gab0_4610_service_mst.pdf

SureMark 4610 Printers

Hardware Service Guide for Models 2CR and 2NR

GA27-5004-00

Note Before using this information and the product it supports, be sure to read IBM Safety InformationRead This First, GA27-4004. and Appendix C, Notices, on page 87.

First Edition (July, 2008) This edition applies to IBM SureMark Printer Models 2CR and 2NR. Current versions of Retail Store Solutions documentation are available on the IBM Retail Store Solutions Web site at http://www.ibm.com/solutions/retail/store/support/. Click Publications. 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 Retail Store Solutions Information Development Department ZBDA PO Box 12195 Research Triangle Park, North Carolina 27709 USAWhen 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 2008. US Government Users Restricted Rights Use, duplication or disclosure restricted by GSA ADP Schedule Contract with IBM Corp.

Contents Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

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

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Who should read this guide . . . . . . . . . . . . . . . . . . . . xi How this guide is organized . . . . . . . . . . . . . . . . . . . . xi Related publications . . . . . . . . . . . . . . . . . . . . . . . xi Publications accessibility . . . . . . . . . . . . . . . . . . . . . xi Providing feedback . . . . . . . . . . . . . . . . . . . . . . . . xi

Chapter 1. Introducing the 4610 Models 2CR and 2NR . . . . . . . . . 1 Models and features . . . . . . . . . . . . . . . . . . . . . . . 1 Warranty information . . . . . . . . . . . . . . . . . . . . . . . 3 Communication and power . . . . . . . . . . . . . . . . . . . . . 3

Locating the power button . . . . . . . . . . . . . . . . . . . . 5 Operating system requirements . . . . . . . . . . . . . . . . . . . 5

RS-232 interface . . . . . . . . . . . . . . . . . . . . . . . . 5 RS-485 interface . . . . . . . . . . . . . . . . . . . . . . . . 5 USB interface . . . . . . . . . . . . . . . . . . . . . . . . . 6 4690 OS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Hardware requirements . . . . . . . . . . . . . . . . . . . . . . 6 Calling for service . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 2. Removing and replacing FRUs . . . . . . . . . . . . . . 9 Handling static-sensitive devices . . . . . . . . . . . . . . . . . . . 9 Reviewing the FRUs and connections . . . . . . . . . . . . . . . . . 9

Identifying the cable connections . . . . . . . . . . . . . . . . . 11 Removing the logic card . . . . . . . . . . . . . . . . . . . . . 12 Removing the interface card . . . . . . . . . . . . . . . . . . . . 14 Removing the thermal printhead assembly . . . . . . . . . . . . . . . 15 Removing the covers . . . . . . . . . . . . . . . . . . . . . . 16

Removing the paper door . . . . . . . . . . . . . . . . . . . . 16 Removing the ribbon door . . . . . . . . . . . . . . . . . . . . 18 Removing the main cover . . . . . . . . . . . . . . . . . . . . 19 Removing the flipper door (document insert cover) . . . . . . . . . . . 20 Removing the skirt cover . . . . . . . . . . . . . . . . . . . . 21

Removing the distribution card . . . . . . . . . . . . . . . . . . . 22 Removing the flipper cartridge . . . . . . . . . . . . . . . . . . . 23 Removing the thermal printhead cable . . . . . . . . . . . . . . . . 24 Removing the impact printhead and carriage assembly . . . . . . . . . . 25 Removing the impact printer transport . . . . . . . . . . . . . . . . 27 Removing the transport motor . . . . . . . . . . . . . . . . . . . 29 Removing the upper throat assembly . . . . . . . . . . . . . . . . . 31 Removing the impact platen assembly . . . . . . . . . . . . . . . . 33 Removing the thermal latch assembly . . . . . . . . . . . . . . . . 37 Removing the ribbon drive assembly . . . . . . . . . . . . . . . . . 39 Removing the document paper-feed motor and gears . . . . . . . . . . . 40 Removing the tear bar assembly . . . . . . . . . . . . . . . . . . 41 Removing the paper stage, rollers and lift spring . . . . . . . . . . . . 42 Removing the thermal cutter assembly . . . . . . . . . . . . . . . . 43 Removing the thermal paper feed motor and gear . . . . . . . . . . . . 45 Removing the paper-out (paper-motion) sensor assembly . . . . . . . . . 46

Copyright IBM Corp. 2008 iii

Removing the low-paper sensor cards . . . . . . . . . . . . . . . . 47 Removing the grounding strap . . . . . . . . . . . . . . . . . . . 49 Removing the flipper springs and rollers . . . . . . . . . . . . . . . 51 Removing the main frame assembly . . . . . . . . . . . . . . . . . 51

Chapter 3. Adjusting and maintaining the 4610 . . . . . . . . . . . . 53 Adjusting the printhead gap . . . . . . . . . . . . . . . . . . . . 53 Using and maintaining the 4610 . . . . . . . . . . . . . . . . . . 55

Replenishing consumable supplies . . . . . . . . . . . . . . . . 55 Correctly inserting documents . . . . . . . . . . . . . . . . . . 62 Cleaning recommendations . . . . . . . . . . . . . . . . . . . 63 Clearing jams in the check flipper area . . . . . . . . . . . . . . . 66

Chapter 4. Running tests and diagnostics . . . . . . . . . . . . . . 69 Testing the 4610 . . . . . . . . . . . . . . . . . . . . . . . . 69

Firmware offline tests . . . . . . . . . . . . . . . . . . . . . 70 Understanding the Light-Path LEDs . . . . . . . . . . . . . . . . . 75 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 76

Appendix A. Product specifications . . . . . . . . . . . . . . . . 77 Physical dimensions . . . . . . . . . . . . . . . . . . . . . . . 77 Temperature and humidity limits . . . . . . . . . . . . . . . . . . 77 Connector pin assignments . . . . . . . . . . . . . . . . . . . . 78

Power supply . . . . . . . . . . . . . . . . . . . . . . . . 78 USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Powered USB . . . . . . . . . . . . . . . . . . . . . . . . 78 RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Cash drawer . . . . . . . . . . . . . . . . . . . . . . . . . 79

Printing width, speed, and acoustics . . . . . . . . . . . . . . . . . 80 Bar codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Resident code pages . . . . . . . . . . . . . . . . . . . . . . 82

Appendix B. Parts listing . . . . . . . . . . . . . . . . . . . . 83 How to use the FRU catalog . . . . . . . . . . . . . . . . . . . . 83 Assembly 1: Models 2CR and 2NR . . . . . . . . . . . . . . . . . 84

Appendix C. Notices . . . . . . . . . . . . . . . . . . . . . . 87 Electronic emission notices . . . . . . . . . . . . . . . . . . . . 89

Federal Communications Commission (FCC) statement . . . . . . . . . 89 European Union EMC Directive conformance statement . . . . . . . . . 89 Industry Canada Class A Emission Compliance statement . . . . . . . . 90 Avis de conformit aux normes dIndustrie Canada . . . . . . . . . . 90 Germany . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Australia and New Zealand . . . . . . . . . . . . . . . . . . . 90 Chinese Class A warning statement . . . . . . . . . . . . . . . . 91 Japanese power line harmonics compliance statement . . . . . . . . . 91 Japanese Voluntary Control Council for Interference (VCCI) statement . . . 91 Korean communications statement . . . . . . . . . . . . . . . . 91 Taiwanese Class A warning statement . . . . . . . . . . . . . . . 92

Taiwan contact information . . . . . . . . . . . . . . . . . . . . 92 Cable ferrite requirement . . . . . . . . . . . . . . . . . . . . . 92 Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . 92 Product Recycling and disposal . . . . . . . . . . . . . . . . . . . 93 Battery return program . . . . . . . . . . . . . . . . . . . . . . 94

For Taiwan: . . . . . . . . . . . . . . . . . . . . . . . . . 94

iv SureMark Hardware Service

For the European Union: . . . . . . . . . . . . . . . . . . . . 94 For California: . . . . . . . . . . . . . . . . . . . . . . . . 95

Flat panel displays . . . . . . . . . . . . . . . . . . . . . . . 95 Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Part number index . . . . . . . . . . . . . . . . . . . . . . . 99

Contents v

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Figures 1. IBM SureMark 4610 printer . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. USB interface card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3. RS-485 interface card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4. RS-232 interface card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5. Power button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6. Location of serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7. Parts review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 8. 4610 Models 2CR and 2NR connectors . . . . . . . . . . . . . . . . . . . . . . 11 9. Opening the paper door and ribbon door . . . . . . . . . . . . . . . . . . . . . . 12 10. Removing the logic card . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 11. Removing the interface card . . . . . . . . . . . . . . . . . . . . . . . . . . 14 12. Removing the thermal printhead assembly . . . . . . . . . . . . . . . . . . . . . 15 13. Opening the paper door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 14. Removing the paper door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 15. Removing the ribbon door . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 16. Removing the main cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 17. Removing the flipper door . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 18. Removing the skirt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 19. Removing the distribution card . . . . . . . . . . . . . . . . . . . . . . . . . . 22 20. Removing the flipper cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . 23 21. Removing the thermal printhead cable . . . . . . . . . . . . . . . . . . . . . . . 24 22. Removing the printhead assembly . . . . . . . . . . . . . . . . . . . . . . . . 25 23. Removing the right transport shaft adjuster screw . . . . . . . . . . . . . . . . . . . 26 24. Impact printer transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 25. Left transport shaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 26. Removing the transport motor . . . . . . . . . . . . . . . . . . . . . . . . . . 29 27. Lifting the frame to access the transport motor . . . . . . . . . . . . . . . . . . . . 30 28. Locating the wear plate and the throat release button . . . . . . . . . . . . . . . . . 31 29. Removing the upper throat assembly . . . . . . . . . . . . . . . . . . . . . . . 32 30. Locating the flipper actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 31. Impact platen and printhead with adjoining parts . . . . . . . . . . . . . . . . . . . 33 32. Locating the platen bracket, platen spring and platen screw . . . . . . . . . . . . . . . 34 33. Removing the e-clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 34. Removing the impact platen . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 35. Removing the thermal latch assembly . . . . . . . . . . . . . . . . . . . . . . . 37 36. Unhooking the spring latch . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 37. Removing the ribbon drive assembly . . . . . . . . . . . . . . . . . . . . . . . 39 38. Removing the e-clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 39. Removing the tear bar assembly . . . . . . . . . . . . . . . . . . . . . . . . . 41 40. Identifying the lift spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 41. Removing the rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 42. Locating the shoulder stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 43. Removing the thermal paper feed motor . . . . . . . . . . . . . . . . . . . . . . 45 44. View with paper-motion sensor assembly open . . . . . . . . . . . . . . . . . . . . 46 45. Removing the paper-out (paper-motion) sensor assembly . . . . . . . . . . . . . . . . 47 46. Removing the low-paper sensor . . . . . . . . . . . . . . . . . . . . . . . . . 48 47. Removing the grounding strap from beneath the frame . . . . . . . . . . . . . . . . . 50 48. Removing the back rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 49. Adjusting the printhead gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 50. Inserting the printhead gap gauge . . . . . . . . . . . . . . . . . . . . . . . . 54 51. Loosening the right-side screw . . . . . . . . . . . . . . . . . . . . . . . . . . 55 52. Opening the paper door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 53. Paper roll placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Copyright IBM Corp. 2008 vii

54. Opening the ribbon cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 55. Ribbon cartridge loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 56. Ribbon path around the printhead . . . . . . . . . . . . . . . . . . . . . . . . 62 57. Inserting checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 58. Cleaning the MICR read head . . . . . . . . . . . . . . . . . . . . . . . . . . 64 59. Cleaning the thermal printhead . . . . . . . . . . . . . . . . . . . . . . . . . . 65 60. Removing the flipper door (lower document insert cover) . . . . . . . . . . . . . . . . 66 61. Lifting up on the thumb tab . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 62. Removing the check flipper cartridge . . . . . . . . . . . . . . . . . . . . . . . 67 63. Paper feed and document feed buttons . . . . . . . . . . . . . . . . . . . . . . 70 64. Pressing the power button and the R button . . . . . . . . . . . . . . . . . . . . . 70 65. Example of the offline selection main menu . . . . . . . . . . . . . . . . . . . . . 71 66. Locating the diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 75 67. SureMark 4610 Models 2CR and 2NR dimensions . . . . . . . . . . . . . . . . . . 77 68. Printable area of an inserted document (portrait) . . . . . . . . . . . . . . . . . . . 81 69. Printable area of an inserted document (landscape) . . . . . . . . . . . . . . . . . . 82

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Tables 1. Model feature description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3. Communication interface, rate and power source . . . . . . . . . . . . . . . . . . . 4 4. Distribution card connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5. Specifications of supported single and multipart forms . . . . . . . . . . . . . . . . . 59 6. Supported flipping specifications . . . . . . . . . . . . . . . . . . . . . . . . . 59 7. Summary of the offline test menu items . . . . . . . . . . . . . . . . . . . . . . 71 8. Lightpath LED conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 10. Summary of dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 11. Power supply pin designations . . . . . . . . . . . . . . . . . . . . . . . . . . 78 12. USB pin designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 13. Powered USB pin designations . . . . . . . . . . . . . . . . . . . . . . . . . 78 14. RS-232 pin designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 15. RS-485 pin designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 16. Cash drawer connector pin designations . . . . . . . . . . . . . . . . . . . . . . 80 17. Station characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 18. Sound characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Copyright IBM Corp. 2008 ix

x SureMark Hardware Service

Preface This manual provides problem determination and testing information and a parts listing of field-replaceable units (FRUs) for the IBM SureMark printers.

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

How this guide is organized This publication is organized as follows: v Chapter 1, Introducing the 4610 Models 2CR and 2NR, on page 1 provides an

overview of the 4610 Models 2CR and 2NR. v Chapter 2, Removing and replacing FRUs, on page 9 describes how to remove

and replace the field replacement units (FRUs). v Chapter 3, Adjusting and maintaining the 4610, on page 53 describes how to

adjust the printhead, replace replenishable supplies, and remove paper jams. v Chapter 4, Running tests and diagnostics, on page 69 describes the offline

tests, information for troubleshooting and running diagnostics procedures. v Appendix A, Product specifications, on page 77 contains technical information

about the IBM 4610 Models 2CR and 2NR, such as physical dimensions, and station characteristics.

v Appendix B, Parts listing, on page 83 lists the FRUs by part number.

Related publications v IBM SureMark Printers: User's Guide for Models 2CR and 2NR, GA27-5003 v IBM SureMark Printers: firmware update diskettes v IBM SureMark Printers: Fonts and Logos Utility Diskette v IBM Safety InformationRead This First, GA27-4004 v IBM SurePOS 700 Series: Hardware Service Guide, GA27-0363 v IBM SurePOS 700 Series: Options and I/0 Devices Service Guide, SY27-0392 v IBM SurePOS 700 Series: System Reference, SA27-4224 v IBM SurePOS 500 Series: System Reference, SA27-4255 v POSS Programming Reference and Users Guide, SC30-3560

SureMark publications are available on the Internet as PDF files. See the RSS web site at www.ibm.com/solutions/retail/store/support/ for more information.

Publications accessibility The softcopy version of this guide and other related publications are accessibility enabled.

Providing feedback Your feedback is important in helping IBM provide accurate and high-quality information.

You can use either of these ways to provide feedback:

Copyright IBM Corp. 2008 xi

v Go to http://www.ibm.com/solutions/retail/store. Click Support, then click Publications. Click the publication comments within the introductory text. Provide the requested information and your comments. Be sure to include the name and form number of the document in the [Publication ID] field.

v Print and complete the form at the end of this document. Return the form to IBM by mail or by giving it to an IBM representative.

If applicable, include a reference to the specific location of the text (for example, the page or table number) on which you are commenting.

Between major revisions of this document, there might be minor technical updates. The latest version of this document is available on the Retail Store Solutions Web site at www.ibm.com/solutions/retail/store/support/publications/.

xii SureMark Hardware Service

Chapter 1. Introducing the 4610 Models 2CR and 2NR The IBM SureMark printer Models 2CR and 2NR are dual-station printers consisting of a high-speed thermal station and an impact station for printing inserted documents. The Models 2CR and 2NR are designed for ease of service. Along with the other customer-replaceable parts, the customer can now replace the interface card, logic card, and thermal printhead.

Models and features The IBM 4610 Models 2CR and 2NR provide: v Easy paper loading v Easy-to-load ribbon cartridge v Fast, quiet receipt printing v High speed thermal station printing v High-speed document flipper (Model 2CR) v Enhanced system management sensors

Paper present Low-paper sensing Paper motion/jams Cutter health Printhead status Printer usage statistics:

- MICR reads (Model 2CR) - Document printing - Characters printed - Checks flipped (Model 2CR)

v Quieter paper cutter v USB, RS-232 and RS-485 interfaces

Figure 1. IBM SureMark 4610 printer

Copyright IBM Corp. 2008 1

v 3 MB flash memory for storing messages, logos, code pages, and electronic journal data

v DBCS thermal font - 24x24 matrix v DBCS impact font - 9x16 or 16x16 matrix v MICR (Model 2CR) v Bar code generation v Downloadable fonts and code pages v Downloadable microcode v Small footprint v Single-pass handling of checks

Table 1. Model feature description Features 2CR 2NR Cash receipt/document insert Thermal/Impact Print speed 80 lps thermal, 4.7 lps narrow format, 4.1 lps wide format for

Impact (8lpi) Usage data

Yes User defined fonts - including proportional fonts Scalable fonts up to 8X Journal station No Single pass MICR, check franking, flipping, printing

Yes

No

MICR reading Check insert station Yes Document insert station Document insert print width 83.0 mm Document insert form width 50 mm minimum Document flipper form width 102 mm maximum

80 mm minimum N/A

Document flipper form length 223 mm maximum 65 mm minimum

N/A

Multipart form Yes

Barcode printing Receipt paper loading Drop and load Receipt paper cutter

Standard Receipt tear bar Receipt paper width 80 mm Print fonts (CPI) 12, 15, 17, 20 Rotate print (line by line) Yes DBCS thermal font - 24x24 matrix Yes

DBCS impact font - 9x16 or 16x16 matrix Yes

Introducing 4610 Models 2CR and 2NR

2 SureMark Hardware Service

Warranty information Table 2 shows the warranty information for each printer model.

Table 2. Warranty information Model type Description Warranty

service 2NR, 2CR RS-232, RS-485, or USB interfaces

Pearl white or iron gray covers IOR 24x7

Note: IOR 24x7 is IBM on-site repair 24 hours times seven days per week.

Communication and power An interface card provides communication with the SureMark printers Models 2CR and 2NR to the system unit. Select the card for your type of communication: the RS485, RS-232, or USB.

A B C D

Figure 2. USB interface card.A Cash drawer B Power supply

C Powered USB D Standard USB


Chapter 1. Introducing the 4610 Models 2CR and 2NR 3

Table 3. Communication interface, rate and power source Device Description Power RS-232 9.6K - 115.2K (selectable using

offline or online configuration) Baud rate

Separate power supply

RS-485 IBM proprietary System unit input voltage +38 V or +24 V (Japan only)

USB USB is 2.0 Compliant Full Speed HID; Bulk transfers at 12 Mbps (Mega bits per second)

System unit input voltage (+24 V); power supply if standard USB connector is used

E F

Figure 3. RS-485 interface card.E Cash drawer F RS-485

G H I

Figure 4. RS-232 interface card.G Cash drawer H Power supply

I RS-232



Locating the power button The power button (P in Figure 5) for the 4610 Models 2CR and 2NR is located under the paper door. A removable cover is provided over the power button.

Operating system requirements Drivers can be downloaded from the Retail Store Solutions Web site at www.ibm.com/solutions/retail/store/support/.

RS-232 interface The RS-232 interface supports systems with the following operating systems: v Windows XP Professional with the 4610 Native Windows Driver (NWD) v Novell Linux Point of Service (NLPOS) v IBM Retail Environment for SUSE Linux v Windows XP Professional with OPOS and JavaPOS support from UPOS 1.96 or

later v Windows Vista with OPOS and JavaPOS support from UPOS 1.96 or later

RS-485 interface The RS-485 interface supports systems with the following operating systems: v 4690 Operating System Version V4R2, V5R1, V5R2 DBCS font download

support included. v IBM Retail Environment for SUSE Linux v Novell Linux Point of Service v IBM PC DOS 2000 or later with POSS for DOS V1.60(b) plus delta package

160(D), or later v Windows XP Professional with OPOS and JavaPOS support from UPOS 1.96 or


P

Figure 5. Power button



USB interface The USB interface supports systems with the following operating systems: v 4690 OS V2R3, which includes JavaPOS 1.4 v Windows XP Professional supported through 4610 NWD v IBM Retail Environment for SUSE Linux v Novell Linux Point of Service v Windows XP Professional with OPOS and JavaPOS support from UPOS 1.96 or


4690 OS Customers must be at these application levels (or higher) when running the 4690 OS:

Application Name Note: Some of these applications will only support the printers if they are set in TI3/4 compatibility mode.

Product Number

Maintenance Level

IBM SUREPOS Application Client/Server Environment for 4690 OS

5745-C44 N/A

IBM Chain Drug Sales Application 5669-212 9701 with PRPQ 5799-QYP IBM 4680/4690 General Sales Application 5696-546 9701 with APAR IR33229 and

PRPQ 5799-QYN IBM 4680/4690 Supermarket Application 5696-536 9701 with APAR IR33228 plus

PRPQ 5799-QYL StoreFlow See note 1 Release 1.4

Notes: 1. 4690 Terminal Services for Windows NT is required when you use Windows NT 4.0 or

Windows 2000 as the primary operating system with this 4690 application.

Hardware requirements SureMark printers work with the following systems: v IBM 4694 systems v IBM 4695 systems (RS-232 connection only and with power supply) v PC or other store controller with an RS-232 or USB port v SurePOS 100 Series systems v SurePOS 700 Series systems v SurePOS 500 Series systems v SurePOS 300 Series systems v IBM Self Checkout solution



Calling for service The serial number and model number (S in Figure 6) are located beside the flipper door.

S

Figure 6. Location of serial number



Chapter 2. Removing and replacing FRUs This section contains the FRU removal and replacement procedures for SureMark 4610 Models 2CR and 2NR. Notes: 1. Before you perform any removal and replacement procedures, see Handling

static-sensitive devices. 2. Locate the machine serial number. See Figure 6 on page 7. 3. Switch OFF the power to the SureMark 4610. Unplug the power cord from the

external power source.

Handling static-sensitive devices Attention: Static electricity can damage electronic devices and your system. To avoid damage, keep static-sensitive devices in their static protective bags until you are ready to install them.

To reduce the possibility of electrostatic discharge, observe the following precautions: v Limit your movement. Movement can cause static electricity to build up around

you. v Handle the device carefully, holding it by its edges or its frame. v Do not touch solder joints, pins, or exposed printed circuitry. v Do not leave the device where others can handle and possibly damage the

device. v While the device is contained in its anti-static bag, touch it and your finger to an

unpainted metal part of the system unit for at least 2 seconds. (This action removes static electricity from the package and from your body.)

v Remove the device from its package and install it directly into your system, without putting it down. If it is necessary to put the device down, place it onto its static-protective bag. (If your device is an adapter, place it component side up.) Do not place the device onto the cover of the system or onto a metal table.

v Take additional care when handling devices during cold weather because heating reduces indoor humidity and increases static electricity.

Reviewing the FRUs and connections Review Figure 7 on page 10 to become familiar with the FRU names and location.


Paper Door

Main Cover

Thermal Cutter Assembly

Document Paper Feed Motorand Gears

Platen Assembly

Tear Bar

Thermal LatchAssembly

Thermal Printhead

Thermal PaperFeed Motor and Gear

Upper ThroatAssembly

Paper FeedRollers

Low PaperSensor

Flipper Rollers

Distribution Card

FlipperCartridge

Logic Card

Printhead Cartridge Assembly

Main Frame Assembly

Transport Motor

Flipper Door

Ribbon Door

Ribbon Drive Assembly

Base Frame

Skirt Cover

Grounding Strip

Interface Card

Paper Out Sensor

Transport shaft and adjusters

Lift Spring

Paper Stage

Figure 7. Parts review

Removing and replacing FRUs


Identifying the cable connections

Table 4. Distribution card connectors. Refer to Figure 8. Location: Connector: A MICR B Flipper motor, transport motor, and ribbon motor C Top cover cutter and sensors D Thermal paper-feed motor E Document paper sensor and receipt paper out sensor F Document paper-feed motor G Thermal printhead H Low-paper sensor I Reserved for future use J Interface card K Impact printhead

Note: To access the distribution card, you must remove the skirt cover. See Removing the skirt cover on page 21.

AB C

D

E

F

GHI

J

K

Figure 8. 4610 Models 2CR and 2NR connectors


Chapter 2. Removing and replacing FRUs 11

Removing the logic card Note: This part is a customer replaceable unit.

Attention: Printer should be powered off. The following ESD handling procedure is recommended: You should touch the metal on the printer frame with the back of your hand before making contact with the printer. Also, see Electrostatic Discharge (ESD) on page 92.

Follow these steps to remove and replace the logic card:

1. Turn off the power to the 4610. 2. Open the paper door by pressing the blue release button (A in Figure 9). 3. As shown in Figure 9, open the ribbon door (B) by pulling downward. 4. Remove the ribbon. See Replacing the ribbon on page 59

A

B

Figure 9. Opening the paper door and ribbon door



5. Release the blue locking lever by lifting upward (C in Figure 10) and then lift out the logic card (D).

To replace, reverse these procedures.

After replacing the logic card, a message might print. For more information, see Changing the interface card or logic card on page 72.

C

D

Figure 10. Removing the logic card



Removing the interface card The interface card is a customer replaceable unit. 1. Disconnect all power from the 4610.

2. As shown in Figure 11, place the printer unit on one side. 3. Press to release the latch (C) and remove the interface card.

To replace, v Align the bottom of the interface card to the slot on the base of the printer and

press to secure the latch.

After replacing the interface card, an message might print. For more information, see Changing the interface card or logic card on page 72.

C

Figure 11. Removing the interface card



Removing the thermal printhead assembly Note: This part is a customer replaceable unit.

Attention: Printer should be powered off. The following ESD handling procedure is recommended: You should touch the metal on the printer frame with the back of your hand before allowing the printhead to make contact with the printer. Also, see Electrostatic Discharge (ESD) on page 92.

Follow these procedures to install the thermal printhead assembly: 1. Open the paper door by pressing the blue release button (see Figure 9 on page

12).

2. See Figure 12. Open the paper-motion/paper-out sensor (1) by grasping the edge and pulling downward.

3. See 2 and press downward on the thermal printhead assembly (indicated with a blue touchpoint).

4. Lift the printhead assembly outward (3) to remove.


Note: When you replace the thermal printhead, run the offline test to reset the statistics. See Firmware offline tests on page 70.

1 32

Figure 12. Removing the thermal printhead assembly



Removing the covers This section describes how to remove the covers.

Removing the paper door The paper door is a customer-replaceable part. Follow these step to remove the paper door:

1. Open the paper door: Press and release the blue release button (P in Figure 13).

2. See Figure 14. Press outward on either side of the tabs (U in Figure 14) and slightly slide the cover down along the back of the printer to remove.

P

Figure 13. Opening the paper door

UU

Figure 14. Removing the paper door



To replace, 1. Align the tab with the slots in the paper cover on the right side and then the left

side. 2. Slide upward to snap the door into position.



Removing the ribbon door The ribbon door is a customer-replaceable part. Follow these steps to remove the ribbon door: 1. Open the ribbon door.

2. See Figure 15. Slightly push the middle tab (F) towards the back of the printer and slide the door to the left to remove.

To replace, 1. Reverse these procedures, making sure that you align the posts with the slots.

F

Figure 15. Removing the ribbon door



Removing the main cover Follow these steps to remove the main cover: 1. Remove the paper door. See Removing the paper door on page 16 2. Remove the ribbon door. See Removing the ribbon door on page 18.

3. Make sure that the thermal cutter assembly is in the closed position as shown in picture 1 of Figure 16.

4. Push the cover (A) to the left near the open paper door button and then lift outward on the left side (B ) of the main cover.

5. After unlocking the covers at these points, gently lift outward on the right cover frame (C).

6. If necessary, repeat step 4 until the cover is no longer attached to the unit. 7. See picture 2, Figure 16 and lift the entire cover upward and off the unit.

To replace, follow these steps. 1. Place the thermal cutter assembly in an open position by pressing the paper

door release button. 2. Place the main cover on the unit, aligning the features at the rear of the printer

first. Then, align the cover around the paper release button. 3. Secure the left and right snap. 4. Repeat the previous steps until the cover is secured around the unit. 5. Replace the ribbon door and the paper door.

A

C

B

1 2

Figure 16. Removing the main cover



Removing the flipper door (document insert cover) The flipper door is a customer-replaceable part. Follow these steps to remove the flipper door 1. Lift up the left front corner of the flipper door (document insert cover).

2. Pull the cover from the printer.

Figure 17. Removing the flipper door



Removing the skirt cover The skirt cover is a customer-replaceable part. Follow these steps to remove the skirt cover: 1. Remove the interface card as described in Removing the interface card on

page 14: 2. Remove the flipper door. See Removing the flipper door (document insert

cover) on page 20.

3. Turn the printer on one side. Press outward on the tabs (see Figure 18) on the bottom skirt cover and lift to remove.

To replace, reverse these procedures, installing the rear of the cover first.

A

Figure 18. Removing the skirt cover



Removing the distribution card Follow these steps to remove the distribution card: 1. Remove the interface card as described in Removing the interface card on

page 14. 2. Remove the logic card as described in Removing the logic card on page 12 3. Follow the steps in Removing the skirt cover on page 21, to remove the skirt

cover.

4. Turn the printer on its side and remove all cables from the distribution card.

5. Press the tabs (R in Figure 19) inward on either side of the card and slide the card forward to remove.

To replace, reverse these steps.

R R

Figure 19. Removing the distribution card



Removing the flipper cartridge The flipper cartridge is a customer-replaceable part. Follow these steps to remove the flipper cartridge:

1. Remove the flipper door as described in Removing the flipper door (document insert cover) on page 20

2. See picture 1 in Figure 20. Lift up the tab on the left side of the flipper cartridge (with a blue label).

3. As shown in picture 2, remove the check flipper cartridge from the printer.


1

2

Figure 20. Removing the flipper cartridge



Removing the thermal printhead cable Follow these steps to remove the thermal printhead cable: 1. Remove the logic card. See Removing the logic card on page 12. 2. Remove the interface card. See Removing the interface card on page 14. 3. Remove all of the covers. See Removing the covers on page 16, 4. Remove the thermal printhead as described in Removing the thermal printhead

assembly on page 15.

5. See Figure 21. Remove the two screws (N) holding the thermal cable clamp. 6. Disconnect the thermal printhead cable from the distribution card. See

Identifying the cable connections on page 11, if necessary. 7. Pull the cable out from the printer.

To replace, reverse these procedures. Notes: 1. The replacement part has a layer of double-sided tape. Remove the backing

from the tape before installing. 2. Locate the cable so that it extends 6 mm (.24 in.) above the top of the clamp.

N

6mm(.24 in)

Figure 21. Removing the thermal printhead cable



Removing the impact printhead and carriage assembly Follow these steps to remove the printhead and carriage assembly:

1. Remove the logic card. See Removing the logic card on page 12. 2. Remove the interface card. See Removing the interface card on page 14.

3. Remove all of the covers. See Removing the covers on page 16. 4. If installed, remove the ribbon cartridge.

5. Disconnect the impact printhead cable from the distribution card.

6. Remove the screw (A in Figure 22) holding the left transport shaft adjuster and spring to the transport shaft.

Note: To replace correctly, notice how the spring is held into place by the transport shaft adjuster

A

Figure 22. Removing the printhead assembly



7. Loosen the screw (K in Figure 23) on the top right side to loosen the right transport shaft adjuster.

8. Disconnect the carriage timing belt (B in Figure 31 on page 33) from the pulley by lifting outward and upward on one side of the belt.

9. Slide the transport shaft (F in Figure 31 on page 33) from the printhead assembly.

10. The printhead and carriage assembly can then be lifted from the unit. 11. An adhesive holds the cable to the frame, so you will need to pull the cable

where it is attached to the frame. Then pull the cable up from the distribution card through the printer to remove.

To replace, 1. Replace the printhead and carriage assembly into the frame. 2. To locate the new cable, position the carriage at its full left position. 3. Make sure that the loop in the cable just touches the left frame wall 4. Secure the cable by removing the adhesive release liner and pressing the cable

to the frame.

Note: Check that the cable does not rub against other parts as the carriage is moved from left to right.

5. Go to step 8 above, and reverse these procedures. 6. Adjust the printhead gap. See Adjusting the printhead gap on page 53. 7. Reset the printhead statistics by running the IBM diagnostics tool. See

Chapter 4, Running tests and diagnostics, on page 69.

K

Figure 23. Removing the right transport shaft adjuster screw



Removing the impact printer transport Figure 24 shows the components of the impact printer transport.

This assembly consists of the belt tensioner assembly, the belt tensioner spring, the carriage timing belt and the transport shaft and adjusters.

Follow these steps to remove the impact printer transport: 1. Open the ribbon door. If a ribbon cartridge is installed, remove it by lifting it

straight upward. 2. Disconnect the carriage timing belt from the pulley by lifting outward and upward

on one side of the belt. 3. Using the spring hook, remove the belt tensioner spring (M in the Figure 24). 4. Lift out and remove the belt tensioner assembly. 5. Remove the transport shaft as follows:

L

M N

O

Figure 24. Impact printer transport.L Transport shaft

M Belt tensioner spring N Belt tensioner assembly

O Carriage timing belt



a. Loosen the screw (A in Figure 25) holding the left transport shaft adjuster and spring to the transport shaft. Remove the adjuster and spring.

b. Remove the screw on the top right side to loosen the right transport shaft adjuster and spring (K in Figure 23 on page 26.

6. Slide the transport shaft from the printhead assembly. 7. Remove the right transport shaft adjuster and spring. 8. Remove the carriage timing belt (O in Figure 24 on page 27) from the impact

printhead carriage.

To replace, reverse the above steps and follow these instructions: Notes: 1. Apply a small amount of silicone oil to the transport shaft. With a clean cloth or

wipe, rub the oil the entire length of the transport shaft. 2. Follow the procedures to adjust the printhead gap. See Adjusting the printhead

gap on page 53.

A

Figure 25. Left transport shaft adjuster



Removing the transport motor Follow these steps to remove the transport motor: 1. Follow the procedures to remove all of the covers. See Removing the covers

on page 16, 2. Remove the ribbon drive assembly as described in Removing the ribbon drive

assembly on page 39. 3. Remove the transport shaft (L in Figure 24 on page 27) as follows:

a. Loosen the screw (A in Figure 22 on page 25) holding the left transport shaft adjuster and spring to the transport shaft. To replace correctly, note how the spring is held into place by the transport shaft adjuster.

b. Loosen the screw on the top right side to loosen the right transport shaft adjuster. See K in Figure 23 on page 26. Note: Since the left transport shaft adjuster will be very loose; remove and set this part and the spring aside

c. Disconnect the carriage timing belt (O in Figure 24 on page 27) from the pulley by lifting outward and upward on one side of the belt.

d. Slide the transport shaft from the printhead assembly.

4. As shown in Figure 26, remove the two screws (S in Figure 26) holding the transport motor assembly to the housing.

5. From the side of the 4610, unplug the cable connected to the transport motor. 6. Open the thermal cutter assembly to an upright position.

S

Figure 26. Removing the transport motor



7. As shown in Figure 27, lift the frame from the base; the transport motor (M) will drop down from beneath the frame.

8. Remove the motor from the unit.


Note: After you replace the transport motor, follow the procedures to adjust the printhead gap. See Adjusting the printhead gap on page 53.

M

Figure 27. Lifting the frame to access the transport motor



Removing the upper throat assembly Follow these steps: 1. Follow the procedures in Removing the ribbon door on page 18. 2. Remove the flipper door. See Removing the flipper door (document insert

cover) on page 20

3. Pushing the impact platen back, lift out the wear plate (B in Figure 28) and set it aside.

4. See Figure 29 on page 32. Using a screwdriver, press downward on the throat release button (A in Figure 28). Push the assembly to the left and it will drop downward.

A

B

Figure 28. Locating the wear plate and the throat release button



5. While pushing the impact platen back, fit the flipper actuator lever down through the space in the frame (A1 in Figure 29). Move the upper throat assembly down and out the front of the printer (A2).

A1

A2

Figure 29. Removing the upper throat assembly

T

Figure 30. Locating the flipper actuator



6. To replace, align the flipper actuator lever through the opening in the frame and snap the upper throat into place. Be sure to align the flipper actuator lever under the flipper actuator (see T in Figure 30 on page 32).

7. Replace the wear plate.


Removing the impact platen assembly To remove the impact platen assembly (C in Figure 31), follow these procedures:

1. Follow the steps to remove the logic card (Removing the logic card on page 12).

2. Except for the skirt cover, follow the procedures to remove all of the covers. See Removing the covers on page 16,

3. Remove the flipper door. See Figure 60 on page 66. 4. For Model 2CR:

a. Remove the interface card. See Removing the interface card on page 14. b. Remove the skirt cover (see Removing the skirt cover on page 21.) c. Disconnect the MICR cable from the distribution card. See Identifying the

cable connections on page 11.

A

C

B

E

D

F

Figure 31. Impact platen and printhead with adjoining parts.A Left transport adjuster spring B Carriage timing belt C Impact platen assembly

D Impact printhead assembly

E Wear plate

F Transport shaft



5. Unplug the document sensor cable, which is located next to the document motor (on the right side behind the impact platen).

6. Pushing the impact platen back, remove the wear plate (B in Figure 28 on page 31 ) and set it aside.

7. See Figure 32. Remove the screw (O) from the impact platen. 8. Remove the impact platen bracket (L), and the tensioner spring (M.

L

M

O

Figure 32. Locating the platen bracket, platen spring and platen screw.L Platen bracket

M Platen spring O Platen screw



9. Remove the e-clip (S in Figure 33). 10. Pull off the gear. 11. To unlock the impact platen, rotate the pin on the right end of the platen shaft

to match the slots on the frame.

12. Slide the impact platen (A in Figure 34) to the left of the unit to remove. 13. Pull the cables through the spaces on the unit to remove.


S

Figure 33. Removing the e-clip

A

Figure 34. Removing the impact platen



Note: After you replace the impact platen assembly, follow the procedures to adjust the printhead gap. See Adjusting the printhead gap on page 53.



Removing the thermal latch assembly Note: This procedure requires the spring hook tool. 1. Except for the skirt cover, follow the procedures to remove all of the covers. See

Removing the covers on page 16, 2. Remove the platen. See Removing the impact platen assembly on page 33.

3. See A in Figure 35. Lift to remove the blue latch button.

A

Figure 35. Removing the thermal latch assembly



4. Remove the two springs (A in Figure 36) on either side of the thermal latch assembly using the spring hook tool.

5. Pull the latch toward the front of the printer to remove.


A

Figure 36. Unhooking the spring latch



Removing the ribbon drive assembly Follow these procedures to remove the ribbon drive assembly: 1. Remove all covers. See Removing the covers on page 16

2. Squeeze the tabs on either side of the ribbon drive assembly (T in Figure 37) to unlock the assembly from the housing.

3. To remove, tilt and rotate the ribbon drive assembly out from the frame. 4. Disconnect the cable from the ribbon drive assembly and remove.


T

Figure 37. Removing the ribbon drive assembly



Removing the document paper-feed motor and gears Follow these steps: 1. Follow the steps to remove the logic card (Removing the logic card on page

12) and interface card (Removing the interface card on page 14). 2. Follow the procedures to remove all of the covers. See Removing the covers

on page 16, 3. Unplug the document feed motor cable from the distribution card. See

Identifying the cable connections on page 11.

4. Remove the e-clip (L in Figure 38) and small gear. 5. Remove the e-clip from the large gear (M in Figure 38). 6. Raise the thermal cutter assembly to the fully open position. Raise the rear of

the frame slightly and then remove the large gear. 7. Remove the document feed motor by unscrewing the screw (N in Figure 38)

and lifting the motor straight up.


L

M

N

Figure 38. Removing the e-clip



Removing the tear bar assembly Follow these steps to remove the tear bar assembly: 1. Follow the procedures to remove all of the covers (except the skirt cover). See

Removing the covers on page 16,

2. As shown in Figure 39, place the thermal cutter assembly in an open position. 3. Lift out the tear bar assembly (B in Figure 39).


B

Figure 39. Removing the tear bar assembly



Removing the paper stage, rollers and lift spring Follow these procedures: 1. Except for the skirt cover, remove all covers. See Removing the covers on

page 16.

CAUTION: Use care when removing a loaded spring.

2. Unhook and remove the lift spring first from the post on the base and then from the thermal cutter assembly.

3. Open the thermal cutter assembly so that it is in an upright position. See Figure 27 on page 30.

4. Rotate the thermal cutter assembly back to locate the shoulder stop (see Figure 42 on page 44) on the paper stage. Push the paper stage towards the rear of the printer to disengage from the stop.

5. Continue to rotate the thermal cutter assembly backward to unhook the paper stage arms and remove.

Figure 40. Identifying the lift spring



Removing the receipt rollers6. Reach inside the paper bucket and lift out the rollers (R in Figure 41).

Note: These rollers can be removed without removing any other parts.


Removing the thermal cutter assembly Follow these steps: 1. Follow the steps to remove the logic card (Removing the logic card on page

12) and interface card (Removing the interface card on page 14). 2. Follow the procedures to remove all of the covers. See Removing the covers

on page 16, 3. Unplug the cable from the distribution card. See Identifying the cable

connections on page 11. 4. Open the thermal cutter assembly. 5. CAUTION:

Use care when removing a loaded spring.Unhook and remove the lift spring (first from the post) and then lift the spring from the thermal cutter assembly and base.

R

Figure 41. Removing the rollers



6. Rotate the thermal cutter assembly backward to locate the shoulder stop (A in Figure 42) on the paper stage. Push the paper stage (B) towards the rear of the printer to disengage from the stop.

7. Rotate the thermal cutter assembly further backward to unhook the paper stage arms.

8. Pull out the thermal cutter assembly


A

B

Figure 42. Locating the shoulder stop



Removing the thermal paper feed motor and gear Follow these steps: 1. Follow the steps to remove the logic card (Removing the logic card on page

12). 2. Except for the skirt cover, follow the procedures to remove all of the covers. See


3. Open the thermal cutter assembly. 4. Remove the screw (J in Figure 43) holding the thermal paper feed motor.

I

H

J

K

Figure 43. Removing the thermal paper feed motor



5. Rotate the motor (I) to the right to remove. 6. Unplug the motor from the connector (H ). 7. Remove the e-clip holding the gear. 8. Lift out the gear (K). 9. To replace, reverse these procedures.

Note: A damaged thermal paper feed motor can cause damage to the logic card. Replacement of the logic card might be needed.

Removing the paper-out (paper-motion) sensor assembly The paper-out (paper-motion) sensor assembly is a customer-replaceable part. Follow these steps to remove the paper-out (paper-motion) sensor assembly: 1. Open the paper door by pressing the blue release latch.

2. Flip down the paper-motion sensor assembly cover. See Figure 44.

Figure 44. View with paper-motion sensor assembly open



3. As shown in Figure 45, push the paper-out sensor assembly (S) to the side. 4. See location C. Unplug the cable from the paper-out sensor and remove.


Removing the low-paper sensor cards Follow these steps to remove the low-paper sensor cards: 1. Remove the interface card. See Removing the interface card on page 14. 2. Follow the procedures to remove the skirt cover. See Removing the skirt cover

on page 21.

SC

Figure 45. Removing the paper-out (paper-motion) sensor assembly



3. Placing the printer on the side, remove the cable (A in Figure 46) from the channel in the base.

4. Then gently bend the low-paper sensor cards (B) and rotate upward to remove.

5. Unplug the low-paper sensor cable from the distribution card. See Identifying the cable connections on page 11.

6. Lift out the low-paper sensor cards.


B

A

Figure 46. Removing the low-paper sensor



Removing the grounding strap Follow these steps to remove the grounding strap: 1. Follow the procedures to remove the interface card. See Removing the

interface card on page 14. 2. Except for the skirt cover, follow the procedures to remove all of the covers. See




3. See Figure 47, top picture. Unlatch the grounding strap from the top of the rib on the base.

4. Pull the grounding strap (see bottom picture) from beneath printer. 5. To replace, reverse these procedures, matching the grounding strap tabs with

the slots on the unit.

G

G

Figure 47. Removing the grounding strap from beneath the frame



Removing the flipper springs and rollers Follow these steps to remove the flipper springs and rollers: 1. Follow the procedures to remove all of the covers. See Removing the covers

on page 16, 2. With the thermal cutter assembly in the open position, lift the frame off the base. 3. Remove the front set of rollers by pulling out the spring.

4. Turn the printer over and remove the back set of rollers (A in Figure 48) by pulling out the spring.


Removing the main frame assembly To remove the main frame assembly, follow the procedures in this section to remove all of the field replacement parts.

A

Figure 48. Removing the back rollers



Chapter 3. Adjusting and maintaining the 4610 Adjusting the printhead gap . . . . . . . . . . . . . . . . . . . . 53 Using and maintaining the 4610 . . . . . . . . . . . . . . . . . . 55

Replenishing consumable supplies . . . . . . . . . . . . . . . . 55 Loading and replacing the paper roll . . . . . . . . . . . . . . . 56 Installing large paper rolls . . . . . . . . . . . . . . . . . . . 59 Replacing the ribbon . . . . . . . . . . . . . . . . . . . . . 59

Correctly inserting documents . . . . . . . . . . . . . . . . . . 62 Cleaning recommendations . . . . . . . . . . . . . . . . . . . 63

Cleaning the MICR read head . . . . . . . . . . . . . . . . . 63 Cleaning the thermal printhead . . . . . . . . . . . . . . . . . 65

Clearing jams in the check flipper area . . . . . . . . . . . . . . . 66

This section provides instructions on adjusting and maintaining your printer.

Adjusting the printhead gap Note: A standard gauge tool is required for this procedure.

Follow these steps to adjust the printhead gap: 1. Open the ribbon cover.

2. Remove the ribbon and move the printhead assembly to the left side of the printer.

A

Figure 49. Adjusting the printhead gap


3. Loosen the screw (A in Figure 49 on page 53) on the left side of the printer.

4. Pull the printhead carriage towards you and insert the 0.9 mm gauge (see A in Figure 50) between the printhead and the impact platen.

5. While keeping the gauge in this position, release the printhead carriage. 6. Tighten the screw and remove the gauge.

7. Move the printhead carriage to the right margin position.

A

Figure 50. Inserting the printhead gap gauge

Adjusting and maintaining the 4610


8. Loosen the screw (K in Figure 51) on the right side. 9. Pull the printhead carriage towards you and insert the 0.9 mm gauge (see

Figure 50 on page 54) between the printhead and the impact platen. 10. While keeping the gauge in this position, release the printhead carriage. 11. Tighten the screw and remove the gauge. 12. Apply a small amount of an appropriate sealant (such as nail polish, a sealant

from Glyptal, Inc., or other sealant) to each screw. 13. Replace the ribbon and close the ribbon cover.

Using and maintaining the 4610 This section contains information about the proper use and maintenance of the 4610 Models 2CR and 2NR. For detailed technical information, see Appendix A, Product specifications, on page 77.

Note: All covers must be installed on the SureMark printer during operation.

Replenishing consumable supplies You are responsible for replenishing consumable supplies. These supplies include: v Supply roll paper v Inserted forms v Ribbon cartridgesMake sure that you have the correct supplies for the 4610.

K

Figure 51. Loosening the right-side screw


Chapter 3. Adjusting and maintaining the 4610 55

Loading and replacing the paper roll Ensure that you have the correct paper for the 4610. See Supported paper types on page 57.

1. Press and release the blue release button (P in Figure 52) to release the paper door.

2. If necessary, remove any unused paper or empty paper roll core from the paper roll bucket before inserting a new paper roll.

Note: Refer to the label inside the rear wall of the printer for a diagram of how to load paper.

P

Figure 52. Opening the paper door



3. See Figure 53 and place the paper roll into the paper roll bucket as shown. The leading edge of the paper should come from the bottom of the roll as shown in the diagram.

Note: The thermal printhead will not print on paper with glue on it. If the new paper roll was sealed by glue, tear off the 6 to 8 inches of paper with glue on it before loading it.

4. Close the paper cover. 5. Press the customer receipt feed button to advance the paper, to verify that the

paper is feeding correctly. Feed 30 cm (about 1 ft.) of paper through to test for correct alignment.

Attention: Do not pull the receipt paper out of the printer with the paper access cover closed. This disengages the paper feed. The paper feed motor must then catch up before the printer can feed the paper, which causes missing lines or partial lines of print. Use the customer receipt feed button to advance the receipt and all lines will print.

Supported paper types:

Attention: Using an inferior grade of paper can affect print quality as well as the life of printheads and the printer mechanism.

Note: When selecting a paper, ensure that the papers archive life meets the requirements of the tax authorities of your country for archiving tax-related data.

Thermal paper: The paper used in the thermal receipt station must meet the following requirements:

Figure 53. Paper roll placement



Width 79.5 0.5 mm (3.13 0.02 in.) Outside Diameter

102 mm (4.0 in.) maximum Thickness

60 m (0.00225 in.) Range: 41 m minimum to 99 m maximum

Important Paper has a significant manufacturing tolerance and nominal paper designations do not reflect actual measurements. The manufacturing tolerance must fall within the published operating thickness range. Customers should test paper in their specific configuration before use. The intent of this specification is that if any spot measurement of the paper is outside the specified range, the paper is deemed not to meet the specification and the customer is responsible for any problems caused by paper jams.

The paper must be wound with the printing side facing out. The paper should not be attached to the core in any manner.

Important Printer reliability and performance are directly related to the quality of the supplies used by the customer. The published parameters for printer performance are established using supplies that meet the specifications listed above.

Thermal paper with watermarks, coupons, or advertisements printed on the front or back of the paper is not covered by IBM specifications. Some inks and printing processes will work acceptably, while others will not. Printer problems that are caused by supplies that do not meet IBM specifications may result in a billable service call, regardless of the existence of a service contract.

For supported papers, see the following Web site: www-1.ibm.com/support/docview.wss?rs=219&uid=pos1R1002033

Document insert forms:

Note: Models 2CR and 2NR support up to three parts on a multipart form.Table 5 on page 59 list the specifications of supported single and multipart forms.Notes: 1. Test all forms in the printer to ensure acceptable performance prior to buying a

significant quantity. 2. No binding holes or other holes should be within 10 mm (0.4 in.) from the right

edge of the form. 3. Forms less than 0.15 mm (0.006 in.) thick with the grain of the paper

perpendicular to the feed direction (short-grain paper) should not be used for landscape printing.



Table 5. Specifications of supported single and multipart forms Specification Value Minimum width: 50 mm (2 in.) Maximum thickness of multipart forms: 0.47 mm (0.0185 in.) Maximum thickness of front sheet, multipart forms:

0.08 mm (0.003 in.)

Minimum thickness of single-part form: 0.10 mm (0.004 in.) Maximum thickness of single-part form: 0.2 mm (0.008 in.) Weight range for single-part forms: 6890 g/m2 (1824 #) For best reliability, paper grain should be in the direction that the paper is fed into the printer.

Supported documents that are flipped: The flipping of multipart forms and short-grain single-part forms is not supported. Table 6 describes the supported flipping specifications.

Table 6. Supported flipping specifications Specification Value Minimum form length: 80 mm (3.14 in.) Maximum form length: 223 mm (8.78 in.) Minimum form width: 65 mm (2.56 in.) Maximum form width: 102 mm (4 in.) Paper weight: 7595 g/m2

Installing large paper rolls The 4610 can accommodate extra large rolls (up to 15 in.) of paper below the printer. Mounting hardware is necessary to avoid placing undue strain on the paper feed motor. See your IBM representative for additional information.

Replacing the ribbon 1. Open the ribbon door. As the door is opened, the printhead moves to a position

where you can easily load a ribbon.



2. If a ribbon cartridge is installed, remove it by lifting it straight up.

Note: You might need to grasp the body of the cartridge rather than the top to remove it.

Figure 54. Opening the ribbon cover



3. Maintain ribbon tension by turning the ribbon cartridge knob as shown in Figure 55. Lower the cartridge into position until the notches on its sides snap into place on the printer guides.

Figure 55. Ribbon cartridge loading



4. Once the cartridge is in place, close the ribbon cover. The ribbon will be moved into the correct position. See Figure 56 for correct ribbon positioning.

Supported ribbon types:

Attention: Using an inferior grade of ribbon can affect print quality and the life of printheads and the printer mechanism.

The 4610 Models 2CR and 2NR require a stuffer-box ribbon type: Feed rollers pull the ribbon from one end of the cartridge and stuff it into the cartridge cavity of the other end. The Epson ERC 35 ribbon meets these specifications; however, other original equipment manufacturers offer replacements that are adequate.

Correctly inserting documents The Models 2CR and 2NR printer is capable of printing verification information on a check and on an inserted document. Figure 57 on page 63 shows the correct positioning of checks and documents:

B A

Incorrect Correct

Figure 56. Ribbon path around the printhead. Correct placement of the ribbon (A) around the printer guides (B).



Cleaning recommendations You should periodically inspect your 4610 unit and clean the cover as required. Use a soft clean cloth with warm soapy water to clean the plastic parts. Do not use abrasives or any alkaline, ammonia, or chloride-based cleaner.

Note: Do not apply cleaning solution directly to the cover. Always apply the cleaner on a clean cloth and then wipe the cover with the damp cloth. Be certain that the cloth is only damp and not dripping wet.

Cleaning the MICR read head The MICR read head should be cleaned after 10 000 checks are processed or every three months. Clean the MICR read head using a cotton swab soaked in isopropyl alcohol.

Follow these steps to clean the MICR read head: 1. Open the ribbon door by pulling downward. 2. Remove the ribbon cartridge by lifting it out. 3. Move the carriage to the right until it stops, or as shown in Figure 58 on page

64.

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4. Prepare a swab with isopropyl alcohol. 5. Gently wipe the head (see M in Figure 58) with the swab several times. Wipe

away any residual alcohol with a dry swab. 6. Replace the ribbon and close the ribbon door.

If cleaning the MICR 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 read head. The printer is equipped to filter noise from many devices. If the MICR reader does not function properly, rearranging the printer relative to the noise source may improve MICR reading. The noise source should be as far away as possible from the right side of the printer.

For additional information on troubleshooting MICR read problems, see Firmware offline tests on page 70.

M

Figure 58. Cleaning the MICR read head



Cleaning the thermal printhead The thermal printhead can be cleaned whenever print quality deteriorates. 1. Open the paper 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.

3. Wipe off any residual alcohol with a dry swab.

If print quality does not improve after cleaning the thermal printhead, call for service.

Thermal Print Line

Detailed View of Thermal Printhead

Paper Cover

Figure 59. Cleaning the thermal printhead



Clearing jams in the check flipper area If a check jams in the check flipper mechanism:

1. Lift up the left front corner of the flipper door (document insert cover) and pull the cover from the printer. (See Figure 60.)

2. If the document is visible, remove the document. 3. Replace the flipper door.

Figure 60. Removing the flipper door (lower document insert cover)

Figure 61. Lifting up on the thumb tab



4. If you cannot remove the document, lift up the tab on the left side of the check flipper cartridge (with a blue label) and remove the check flipper cartridge from the printer. (See Figure 62.)

5. Reach inside the document insert station and carefully remove the jammed check.

6. Reinstall the check flipper cartridge and the flipper door.

Figure 62. Removing the check flipper cartridge



Chapter 4. Running tests and diagnostics This chapter describes the IBM Diagnostics for POS Systems and Peripherals, offline tests, and troubleshooting procedures.

Attention: For firmware and driver updates, see the IBM SureMark Printers: Programming Guide for Models 2CR and 2NR, GA27-5005

Testing the 4610 When you switch on the SureMark printer, it runs a power-on self-test (POST). If the POST finds no errors, the printer is ready for operation. Follow these steps if you receive an error: 1. If the printer is powered ON, power OFF the printer and power it ON again.

v If the printer is attached to the system with the RS-232 cable or the standard USB cable with a power brick, disconnect the power cord, then reconnect the power cord to a properly wired and grounded power source.

v If the printer is attached to the system with the RS-485 cable, power OFF the POS system, and then switch on the system, which also powers ON the printer.

v If the printer is attached to the system with a powered USB cable, the USB attached printer can be hot-plugged.

2. Check the status of the printer-ready indicator: Printer-ready indicator ON:

The power-on self-test completed successfully. Printer-ready indicator OFF or blinking:

The POST failed.3. If the POST fails or if you suspect problems with your system, see

Troubleshooting on page 76. 4. See Firmware offline tests on page 70 and run the offline tests. If the offline

tests fail or you suspect problems with your system, see Troubleshooting on page 76.


Firmware offline tests To enter the firmware offline test and setup procedures follow these steps:

1. Use one of the following methods to enter the offline test mode: a. Switch on the printer while pressing the paper feed button (A in Figure 63).

b. Open the paper cover and press the R button while also pressing the power button. Use a paper clip if the power button cover is installed. Then, close the paper cover.

2. The following offline selection menu is printed. See Figure 65 on page 71.

A

Figure 63. Paper feed and document feed buttons

Figure 64. Pressing the power button and the R button

Running tests and diagnostics


3. Follow the instructions that are printed for each required test.

Summary of offline test menus IBM recommends that you use the firmware offline test menus to perform the offline tests. However, note that some existing offline test methods still apply (see Earlier methods for offline tests on page 74). Table 7 describes the available firmware offline test menus:

Table 7. Summary of the offline test menu items

Menu item Definition Sub-menu (if applicable) Definition

1. Thermal receipt test Prints a receipt 2. Choose emulation mode

Displays the sub-menus (see next column)

Compatibility with Legacy 4610

Changes the command set and statuses to support the previous drivers and applications (such as plug and play for existing 4610 printers).

Native mode Changes the command set and statuses to support the low-paper detection, paper jam detection, and other 4610 Model 2CR and 2NR sensors.

3. Model selection You specify the printer type: MICR reading or non-MICR reading model. 4. EIS-232/RS-232 flow control

Provides a list of available baud rates and flow controls.

5. More selections Provides additional menus:

Off-line Selection started To select a sub-menu or test: FIRST, press the paper feed button the indicated number of times. THEN, press again and hold button down at least 1 second to confirm selection.

Sub-menus and tests Codes Thermal Receipt test 1 Choose Emulation Mode 2 Model Selection 3 EIA-232/RS-232 Flow Control 4 More Selections 5

To exit Off-line setup, open printer cover.

Figure 65. Example of the offline selection main menu. See Table 7 for an explanation of these menu items.


Chapter 4. Running tests and diagnostics 71

Table 7. Summary of the offline test menu items (continued)

Menu item Definition Sub-menu (if applicable) Definition 1. MCT listing Information for service personnel 2. Low-paper calibration

You are instructed to insert a small roll of paper in the printer. During the test the printer ejects all of the paper from this roll to calibrate the low-paper sensor.

3. MICR read test 4. Document print test

Starts print test

5. For more selections:

Provides additional menus:

1. Hex dump mode A debug mode that is used when attached using a RS 232 that will have the printer print the data/commands that it receives. This enables the application writer the ability to see what data is actually being received at the printer.

2. Execute printhead test

Starts printhead test

3. Reset TPM user data Execute after thermal Printhead is replaced

Select after you install a new thermal printhead.

4. Main menu Return to main menu

Changing the interface card or logic card Oftentimes during the servicing process, you will change an interface card or logic card in the printer. If one of the cards is a new FRU, then the printer firmware automatically updates the new card with the printer settings and other information. (These settings include the serial number, baud rate, and model number.) The first time you power on the printer with a FRU card in it, the update will occur and the printer will reset.

For proper operation, the information on the interface and logic cards must match. If you install either card (interface or logic) with previously written firmware information, you must direct the firmware to overwrite the correct card.

The following message is printed when an information mismatch occurs:



A card in the printer has been replaced Main Logics S/N is 41-MVT02 Interface Cards S/N is 41AAVT50 Check the serial number (S/N) of the printer. The S/N is located next to the document insert station and on the bottom of the printer.

If S/N matches one of the above, please update the card with the incorrect S/N.

If S/N does not match one of the above, Refer to the Hardware Service Manual.

To select a sub-menu or test: FIRST, Press the paper feed button the number the indicated number of times. THEN, press again and hold button down at least 1 second to confirm selection.

OPTIONS. . . . . . . . . . Presses 1. Main Logic Update Menu . . . . 1 2. Interface Card Update Menu . . 2 3. Continue without updating . . 3

To exit Off-line setup, open printer cover.

If you select option 1, the following message prints: Main Logic Card Update Menu Data will be copied from the interface card to the main logic Printer will reset when update is done. To update the Main Logic Card, Press the paper feed button

To Exit without updating, Open Printer Cover.

If you select option 2, the following message will print: Interface Card Update Menu To update the Interface Card, Press the paper feed button Data will be copied from the main logic to the Interface Card.

To Exit without updating, open printer cover

Selecting Option 3. Continuing without updating could produce unexpected results.

Storing a new serial number in the firmware For proper printer operation, the firmware must correlate the serial number of the printer with the serial number of the logic card. When you replace either the logic card or the interface card, the serial number is restored into the new card. However, if both cards are replaced, you must store the correct serial number in the firmware.

For more information, see the IBM Retail Store Solutions support Web site at www.ibm.com/solutions/retail/store/support/.



Earlier methods for offline tests The section provides the previous methods for initiating offline tests. Although these methods are supported, IBM recommends that you use the firmware menu and sub-menus to initiate all offline tests.

Resetting the printer and the document sensor threshold: To reset the printer, 1. Press and hold the paper feed and document feed buttons (A and B in

Figure 63 on page 70) to enter offline mode. 2. When the printer-ready indicator begins blinking, release both buttons. 3. Open and close the paper door by pressing the paper release button C in

Figure 63 on page 70.

Customer receipt test:

Note: IBM recommends that you use the offline menus to initiate this test.

To initiate the customer receipt test, follow these steps: 1. Press and hold both the paper feed and document feed buttons (A and B in

Figure 63 on page 70) to enter offline mode 2. When the printer-ready indicator begins blinking, release both buttons. 3. Press and release the paper feed button to start the test

Document insert station test:


To initiate the document insert station test, follow these steps: 1. Press and hold both the paper feed and document feed buttons (A and B in

Figure 63 on page 70) buttons to enter offline mode. 2. When the printer-ready indicator begins blinking, release both buttons. 3. Press and release the document feed button to start the test.

MICR read, flipper test:


The MICR read test is accessed through the sub-menus in offline mode.

Follow these steps to start the MICR read and flipper test: 1. Insert the check face down with the magnetic ink characters to the right. 2. To enter offline mode, press and hold both buttons until the printer-ready

indicator begins blinking. 3. Then release both buttons. 4. Press and release both buttons again. The printer reads the check. 5. Characters that match the magnetic ink characters are printed on the customer

receipt. The check is then flipped over, and ejected.Understanding MICR test results: If the characters printed do not match the magnetic ink characters, check the MICR read head. The printer will insert question marks if the MICR read engine cannot decode a number. An X appears if the printer had to read the document twice to determine a good read. If the printer detects noise, it will print out the amplitude and frequency of the noise, if possible.



Understanding the Light-Path LEDs The Light-Path LEDs are located by opening the paper door. See Table 8 for a description of these indicators.

Table 8. Lightpath LED conditions LED Failing Component 1 Main logic card 2 Interface card 3 Thermal printhead

Figure 66. Locating the diagnostic LEDs



Troubleshooting Table 9 contains common steps to identify and resolve problems. For the latest troubleshooting guidance and symptom-fix tip information, go to the IBM Knowledgebase support Web site at: www2.clearlake.ibm.com/store/support/html/knowledgebase.html. This site contains additional information that is gathered from field experience, and might not have been available at the publishing date of this document.

Table 9. Troubleshooting If the problem is... Then do this... Printer-ready indicator is OFF. v Check the power to the printer.

v If connected to a system using the RS-485 communication port, check that the system is powered ON and cable 7 is connected.

v If using the RS-232 communication port or a USB port with a power brick, check that the brick power supply is connected to the printer and plugged into an AC power source.

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