service manual 4610

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4610 SureMark Three-Station Printer

All Models

Hardware Service Manual

GY27-0399-00


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4610 SureMark Three-Station Printer

All Models

Hardware Service Manual

GY27-0399-00


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Note

Before using this information and the product it supports, be sure to read Safety information on page vii and the generalinformation under Appendix. Notices on page A-1.

First Edition (March 2001)

This edition applies to the IBM SureMark 4610 Three-Station Point-of-Sale Printer.

This publication is available on the IBM Retail Store Solutions Electronic Web site.

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

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

3. SelectPublicationsto access IBM Retail Store Solutions Electronic Support Web site.

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

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

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

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

Copyright International Business Machines Corporation 1997, 2001. All rights reserved.US Government Users Restricted Rights Use, duplication or disclosure restricted by GSA ADP Schedule Contractwith IBM Corp.


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Contents

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . vWho should read this manual . . . . . . . . . . . . . . . . . . . . vPrerequisites to this manual . . . . . . . . . . . . . . . . . . . . vHow this manual is organized . . . . . . . . . . . . . . . . . . . . v

Related publications and diskettes . . . . . . . . . . . . . . . . . . vTell us what you think . . . . . . . . . . . . . . . . . . . . . . . viSafety information . . . . . . . . . . . . . . . . . . . . . . . . vii

Chapter 1. Introduction to the 4610 SureMark Three-Station Printer . . . 1-1Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Available Models . . . . . . . . . . . . . . . . . . . . . . . . 1-2Communications Overview . . . . . . . . . . . . . . . . . . . . 1-3Physical requirements . . . . . . . . . . . . . . . . . . . . . . 1-5Software Requirements . . . . . . . . . . . . . . . . . . . . . 1-7Miscellaneous Information . . . . . . . . . . . . . . . . . . . . 1-8Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Chapter 2. Installation, service, and utility software adjustments. . . . . 2-1Software adjustments (all models) . . . . . . . . . . . . . . . . . 2-14610 fonts and logos utility diskette . . . . . . . . . . . . . . . . . 2-3Firmware update (Models TN3 and TN4 only) . . . . . . . . . . . . . 2-3Emulating the IBM Model 3 or Model 4 printers. . . . . . . . . . . . . 2-5MICR data parser sample code (Model TN4 only) . . . . . . . . . . . . 2-6Resources on the Internet . . . . . . . . . . . . . . . . . . . . 2-6

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

Chapter 4. FRU removal and replacement . . . . . . . . . . . . . . 4-1Top covers procedures (Models TN3 and TN4) . . . . . . . . . . . . . 4-2Document insert station procedures . . . . . . . . . . . . . . . . . 4-9Logic cards procedure . . . . . . . . . . . . . . . . . . . . . 4-43Customer receipt station procedures . . . . . . . . . . . . . . . . 4-45Journal station procedures . . . . . . . . . . . . . . . . . . . . 4-67Interface Card Assembly Procedures . . . . . . . . . . . . . . . . 4-77

Chapter 5. Hardware adjustment procedures . . . . . . . . . . . . 5-1Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . . 5-1Mechanical adjustments . . . . . . . . . . . . . . . . . . . . . 5-2

Chapter 6. Operation. . . . . . . . . . . . . . . . . . . . . . 6-1Indicators, controls, and stationsthermal/impact printers . . . . . . . . 6-1Check verification and printing . . . . . . . . . . . . . . . . . . . 6-2Ribbon loading. . . . . . . . . . . . . . . . . . . . . . . . . 6-6Clearing jams in the check flipper area . . . . . . . . . . . . . . . . 6-8MICR reader read head cleaning . . . . . . . . . . . . . . . . . 6-10Thermal printheads cleaning . . . . . . . . . . . . . . . . . . . 6-11

Chapter 7. Parts listing . . . . . . . . . . . . . . . . . . . . . 7-1Assembly 1: Cover assembly . . . . . . . . . . . . . . . . . . . 7-2Assembly 2: Journal station cover and button assembly . . . . . . . . . 7-4

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Assembly 3: Customer receipt station operator button assembly . . . . . . 7-6Assembly 4: Logic dards and shock mounts . . . . . . . . . . . . . . 7-8Assembly 5: Document insert station . . . . . . . . . . . . . . . . 7-10Assembly 6: Customer receipt thermal printhead assembly and cover . . . . 7-12Assembly 7: Printhead transport and ribbon drive assembly. . . . . . . . 7-14Assembly 8: Impact printhead assembly . . . . . . . . . . . . . . . 7-16Assembly 9: Document insert station platen and lever . . . . . . . . . . 7-18

Assembly 10: Document insert drive shaft assembly . . . . . . . . . . 7-20Assembly 11: Document insert station gears and motor . . . . . . . . . 7-22Assembly 12: Customer receipt drive, cutter, and platen . . . . . . . . . 7-24Assembly 13: Models TN3 and TN4 interface assembly . . . . . . . . . 7-26Assembly 14: Model GR3 fiscal interface assembly . . . . . . . . . . . 7-28Assembly 15: Journal assemblyboth sides view. . . . . . . . . . . 7-30Assembly 16: Hardware Kits . . . . . . . . . . . . . . . . . . . 7-32Assembly 17: Cable assemblies, filler panel, power supply . . . . . . . . 7-34Assembly 18: Complete printer replacement as a FRU . . . . . . . . . 7-36

Appendix. Notices . . . . . . . . . . . . . . . . . . . . . . . A-1Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . A-2Electronic emission notices . . . . . . . . . . . . . . . . . . . . A-3

Japanese voluntary control council for interference (VCCI) statement . . . . A-4Taiwanese class A warning statement . . . . . . . . . . . . . . . . A-5Korean communications statement . . . . . . . . . . . . . . . . . A-5Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . . A-5

Part Number Index . . . . . . . . . . . . . . . . . . . . . . A-1

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

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Preface

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

Who should read this 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-SalePrinters: Users Guide, GA27-4291

How this manual is organized

v Chapter 1. Introduction to the 4610 SureMark Three-Station Printeron page 1-1

provides an overview of the IBM SureMark 4610 Three-Station 4610 Printer.v Chapter 2. Installation, service, and utility software adjustmentson page 2-1

provides information on installation, service, and utility software.

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

v Chapter 4. FRU removal and replacementon page 4-1 provides informationabout procedures for removing and replacing printer components. providesinformation about procedures for removing and replacing components specific tothe Model GR3fiscal printer.

v Chapter 5. Hardware adjustment procedureson page 5-1 provides informationabout procedures for operation of the printer.

v Chapter 6. Operationon page 6-1provides part numbers of the fieldreplaceable units (FRUs) for the SureMark printer.

v Appendix. Noticeson page A-1contains electronic emission notices and othergeneral information.

v Safety Informationon page 4-81contains the lithium battery safety statement.

Related publications and diskettes

v IBM 4610 SureMark Point-of-Sale Printers: Users Guide, GA27-4291

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

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

v

IBM Safety Information Read This First, GA27-4004.

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

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

Copyright IBM Corp. 1997, 2001 v


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Tell us what you think

Your feedback is important in helping us to provide the most accurate andhigh-quality information. Please take a few moments to tell us what you think aboutthis book. The only way for us to know if you are satisfied with our books, or howwe might improve their quality is through feedback from customers like you. If youhave any comments about this book, please fill out one of the forms at the back of

this book and return it by mail, by fax, or by giving it to an IBM representative. Ifapplicable, include a reference to the specific location of the text on which you arecommenting. For instance, include the page or table number. If you desire ananswer to a query, please include your name and either your address, FAX number,or telephone number.

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

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Safety information

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

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

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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 decabos e conexes em equipamentos eltricos.

Fare!Fr du installerer dette produkt, skal du lse sikkerhedsforskrifterne iSikkerhedsforskrifterLs dette frstGA27-4004. Vejledningen beskriver den

fremgangsmde, du skal bruge ved tilslutning af kabler og udstyr.

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

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VAARAEnnen kuin aloitat tmn tuotteen asennuksen, lue julkaisussa

TurvaohjeetLuetmensin, GA27-4004, olevat turvaohjeet. Tsskirjasessaon ohjeet siit, miten shklaitteet kaapeloidaan ja kytketn turvallisesti.

DangerAvant dinstaller le prsent produit, consultez le livret Informations pour lascuritLisez-moi dabord, GA27-4004, qui dcrit les procduresrespecterpour effectuer les oprations de cblage et brancher les quipementslectriques en toute scurit.

VorsichtBevor mit der Installation des Produktes begonnen wird, dieSicherheitshinweise in SicherheitsinformationenBitte zuerst lesen,IBM FormGA27-4004. Diese Verffentlichung beschreibt die Sicherheitsvorkehrungen frdas Verkabeln und Anschlieen elektrischer Gerte.

VigyzatMieltt megkezdi a berendezszembe helyezst, olvassa el a IBM SafetyInformationRead This First, GA27-4004 knyvecskben lert biztonsgiinformcikat. Ez a knyv lerja, milyen biztonsgi intzkedseket kellmegtenni az elektromos berendezs huzalozsakor illetve csatlakoztatsakor.

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Pericoloprima di iniziare linstallazione di questo prodotto, leggere le informazioni

relative alla sicurezza riportate nellopuscolo Informazioni di sicurezzaPrimeinformazioni da leggerein cui sono descritte le procedure per il cablaggio ed ilcollegamento di apparecchiature elettriche.

Fare

Fr du begynner installere dette produktet, mdu lesesikkerhetsinformasjonen 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 seguranaInformaes de SeguranaLeia Primeiro,GA27-4004. Este documentodescreve como efectuar, de um modo seguro, as ligaes elctricas dosequipamentos.

Peligro

Antes de empezar a instalar este producto, lea la informacin de seguridad enInformacin de SeguridadLea Esto Primero,GA27-4004. Este documentodescribe los procedimientos de sequridad para cablear y enchufar equiposelctricos.

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VarninglivsfaraInnan du brjar installera den hr produkten br du lsa

skerhetsinformationen i dikumentet SkerhetsfreskrifterLs detta frst,GA27-4004. Dr beskrivs hur du pett skert stt ansluter elektrisk utrustning.

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GA27-4004

GA27-4004

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Preface xv


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Chapter 1. Introduction to the 4610 SureMark Three-StationPrinter

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Available Models . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Non-fiscal printer application. . . . . . . . . . . . . . . . . . . 1-2Fiscal printer application . . . . . . . . . . . . . . . . . . . . 1-2Features available for the 4610 printer . . . . . . . . . . . . . . . 1-2Differences in the Models TN3 and TN4 Printers and the Model GR3 Printer 1-3

Communications Overview . . . . . . . . . . . . . . . . . . . . 1-3Communications requirements . . . . . . . . . . . . . . . . . . 1-3Communication interfacesfor Models TN3 and TN4 . . . . . . . . . 1-3RS-232 XON/XOFF mode selection switch . . . . . . . . . . . . . 1-4RS-232/RS-485 connections for Models TN3 and TN4 . . . . . . . . . 1-4Communication interface baud rates. . . . . . . . . . . . . . . . 1-5

Physical requirements . . . . . . . . . . . . . . . . . . . . . . 1-5Temperature and humidity limits for all Models . . . . . . . . . . . . 1-5Physical dimensions of all Models . . . . . . . . . . . . . . . . 1-5

Hardware requirements . . . . . . . . . . . . . . . . . . . . 1-7Software Requirements . . . . . . . . . . . . . . . . . . . . . 1-7

Operating system levels for Models TN3 and TN4. . . . . . . . . . . 1-7Operating system levels for Model GR3 . . . . . . . . . . . . . . 1-7

Miscellaneous Information . . . . . . . . . . . . . . . . . . . . 1-8Resident code pages . . . . . . . . . . . . . . . . . . . . . 1-8Bar Codes . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Resources on the Internet . . . . . . . . . . . . . . . . . . . 1-8

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Overview

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

Journal Feed Button

Customer Receipt Printer

Ribbon Cover(Document insert cover)

Document Printer

Printer Ready LED

Customer Receipt Feed Button

Document Present LED

Document Feed Button

Paper Cover

CustomerReceipt

Journal papercover

Figure 1-1. IBM 4610 SureMark Point-of-Sale Printer

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The dual thermal printheads enable quiet, fast printing of customer receipts andstore journals. The printer also has the capability to print and frank checks and toprint multipart forms through the document insert station. All SureMark printersprovide:v Fast quiet receipt printingv Fast quiet journal printing with a take-up spoolv Easy to load paper and easy-to-load ribbon cartridge

v Bar code generation

Only the Suremark Models TN3 and TN4 printers provide:v Dual interface support: RS-232(EIA 232) and RS-485(EIA 485)v Downloadable microcodev Downloadable fonts and code pagesv Single-pass handling of checks (Model TN4)

The SureMark Model GR3 printer provides: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.

Available Models

The IBM SureMark Three-Station printers are available for fiscal and non-fiscalapplications.

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

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

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

these Models.

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

Fiscal printer applicationThis section lists the following fiscal 4610 Model:

Model GR3 (Fiscal Printer)A printer Model that supports receipt, journal, and document

printing. This printer Model contains special hardware andmicrocode required by certain countries.

Features available for the 4610 printerThe following features are available:v 40-Character VFD Post Extensionv Distributed Printer Cable (RS-485)v Integrated Cable (RS-485)v Short RS-232 Communications Cable, 2 m (about 6.6 ft), P/N 86H2192 (TN3 and

TN4 only)

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v Long RS-232 Communications Cable, 4 m (about 13.1 ft), P/N 86H2195 (TN3and TN4 only)

v Power Supply RS-232, P/N 42H1176 (TN3 and TN4 only)v Power Cords (country-specific)v Journal Keylockv IBM 4694 Fiscal Fence (GR3 only)v Cash drawer (TN3 and TN4 only)

Differences in the Models TN3 and TN4 Printers and the Model GR3Printer

Differences between Models TN3 and TN4 of the 4610 printer and Model GR3occur in three categories:v Hardwarev Microcodev Compatability Modes

HardwareThe Model GR3 printer has a different trap door on the bottom of the printer withhardware supporting fiscal features including a fiscal seal and memory epoxied to

the circuit board.

Model GR3 supports only hardware for a RS-485 interface assembly.

MicrocodeModels TN3 and TN4 can download microcode downloads. The microcodedownload feature is not available on the GR3 Model due to the fiscal regulationslimiting code changes.

Compatibility modesModels TN3 and TN4 support Model 4 Emulation. Model 4 Emulation is notsupported in all operating system environments. Model GR3 is generally compatiblewith 3F Models. Application changes are required when printing inserted

documents.

Communications Overview

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

Communications requirementsFor Models TN3 and TN4, with RS-232 communications, a 24 V DC power supplywith 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 a RS-485 cable is required. TheRS-485 cable supplies power directly to the printer.

Models TN3 and TN4 support both RS-232 and RS-485 interfaces. The GR3 Modeldoes not support the RS-232 interface. See the 4610 Suremark Three-StationPrinter: Programming Guidefor more information about the RS-232 interface.

Communication interfaces for Models TN3 and TN4These SureMark printer Models feature a standard RS-232 and an IBM RS-485interface. RS-485 operates at a 187.5K baud rate. RS-232 (TN3 and TN4 only)

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supports 9600 and 19 200 baud rates. The baud rate is selected using SW1 - 1 onthe main logic card. The switch is located on the lower left corner of the logic cardand is accessible without removing the printer covers. SeeFigure 1-2. Set theswitch as follows:

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

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

RS-232 XON/XOFF mode selection switchThe SureMark printer, Models TN3 and TN4, supports RS-232 protocol usingDTR/DSR lines to control data transmission. It also supports XON/XOFF modes

where system and printer software control the flow of data. Select these modesusing SW1-2 on the main logic card. The switch is located on the lower left cornerof the logic card and is accessible without removing the printer covers. Set theswitch as follows:

SW1-2 OFF - DTR/DSR ControlSW1-2 ON - XON/XOFF Control (Required when using a 3-wire RS-232 cable)

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

RS-232/RS-485 connections for Models TN3 and TN4

The SureMark printer, Models TN3 and TN4, operates using either RS-232 orRS-485 communications protocol. RS-232 is typically associated with PC systems.The printer contains a 9-pin D-shell connector for RS-232 communications. Thisconnector is located on the interface card and is accessible under the printerwithout the need to remove the printer covers. The connector has the following pinfunctions:

Pin Signal Pin Signal

1 Not Connected 6 DSR

2 Transmit 7 Not Connected

RS 232ModeSwitch

CashDrawerPort

Power SupplyPort (RS 232Only)

RS 232Port

RS 485 Port

1

2

OFF

Figure 1-2. Cable Connectors and RS-232 Mode Switch for Thermal/Impact SureMark Printers. (View is from thebottom rear of the printer)



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Pin Signal Pin Signal

3 Receive 8 Not Connected

4 DTR 9 Not Connected

5 Signal Ground

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

Communication interface baud ratesAll SureMark printer Models feature an IBM RS-485 interface. RS-485 operates at a187.5K baud rate. RS-232 (TN3 and TN4 only) supports 9600 and 19 200 baudrates. Model GR3 works on RS-485 only.

Physical requirements

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

relative humidity including condensation, but excluding rain.

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

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

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

Physical dimensions of all Models

Width 322 mm (12.68 in)

Depth 258.7 mm (10.19 in)

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

Weight 6.89 kg (15.15 lb)



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Front

Top

7.48 inches(190.07 mm)

12.68 inches(322 mm)

7.48 inches

(190.07 mm)



Figure 1-3. SureMark Printer Dimensions



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Power requirements of all ModelsThe SureMark printer does not contain a power supply. When the printer isoperating in RS-232 mode, an external power supply must be attached to connectorJ2 of the interface card of the printer. This connector is located under the printerand is accessible without removing the printer covers. Connector J2 has thefollowing pin function:Pin Signal

1 +24 V dc2 Not connected3 Ground

When the SureMark printer is operating in RS-485 mode, power is supplied to theprinter from the IBM POS terminal. The terminal supplies 38V dc and 5V dc to theprinter.

Hardware requirementsSureMark printers work with the following terminals:v 4694v PC or other store controller with an RS-232Models TN3 and TN4 only with

power supply

Software Requirements

The full function of Models TN3 and TN4 is supported only in native mode withRS-232 attachment. No unique driver is required.

Operating system levels for Models TN3 and TN4Model TN3 and TN4 printers can be attached as a Model 4 printer to systemsrunning 4690 OS. When attached as a Model 4 printer, the 4610 Models TN3 barcode printing function and Model TN4 bar code printing and check handlingfunctions cannot be accessed.

Operating system levels for Model GR3Fiscal Model GR3 driver support is available on 4690 OS, POSSWIN, and DOS.The driver is the same one used for support of the Models 3F, 3FA, 3BS, 3BM, and3F2 fiscal printers.v 4690 OS V1 Level K010 or laterv 4690 OS V2R2 Level 0020 or laterv 4690 OS V2R3 Level 00A0 or laterv POSS for Windows 1.42 or laterv POSS for DOS 1.6A or later

If you use the RS-485 interface, you must use POSS or 4690 OS drivers. SeeResources on the Interneton page 1-8 for information about downloading thedrivers. If you use the RS-232 interface, use the commands described in the 4610SureMark Three-Station Printer: Programming Guide.

POSS drivers can be downloaded from the Retail Store Solutions Web site. SeeResources on the Interneton page 1-8 for more information.



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Miscellaneous Information

Resident code pagesThese code pages are resident in the Model TN3 and TN4 printers:v Genericv 437 (US)v 858 (International)v 860 (Portuguese)v 863 (Canadian French)v 865 (Norwegian)

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

For fiscal Model GR3, the code pages are controlled by the fiscal microcode.

Bar Codes

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

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

emulation mode.

Resources on the InternetThe IBM Retail Store Solutions Web site at www.ibm.com/solutions/retail/contains publications, downloads, and a knowledge base for the 4610 Printer. Onthe main page of the Web site, selectSupport. The resources that relate to the4610 Printer are found in the following areas of the page that is then displayed:v 4610 SureMark POS Printer entry in the Terminal Hardware folderv Peripheral Drivers folder, if you use RS-485 connections

Note: Published IBM manuals can be accessed using the Publications icon. Accessdiskettes, drivers, and miscellaneous documentation, such as README files

and OEM paper certification information by using the Downloads icon. TheKnowledgebase icon provides access to previously asked questions andtheir answers.

Limitations

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



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

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



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Chapter 2. Installation, service, and utility softwareadjustments

Software adjustments (all models) . . . . . . . . . . . . . . . . . 2-1Using the reference/service diskettes (RS-485 or RS-232 for TN3 and TN4

printer models) . . . . . . . . . . . . . . . . . . . . . . . 2-14610 fonts and logos utility diskette . . . . . . . . . . . . . . . . . 2-3Firmware update (Models TN3 and TN4 only) . . . . . . . . . . . . . 2-3

Using a firmware update diskette . . . . . . . . . . . . . . . . . 2-3Updating Models TN3 and TN4 firmware using temporary RS-232

attachment . . . . . . . . . . . . . . . . . . . . . . . . 2-4Limitation on updating firmware on Models TN3 and TN4 . . . . . . . . 2-4

Emulating the IBM Model 3 or Model 4 printers. . . . . . . . . . . . . 2-5Enabling emulation using utility diskettes . . . . . . . . . . . . . . 2-5Limitations for emulation . . . . . . . . . . . . . . . . . . . . 2-5

MICR data parser sample code (Model TN4 only) . . . . . . . . . . . . 2-6Resources on the Internet . . . . . . . . . . . . . . . . . . . . 2-6

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

Software adjustments (all models)

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

Using the reference/service diskettes (RS-485 or RS-232 for TN3 and

TN4 printer models)1. Load the reference/service diskette. See the hardware service manual for your

system for reference/service diskette procedures.

2. SelectTest Menu.

3. SelectRun POS Device Testsfor an RS-485 connection. SelectRS232 4610Printer Testfor an RS-232 connection.

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

5. SelectPrinter Utilities.

6. Select the adjustment you want to make from the menu.v Print current adjustment values

v Character alignment procedurev DI front load print line adjustmentv Document landscape adjustmentv Engineering use onlyv Change 4610 Model Configurationv Reset printer statistics

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

8. PressS1(Escon the Enhanced A/N Keyboard) to return to the previous menu.



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CURRENT ADJUSTMENT VALUESH 5 = Character alignment

TL5 = Top line front insertBL3 = Bottom line top insert

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

5 = selected line

CHARACTER ALIGNMENT PROCEDURE

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

TL1

TL4

TL7

TL2

TL5

TL8

TL3

TL6

TL9

Figure 2-1. Adjustment and Alignment Printouts

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4610 fonts and logos utility diskette

This utility is for both RS-232 and RS-485 operation. You can download the utilityfrom the Retail Store Solutions Web site.

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

messagesv Convert fonts and logo files from impact to thermal

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

Firmware update (Models TN3 and TN4 only)

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

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

v Firmware update diskettes

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

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

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

1. Download the latest level of firmware update diskette from the Web. You canselect from several update methods, including attended, unattended, andautomatic.

2. Insert the firmware update diskette in drive A.

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

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

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

a. PressEnter(OK) at the logo screen to proceed.

b. Choose connection type (RS-485 or RS-232). For RS-232 connections, alsomake the following selections (refer to the communications mode selectionsswitches, located on the bottom rear of the SureMark printer, to determinethe 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. PressEnter(OK) to proceed.

d. PressF10(Menu).

Software Adjustments

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


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e. SelectO(Operations).

f. SelectA(Advanced Options).

g. SelectU(Update Firmware).

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

i. PressEnter(YES) again to commit to firmware update.

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

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

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

7. Remove the diskette from drive A.

8. PressCtrl-Alt-Delto reboot the system.

Updating Models TN3 and TN4 firmware using temporary RS-232attachment

To use the firmware update diskettes to update SureMark printer firmware forconfigurations that donothave a diskette drive and PC display and keyboard, youmust provide a temporary RS-232 attachment to a host PC that does have adiskette drive.

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

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

v

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

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

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

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

host PC that has a diskette drive.3. Follow the procedure inUsing a firmware update disketteon page 2-3, 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 TN3 and TN4The following limitation must be considered when updating firmware on theSureMark printer:

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

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firmware update is complete, re-enable Model 4 emulation. SeeEmulating theIBM Model 3 or Model 4 printersfor additional information.

Emulating the IBM Model 3 or Model 4 printers

It is possible to emulate the IBM Model 3 or Model 4 printer with the SureMarkprinter. You must change the configuration to enable the SureMark printer 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 theConfigure MCT Utility Diskette. Download the latest-level diskette from the RetailStore Solutions Web site.

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

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

Note: All SureMark printer firmware levels support emulation.

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

1. Insert the utility diskette in drive A.

2. Power on the system unit.

3. SelectMOD4when 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 isreconfigured.2. PressCtrl-Alt-Deleteto reboot the system. The system IPLs.

To disable when emulation is currently enabled:

1. Select Disable Model 4 emulation.2. EnterCtrl-Alt-Deleteto reboot the system. The system IPLs.

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

v Printing the face of checks requires application changes (franking the back 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 47characters.

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

v User-defined special characters are not supported.

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

Firmware Update (non-fiscal)

Chapter 2. Installation, service, and utility software adjustments 2-5


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MICR data parser sample code (Model TN4 only)

The MICR data parser download package includes:

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

v An exception data file that is used with the parsing code. You can edit this file to

add new check formats, if necessary.

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

Resources on the Internet

The IBM Retail Store Solutions Web site, www.ibm.com/solutions/retail/, containspublications for the SureMark printer. The Web site also provides access todiskettes, drivers, and miscellaneous publications, such as README files andinformation about OEM papers that have been certified.

SelectSupportat the left on the main page of the Web site, then select IBMSureMark Printer. The displayed page contains links both to publications and to

diskettes and drivers that you can download for the SureMark printers.

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Chapter 3. Problem determination for the 4610 Three-StationPrinter

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

Customer receipt test . . . . . . . . . . . . . . . . . . . . . 3-1Journal station test . . . . . . . . . . . . . . . . . . . . . . 3-1Document insert test . . . . . . . . . . . . . . . . . . . . . 3-2MICR reader and check flipper test (Model TN4 only) . . . . . . . . . 3-4

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

Fiscal unit return codes

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

1. Go towww.ibm.com/solutions/retail/store

2. Select Supportat the left on the main page of the web site

3. Select Publicationsto access IBM Retail Store Solutions Electronic Supportpublications.

Offline tests

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

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

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

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

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

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

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

If any characters that appear inFigure 3-1 on page 3-3are missing from the testpattern you print, or if the solid line is missing, go to Symptomson page 3-6.

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

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

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

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

9600 or 19 200 baud rate



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DTR/DSR or XON/XOFF controlv A solid line should appear as the last line of the test pattern.


Document insert test

1. Insert a document in the Document Insert station. The Document Presentindicator should come on.

v If the Document Present indicator does not come on, realign the document. Ifthe Document Present indicator still does not come on, go to Documentsensor threshold reseton page 5-11.

v If pressing the document feed button does not feed the document, go toSymptomson page 3-6.

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

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

4. See Figure 3-1 on page 3-3 and verify that your printer has printed correctinformation for your model and configuration:v Model type (MICR reader enabled, check flipper enabled for Model TN3 or

Model TN4)v Communication options (RS-232 or RS-485)v RS-232 parameters, if applicablev A solid line should appear as the last line of the test pattern


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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.

3. The serial interface will be specified asRS232orRS485, depending on whichinterface is used to attach the printer to the system unit.

4. The line speed information appears only when the RS-232 interface is used.The value can be either9.6K baudor19.2K baud, depending on the RS-232switch settings. (SeeRS-232 XON/XOFF mode selection switchonpage 1-4.)

5. RS-232 is not supported on Model GR3.

6. The RS-232 control mode information appears only when the RS-232 interfaceis used. The value can be either DTR/DSRorXON/XOFF, depending on the

RS-232 switch settings.7. The feature enabled lines will appear only when the feature is installed.

8. These lines break at different points for the test pattern printed in thedocument insert (DI) station.

9. This section contains printer usage statistics that you can use for problemdetermination. (This information is not printed on Model TN3.)

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

The Printers S/N is 1234567

Microco de EC level is 30

Serial Interface: RS232: 19.2K Baud, XON / XOFFMICR reader enabledCheck Flipper enabled|"#$%&'()*+,-./0123456789:;?ABCDEFGHIKJKLMNOPQRSTUVWXYZ[\]^_ abcdefghijklmnopqrstuvwxyz{|}~.CcSs Gg H I II

Cuts: 125850CR Characters Printed: 142834CR Motor Steps: 659340CR Cover Openings: 593DI Characters Printed:

DI Feed Motor Steps:DI Transpor t Motor Passes:DI Home Errors:DI Cover Opening s:DI Documents Inserted:MICR Reads:High Interference MICR Reads:MICR Read Failures:

Serial Interface

II OO UUUyY

Serial nterface

1

3

9

8

2

6

7

`` ` ^^ ` `

4 5,

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

Offline Test

Chapter 3. Problem Determination for All Models 3-3


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MICR reader and check flipper test (Model TN4 only)

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

1. Insert the check face down with the magnetic ink characters to the right.2. Press and hold both buttons to enter offline mode. When the printer 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 customerreceipt and the check is flipped over. Go toSymptomson page 3-6 if:

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

v Question marks or anXappear in the printed line.

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

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

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

Figure 3-2. MICR Reader Test ResultsGood Noise Level

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Figure 3-3. MICR Reader Test ResultsNoise Level Needs Adjusting

Offline Test



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Symptoms

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

Table 3-1. Printer Symptoms or Messages

Symptom Repair actions listed in most likely order of failure

Printer does not power ON (All LEDs are

off).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 toRemoving and replacingthe main logic and sub-logic cards and connector-attached interfacecard (Models TN3 and TN4)on page 4-43.

4. Exchange the main logic card. Go toRemoving and replacing themain logic and sub-logic cards and connector-attached interface card(Models TN3 and TN4)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 toRemoving and replacing the switchcard and printhead spaceron page 4-42.

4. Exchange the main logic card. Go toRemoving and replacing themain logic and sub-logic cards and connector-attached interface card(Models TN3 and TN4)on page 4-43.

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

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

3. Ensure that the covers are closed.

4. Adjust the thermal paper switch. Go toThermal paper switchadjustmenton page 5-10.

5. Run the printer offline tests. Go toOffline testson page 3-1.

Customer receipt (thermal) does notadvance paper.

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

2. Go toCustomer receipt paper movement and cutter problemsonpage 4-56to isolate the problem.

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

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

Customer receipt cutter does not workcorrectly.

1. Check that the paper is loaded correctly.

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

3. Perform the cutter blade run-in procedure. Go toCutter blade run-inon page 5-7.

4. If paper is folded or partially cut, go toCustomer receipt papermovement and cutter problemson page 4-56.

Customer receipt (thermal) is missingcharacter dots. 1. Check to see if the thermal paper is correctly installed.

2. Check to see if the printhead cables are seated correctly. Go toRemoving and replacing the thermal printhead assemblyonpage 4-53.

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

4. Adjust the printhead. Go toThermal printhead adjustment forcustomer receipt and journal stationon page 5-8.

5. Exchange the CR (thermal) latch and print assembly. Go toRemoving and replacing the thermalprinthead latchon page 4-49.

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


Journal station (thermal) does notadvance paper.

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

2. Go toJournal station paper movementon page 4-73to isolate theproblem.

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

Check for paper jams.

Journal station (thermal) is missingcharacter dots.

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

2. Check to see if the printhead cables are seated correctly. Go toRemoving and replacing thermal printhead assemblyon page 4-69.

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

4. Adjust the printhead. Go toThermal printhead adjustment forcustomer receipt and journal stationon 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 toPrinthead platengap adjustmenton page 5-4.

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

4. Check the printhead for bent print wires. Remove the printhead (seeRemoving and replacing the printheadon page 4-10) for access.

5. Exchange the printhead. Go toRemoving and replacing theprintheadon page 4-10.

6. Exchange the logic card. Go toRemoving and replacing the mainlogic and sub-logic cards and connector-attached interface card(Models TN3 and TN4)on page 4-43.

7. Exchange one or more of the following components: DI gears, DI feedroll shaft assembly, and feedroll assembly. Go to Removing andreplacing the printhead carriage assemblyon page 4-16 andRemoving and replacing the cutter gears and cutter clutchonpage 4-62.

DI station does not advancedocument/check.

1. Check the paper feed throat for an obstruction.

2. Ensure that the gear train is free.

3. Check the DI open lever adjustment. Go toDocument insert openlever adjustmenton page 5-6.

4. Ensure that the DI forms compensation is correctly set. Go toDIforms compensation adjustmenton page 5-2.

5. Exchange the DI motor. Go toRemoving and replacing the documentinsert motor and gearson page 4-40.

6. Exchange the DI gears, DI feed roll shaft assembly, and feedrollassembly. Go toRemoving and replacing the printhead carriage

assemblyon page 4-16and Removing and replacing the cuttergears and cutter clutchon page 4-62.

7. Replace the main logic card. Go toRemoving and replacing the mainlogic and sub-logic cards and connector-attached interface card(Models TN3 and TN4)on page 4-43.

Symptoms



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DI (impact) printhead does not movecorrectly.

1. Ensure that the printhead path is free.

2. Check that the transport shafts are not loose.

3. Check the timing belt assembly. If you need to exchange it, go toRemoving and replacing the printhead carriage assemblyon

page 4-16.

4. Check the tensioner. If you need to exchange it, go toRemoving andreplacing the tensioneron page 4-15.

5. Check the home sensor cable for continuity.

6. Exchange the home sensor (seeRemoving and replacing the homesensoron page 4-11).

7. Exchange the transport motor. Go toRemoving and replacing thetransport motoron page 4-20.

8. Replace the main logic card. Go toRemoving and replacing the mainlogic and sub-logic cards and connector-attached interface card(Models TN3 and TN4)on page 4-43.

Ribbon does not advance. 1. Exchange the ribbon cartridge. Go toRibbon loadingon page 6-6.

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

3. Check the printhead gap and ribbon guide. Go toPrinthead platengap adjustmenton page 5-4.

4. Exchange the ribbon drive assembly. Go toRemoving and replacingthe transport motoron page 4-20.


Printer Ready and/or Document PresentLEDs are blinking.

1. Press the customer receipt feed button.

2. Check the paper supply.

3. Ensure that both covers are closed.4. Run the printer offline tests. Go toOffline testson 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 properlyto the logic card.

9. Verify that the journal stations sensor screw is tight.

10. Replace the journal stations sensor switch.

MICR does not read correctly. 1. Clean the MICR head with cleaning card. Go toMICR reader readhead cleaningon 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 toFigure 4-18 on page 4-25.)

4. Exchange the MICR read head. Go toRemoving and replacing theMICR read headon page 4-28.

5. Exchange the pressure pad. Go toRemoving and replacing thedocument insert sensor assemblyon page 4-24.


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

2. Remove any debris.

3. Using brush, clean belts of any dust.

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

5. Exchange the flipper cartridge assembly. Go toRemoving andreplacing the document insert lower cover and flipper cartridgeonpage 4-9.

6. Exchange the flipper drive assembly. Go toRemoving and replacingthe lower forms entry frame or flipper assemblyon page 4-30.

DI not moving documents correctly. Perform the DI forms compensation adjustment procedure. Go toDIforms compensation adjustmenton page 5-2.

Uneven print on receipt. Go toThermal printhead adjustment for customer receipt and journalstationon page 5-8.

T7151 Printer card or cable is failing.1. Check or exchange the printer interface cable.2. Exchange the printer main logic card. Go toRemoving and replacing

the main logic and sub-logic cards and connector-attached interfacecard (Models TN3 and TN4)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 toRemoving and replacing theprinthead carriage assemblyon page 4-16.

5. Exchange the logic card.

6. Exchange the transport motor. Go toRemoving and replacing thetransport motoron page 4-20

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

2. Exchange the ribbon cover. Go toRemoving and replacing the printercoverson page 4-2.


T7156 Document is inserted in the printerand printer fails.

1. Check for obstructions.

2. Rerun the diagnostic test.

3. Exchange the DI sensor, then reset the sensor threshold. Go toRemoving and replacing the document insert sensor assemblyonpage 4-24, thenDocument sensor threshold reseton page 5-11.

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

1. Exchange the document and run the test again.

2. Exchange the DI sensor. Reset the sensor threshold. Go toRemoving and replacing the document insert sensor assemblyonpage 4-24, thenDocument sensor threshold reseton page 5-11.

T7159 EEPROM error. Exchange the main logic card. Go toRemoving and replacing the mainlogic and sub-logic cards and connector-attached interface card (ModelsTN3 and TN4)on page 4-43.

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

T7163 Flipper error. SeeFlipper is not workingsymptom.

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Chapter 4. FRU removal and replacement

Top covers procedures (Models TN3 and TN4) . . . . . . . . . . . . . 4-2Removing and replacing the printer covers . . . . . . . . . . . . . 4-2Removing and replacing the top cover operator buttons . . . . . . . . 4-8

Document insert station procedures . . . . . . . . . . . . . . . . . 4-9Removing the Document Insert Station Cover . . . . . . . . . . . . 4-9Removing and replacing the document insert lower cover and flipper

cartridge . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Removing and replacing the printhead . . . . . . . . . . . . . . 4-10Removing and replacing the home sensor . . . . . . . . . . . . . 4-11Removing and replacing the ribbon drive assembly . . . . . . . . . . 4-13Removing and replacing the tensioner . . . . . . . . . . . . . . 4-15Removing and replacing the printhead carriage assembly . . . . . . . 4-16Removing and replacing the transport motor . . . . . . . . . . . . 4-20Removing and replacing the printhead cable . . . . . . . . . . . . 4-22Removing and replacing the document insert sensor assembly . . . . . 4-24Removing and replacing the document insert platen assembly. . . . . . 4-26

Removing and replacing the MICR read head . . . . . . . . . . . . 4-28Removing and replacing the lower forms entry frame or flipper assembly 4-30Removing and replacing the document insert backup roller and insert lever

assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-34Removing and replacing the document insert (DI) feed roller . . . . . . 4-37Removing and replacing the document insert motor and gears . . . . . 4-40Removing and replacing the switch card and printhead spacer . . . . . 4-42

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

connector-attached interface card (Models TN3 and TN4) . . . . . . 4-43Customer receipt station procedures . . . . . . . . . . . . . . . . 4-45

Removing the customer receipt station cover . . . . . . . . . . . . 4-45

Removing and replacing the thermal cables and paper switch . . . . . . 4-47Removing and replacing the thermalprinthead latch . . . . . . . . . 4-49Removing and replacing the thermal printhead drag strip. . . . . . . . 4-51Removing and replacing the thermal printhead assembly. . . . . . . . 4-53Removing and replacing the thermal platen assembly . . . . . . . . . 4-56Customer receipt paper movement and cutter problems . . . . . . . . 4-56Removing and replacing the customer receipt motor . . . . . . . . . 4-58Removing and replacing the rotating cutter blade and thermal guide . . . 4-60Removing and replacing the cutter gears and cutter clutch . . . . . . . 4-62Removing and replacing the customer receipt paper guide . . . . . . . 4-63Removing and replacing the customer receipt paper bucket. . . . . . . 4-65

Journal station procedures . . . . . . . . . . . . . . . . . . . . 4-67Removing the journal station cover . . . . . . . . . . . . . . . . 4-67

Removing and replacing the journal station button . . . . . . . . . . 4-67Removing and replacing the journal printhead cover assembly . . . . . 4-67Removing and replacing thermal printhead assembly . . . . . . . . . 4-69Removing and replacing the platen assembly . . . . . . . . . . . . 4-70Removing and replacing the journal motor assembly . . . . . . . . . 4-72Journal station paper movement . . . . . . . . . . . . . . . . . 4-73Removing and replacing the optical paper sensor . . . . . . . . . . 4-74Removing the gear kit with clutch and E-clip . . . . . . . . . . . . 4-75Removing and replacing the journal cover sensor switch . . . . . . . . 4-76

Interface Card Assembly Procedures . . . . . . . . . . . . . . . . 4-77Electrostatic discharge (ESD) . . . . . . . . . . . . . . . . . . 4-77



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Removing and replacing the Interface card Assembly (models TN3 andTN4) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Removing and replacing the Model GR3 fiscal interface assembly . . . . 4-78

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

??

For the Model GR3,. See Figure 4-64 on page 4-78.

For the Model GR3, you must remove the fiscal interface assembly in order toremove the two top cover retention screws. Removal of the two screws isessential to the removal of the top cover. See Removing the Model GR3 fiscalprinter coveron page 4-84

.

Top covers procedures (Models TN3 and TN4)

The paper cover refers to the cover for the customer receipt station. The ribboncover refers to the cover for the document insert station. These terms are usedinterchangeably and are shown. These covers are shown below in figure Figure 4-1on page 4-3.

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

journal station.

Removing and replacing the printer covers

Important

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

Removing the printer cover1. 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 onpage 4-4.

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

3. Open the customer receipt paper cover. Place the top of a screwdriver handlebetween the side of the printer and the top cover. Then close the top cover on



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the screwdriver, do this one side at a time. This frees the pivots on both sides.Slide the paper cover forward and out. See figureFigure 4-1.

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

Note: When reassembling, be sure that the clear plastic paper guide is inserted

through the slot in the paper cover.

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 therubber grommet from the binding post.

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

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

Figure 4-1. Removing the Paper and Ribbon Covers

Top Covers

Chapter 4. Cover removal and replacement 4-3


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9. Reassemble.

Latch tabs

Figure 4-2. Release the Rear Latch Tabs

Top Covers



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After completing this procedure, return to the procedure you were performing fromthe following list:v Removing and replacing the top cover operator buttonson page 4-8v Removing and replacing the printheadon page 4-10v Removing and replacing the home sensoron page 4-11v Removing and replacing the ribbon drive assemblyon page 4-13v Removing and replacing the tensioneron page 4-15v Removing and replacing the printhead carriage assemblyon page 4-16v Removing and replacing the transport motoron page 4-20v Removing and replacing the printhead cableon page 4-22v Removing and replacing the document insert sensor assemblyon page 4-24v Removing and replacing the document insert platen assemblyon page 4-26v Removing and replacing the MICR read headon page 4-28v Removing and replacing the lower forms entry frame or flipper assemblyon

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

assemblyon page 4-34v Removing and replacing the document insert (DI) feed rolleron page 4-37v Removing and replacing the document insert motor and gearson page 4-40v Removing and replacing the switch card and printhead spaceron page 4-42v Removing and replacing the main logic and sub-logic cards and

connector-attached interface card (Models TN3 and TN4)on page 4-43

Top Cover

Mounting Post

Gasket

Latch

Figure 4-4. Removing the Top Cover

Top Covers



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Removing and replacing the top cover operator buttons

Important

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

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

2. Remove the covers. Go toRemoving and replacing the printer coversonpage 4-2and then return to this procedure.

3. On the under side of the base cover, press both sides of the key switch latchinward and lift the buttonout. SeeFigure 4-5.

4. Reassemble.

Insulator

Switch Card

Hex Screw

Printhead Spacer

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

Top Covers



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Document insert station procedures

Removing the Document Insert Station CoverOpen thedocument insert coverusing the lift tab. From the right side, push thedocument insert cover towards the left side while pressing the lock tab, and removethe cover.

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

Removing and replacing the document insert lower cover and flippercartridge

Important

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

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

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

3. Use the lift tab to remove theflipper cartridge.

4. Reassemble.

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

Document Insert Station Procedures



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Removing and replacing the printhead

Important

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

After completing this procedure, return to the procedure you were performing fromthe following list:v Removing and replacing the lower forms entry frame or flipper assemblyon

page 4-30


2. Open the ribbon cover. Go toRemoving and replacing the printer coversonpage 4-2and then return to this procedure.

3. Remove the ribbon cartridge.

4. Remove the mounting screw from the printhead. SeeFigure 4-7.

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

6. Remove any dust from the home sensor.

7. Reassemble.

8. Adjust the printhead gap. Go toPrinthead platen gap adjustmenton page 5-4and then return to this procedure.

9. When you replace the impact printhead, run the service diskette and selectReset Statisticsfor the FRU. See Software adjustments (all models)onpage 2-1.

Figure 4-7. Replacing the Printhead




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Removing and replacing the home sensor

Important

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


2. Open the document insert ribbon cover. Go toRemoving and replacing theprinter coverson page 4-2and then return to this procedure.

3. Remove the ribbon cartridge.

4. Disconnect the home sensor cable. SeeFigure 4-8.

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

6. Loosen the home sensor mounting screw.

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

8. Reassemble.

Figure 4-8. Disconnecting the Home Sensor




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Figure 4-9. Replacing the Home Sensor




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Front Shock Mount

Ribbon Drive Assembly

Ribbon Drive Assembly Cable

Main Logic

Printer Assembly

Figure 4-10. Removing the Ribbon Drive Assembly




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Removing and replacing the tensioner

Important

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


2. Open the ribbon cover.

3. Position the carriage assembly in the center. SeeFigure 4-11.

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

5. Remove thetensioner spring.

6. Remove thetensionerby sliding it towards the right and lifting it out.

7. Reassemble.

8. Run one of the 4610 diagnostic and adjustment utilities. SeeSoftwareadjustments (all models)on page 2-1for additional information and return here.

Timing Belt

Tensioner

Tensioner Spring

Transport Motor

Figure 4-11. Removing the Tensioner




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Removing and replacing the printhead carriage assembly

Important

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

After completing this procedure, return to the procedure you were performing fromthe following list:v Removing and replacing the home sensoron page 4-11v Removing and replacing the printhead carriage assemblyon page 4-16


2. Remove the cover. Go toRemoving and replacing the printer coversonpage 4-2and then return to this procedure.

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

4. Push thetensionerinward and remove thetiming beltfrom the transportmotor pulley. SeeFigure 4-12 on page 4-17.

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

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

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

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

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

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

10. Remove thetiming beltfrom theprinthead carriage assembly. SeeFigure 4-12 on page 4-17 and Figure 4-14 on page 4-18.

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

12. Remove thefront transport carrier bearing. SeeFigure 4-14 on page 4-18.

13. Reassemble.

14. Adjust the printhead.

15. Run one of the 4610 diagnostic and adjustment utilities. SeeSoftwareadjustments (all models)on page 2-1and then return to this procedure.




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Right Eccentric

Front Carrier Bearing

Printer Carriage Assembly

Ribbon Guide

LeftPrintheadGap Eccentric

Printhead GapEccentric Detail

Rear Transport Shaft

FrontTransport Shaft

Screw

Backup Roller

Slot

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




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Figure 4-15. Removing the Front Transport Carrier Bearing




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Removing and replacing the transport motor

Important

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


2. Remove the cover. Go toRemoving and replacing the printer coversonpage 4-2and return to this procedure.

3. Remove the ribbon drive assembly. Go toRemoving and replacing the ribbondrive assemblyon page 4-13.

4. Disconnect the printhead cable from the main logic card. Go toRemoving andreplacing the printhead cableon page 4-22.

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

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

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

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

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

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

10. Reassemble.

11. If the transport shaft was removed, adjust the printhead gap. Go toPrintheadplaten gap adjustmenton page 5-4.

12. When you replace the transport motor, run the service diskette and selectReset Statisticsfor the FRU. See Software adjustments (all models)onpage 2-1.




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Transport Motor

Figure 4-16. Removing the Transport Motor




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Removing and replacing the printhead cable

Important

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

After completing this procedure, return to the procedure you were performingfrom the following list:v Removing and replacing the transport motoron page 4-20v Removing and replacing the MICR read headon page 4-28


2. Remove the cover. Go toRemoving and replacing the printer coversonpage 4-2and then return to this procedure.

3. Remove the ribbon drive assembly. Go toRemoving and replacing the ribbondrive assemblyon page 4-13.

4. Disconnect theprinthead cablefrom the main logic card.

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

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

7. Peel the adhesive loose from the frame.

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

9. Pull theprinthead cablethrough and out of the frame.

Note: Take note of how the cable is route