark Three-Station Printer All Models

Hardware Service Manual

Updated August 13, 2003

Updated August 13, 2003

Updated August 13, 2003

. . . . 4-1 . . . . 4-2 . . . . 4-9 . . . . 4-43 . . . . 4-49 . . . . 4-71 . . . . 4-81

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Copyright IBM Corp. 2001, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

A-13. A-14. A-15. A-16. | A-17.

A-13 A-14 A-15 A-16 A-16

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Copyright IBM Corp. 2001, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Who should read this manual

Prerequisites to this manual

How this manual is organized

Related publications and diskettes

Copyright IBM Corp. 2001, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Copyright IBM Corp. 2001, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Tell us what you think

Copyright IBM Corp. 2001, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Copyright IBM Corp. 2001, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Updated August 13, 2003

Three Station Printer: Service

Updated August 13, 2003

Available model designations

Copyright IBM Corp. 2001, 2003

Updated August 13, 2003

4694 POS Terminal (RS-485) or External supply (RS-232)

POS Terminal (except Argentina supply internal to printer) POS Terminal

Pearl White Iron Gray

Litho Gray Iron Gray