SureMark 4610 Printers
Hardware Service Guide for Models 2CR and 2NR
GA27-5004-00
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 Information—Read 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 reader’s 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 USA When you send information to IBM, you grant IBM a nonexclusive right to use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you. © Copyright International Business Machines Corporation 2008. US Government Users Restricted Rights – Use, duplication or disclosure restricted by GSA ADP Schedule Contract with IBM Corp.
Contents Figures
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Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Preface . . . . . . . . Who should read this guide How this guide is organized Related publications . . . Publications accessibility . Providing feedback . . . .
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Chapter 1. Introducing the 4610 Models and features . . . . . Warranty information . . . . . Communication and power . . . Locating the power button . . Operating system requirements . RS-232 interface . . . . . . RS-485 interface . . . . . . USB interface . . . . . . . 4690 OS. . . . . . . . . Hardware requirements . . . . Calling for service . . . . . .
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2CR . . . . . . . . . . . . . . . . . . . . . .
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xi xi xi xi xi xi
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1 1 3 3 5 5 5 5 6 6 6 7
Chapter 2. Removing and replacing FRUs . . . . . Handling static-sensitive devices . . . . . . . . . . Reviewing the FRUs and connections . . . . . . . . Identifying the cable connections . . . . . . . . Removing the logic card . . . . . . . . . . . . Removing the interface card . . . . . . . . . . . Removing the thermal printhead assembly . . . . . . Removing the covers . . . . . . . . . . . . . Removing the paper door . . . . . . . . . . . Removing the ribbon door . . . . . . . . . . . Removing the main cover . . . . . . . . . . . Removing the flipper door (document insert cover) . . Removing the skirt cover . . . . . . . . . . . Removing the distribution card . . . . . . . . . . Removing the flipper cartridge . . . . . . . . . . Removing the thermal printhead cable . . . . . . . Removing the impact printhead and carriage assembly . Removing the impact printer transport . . . . . . . Removing the transport motor . . . . . . . . . . Removing the upper throat assembly . . . . . . . . Removing the impact platen assembly . . . . . . . Removing the thermal latch assembly . . . . . . . Removing the ribbon drive assembly . . . . . . . . Removing the document paper-feed motor and gears. . Removing the tear bar assembly . . . . . . . . . Removing the paper stage, rollers and lift spring . . . Removing the thermal cutter assembly . . . . . . . Removing the thermal paper feed motor and gear . . . Removing the paper-out (paper-motion) sensor assembly © Copyright IBM Corp. 2008
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Removing Removing Removing Removing
the the the the
low-paper sensor cards . grounding strap . . . . flipper springs and rollers main frame assembly . .
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47 49 51 51
Chapter 3. Adjusting and maintaining the Adjusting the printhead gap . . . . . . Using and maintaining the 4610 . . . . Replenishing consumable supplies . . Correctly inserting documents . . . . Cleaning recommendations . . . . . Clearing jams in the check flipper area .
4610 . . . . . . . . . . . .
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53 53 55 55 62 63 66
Chapter 4. Running tests and diagnostics Testing the 4610 . . . . . . . . . . Firmware offline tests . . . . . . . Understanding the Light-Path LEDs . . . Troubleshooting . . . . . . . . . .
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Appendix A. Product specifications Physical dimensions . . . . . . . Temperature and humidity limits . . Connector pin assignments . . . . Power supply . . . . . . . . USB . . . . . . . . . . . . Powered USB . . . . . . . . RS-232 . . . . . . . . . . . RS-485 . . . . . . . . . . . Cash drawer . . . . . . . . . Printing width, speed, and acoustics . Bar codes . . . . . . . . . . . Resident code pages . . . . . .
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77 77 77 78 78 78 78 78 79 79 80 82 82
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Appendix B. Parts listing . . . . . . . . . . . . . . . . . . . . 83 How to use the FRU catalog . . . . . . . . . . . . . . . . . . . . 83 Assembly 1: Models 2CR and 2NR . . . . . . . . . . . . . . . . . 84 Appendix C. Notices . . . . . . . . . . . . . . . Electronic emission notices . . . . . . . . . . . . . Federal Communications Commission (FCC) statement . . European Union EMC Directive conformance statement . . Industry Canada Class A Emission Compliance statement . Avis de conformité aux normes d’Industrie Canada . . . Germany . . . . . . . . . . . . . . . . . . . Australia and New Zealand . . . . . . . . . . . . Chinese Class A warning statement . . . . . . . . . Japanese power line harmonics compliance statement . . Japanese Voluntary Control Council for Interference (VCCI) Korean communications statement . . . . . . . . . Taiwanese Class A warning statement . . . . . . . . Taiwan contact information . . . . . . . . . . . . . Cable ferrite requirement . . . . . . . . . . . . . . Electrostatic Discharge (ESD) . . . . . . . . . . . . Product Recycling and disposal . . . . . . . . . . . . Battery return program . . . . . . . . . . . . . . . For Taiwan: . . . . . . . . . . . . . . . . . .
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For the European For California: . Flat panel displays Monitors . . . . Trademarks . . .
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Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Part number index . . . . . . . . . . . . . . . . . . . . . . . 99
Contents
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Figures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53.
IBM SureMark 4610 printer . . . . . . . . . . . . USB interface card . . . . . . . . . . . . . . . RS-485 interface card . . . . . . . . . . . . . . RS-232 interface card . . . . . . . . . . . . . . Power button . . . . . . . . . . . . . . . . . . Location of serial number . . . . . . . . . . . . . Parts review . . . . . . . . . . . . . . . . . 4610 Models 2CR and 2NR connectors . . . . . . . Opening the paper door and ribbon door . . . . . . . Removing the logic card . . . . . . . . . . . . . Removing the interface card . . . . . . . . . . . Removing the thermal printhead assembly . . . . . . Opening the paper door . . . . . . . . . . . . . Removing the paper door. . . . . . . . . . . . . Removing the ribbon door . . . . . . . . . . . . Removing the main cover . . . . . . . . . . . . Removing the flipper door . . . . . . . . . . . . Removing the skirt cover . . . . . . . . . . . . . Removing the distribution card . . . . . . . . . . . Removing the flipper cartridge . . . . . . . . . . . Removing the thermal printhead cable . . . . . . . . Removing the printhead assembly . . . . . . . . . Removing the right transport shaft adjuster screw . . . . Impact printer transport . . . . . . . . . . . . . Left transport shaft adjuster . . . . . . . . . . . . Removing the transport motor . . . . . . . . . . . Lifting the frame to access the transport motor . . . . . Locating the wear plate and the throat release button . . Removing the upper throat assembly . . . . . . . . Locating the flipper actuator . . . . . . . . . . . . Impact platen and printhead with adjoining parts . . . . Locating the platen bracket, platen spring and platen screw Removing the e-clip . . . . . . . . . . . . . . . Removing the impact platen . . . . . . . . . . . . Removing the thermal latch assembly . . . . . . . . Unhooking the spring latch . . . . . . . . . . . . Removing the ribbon drive assembly . . . . . . . . Removing the e-clip . . . . . . . . . . . . . . . Removing the tear bar assembly . . . . . . . . . . Identifying the lift spring . . . . . . . . . . . . . Removing the rollers . . . . . . . . . . . . . . Locating the shoulder stop . . . . . . . . . . . . Removing the thermal paper feed motor . . . . . . . View with paper-motion sensor assembly open . . . . . Removing the paper-out (paper-motion) sensor assembly . Removing the low-paper sensor . . . . . . . . . . Removing the grounding strap from beneath the frame . . Removing the back rollers . . . . . . . . . . . . Adjusting the printhead gap . . . . . . . . . . . . Inserting the printhead gap gauge . . . . . . . . . Loosening the right-side screw . . . . . . . . . . . Opening the paper door . . . . . . . . . . . . . Paper roll placement . . . . . . . . . . . . . .
© Copyright IBM Corp. 2008
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Opening the ribbon cover . . . . . . . . . . . . Ribbon cartridge loading . . . . . . . . . . . . Ribbon path around the printhead . . . . . . . . Inserting checks . . . . . . . . . . . . . . . Cleaning the MICR read head . . . . . . . . . . Cleaning the thermal printhead. . . . . . . . . . Removing the flipper door (lower document insert cover) Lifting up on the thumb tab . . . . . . . . . . . Removing the check flipper cartridge . . . . . . . Paper feed and document feed buttons . . . . . . Pressing the power button and the R button . . . . . Example of the offline selection main menu . . . . . Locating the diagnostic LEDs . . . . . . . . . . SureMark 4610 Models 2CR and 2NR dimensions . . Printable area of an inserted document (portrait) . . . Printable area of an inserted document (landscape) . .
SureMark Hardware Service
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60 61 62 63 64 65 66 66 67 70 70 71 75 77 81 82
Tables 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Model feature description . . . . . . . . . . . Warranty information . . . . . . . . . . . . . Communication interface, rate and power source . . Distribution card connectors . . . . . . . . . . Specifications of supported single and multipart forms Supported flipping specifications . . . . . . . . Summary of the offline test menu items . . . . . Lightpath LED conditions . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . Summary of dimensions . . . . . . . . . . . Power supply pin designations . . . . . . . . . USB pin designations . . . . . . . . . . . . Powered USB pin designations . . . . . . . . RS-232 pin designations . . . . . . . . . . . RS-485 pin designations . . . . . . . . . . . Cash drawer connector pin designations . . . . . Station characteristics . . . . . . . . . . . . Sound characteristics . . . . . . . . . . . .
© Copyright IBM Corp. 2008
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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 v v v v v v v v
IBM SureMark Printers: User's Guide for Models 2CR and 2NR, GA27-5003 IBM SureMark Printers: firmware update diskettes IBM SureMark Printers: Fonts and Logos Utility Diskette IBM Safety Information—Read This First, GA27-4004 IBM SurePOS 700 Series: Hardware Service Guide, GA27-0363 IBM SurePOS 700 Series: Options and I/0 Devices Service Guide, SY27-0392 IBM SurePOS 700 Series: System Reference, SA27-4224 IBM SurePOS 500 Series: System Reference, SA27-4255 POSS Programming Reference and User’s 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
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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/.
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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.
Figure 1. IBM SureMark 4610 printer
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 © Copyright IBM Corp. 2008
1
Introducing 4610 Models 2CR and 2NR 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 Print speed
Thermal/Impact 80 lps thermal, 4.7 lps narrow format, 4.1 lps wide format for Impact (8lpi)
Usage data User defined fonts - including proportional fonts
Yes
Scalable fonts up to 8X Journal station
No
Single pass MICR, check franking, flipping, printing MICR reading
No Yes
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 Barcode printing Receipt paper loading Receipt paper cutter Receipt tear bar Receipt paper width Print fonts (CPI)
2
Yes Drop and load Standard 80 mm 12, 15, 17, 20
Rotate print (line by line)
Yes
DBCS thermal font - 24x24 matrix
Yes
DBCS impact font - 9x16 or 16x16 matrix
Yes
SureMark Hardware Service
Introducing 4610 Models 2CR and 2NR
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
Introducing 4610 Models 2CR and 2NR
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
Table 3. Communication interface, rate and power source
4
Device
Description
RS-232
9.6K - 115.2K (selectable using Separate power supply offline or online configuration) Baud rate
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
SureMark Hardware Service
Power
Introducing 4610 Models 2CR and 2NR
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.
P
Figure 5. 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 later v Windows Vista with OPOS and JavaPOS support from UPOS 1.96 or later
Chapter 1. Introducing the 4610 Models 2CR and 2NR
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Introducing 4610 Models 2CR and 2NR
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 later v Windows Vista with OPOS and JavaPOS support from UPOS 1.96 or later
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
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SureMark Hardware Service
Introducing 4610 Models 2CR and 2NR
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 1. Introducing the 4610 Models 2CR and 2NR
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SureMark Hardware Service
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.
© Copyright IBM Corp. 2008
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Removing and replacing FRUs
Paper Door
Main Cover
Thermal Cutter Assembly
Document Paper Feed Motor and Gears Platen Assembly
Tear Bar Thermal Latch Assembly
Transport shaft and adjusters
Thermal Printhead Paper Out Sensor
Logic Card
Paper Stage Lift Spring Thermal Paper Feed Motor and Gear Printhead Cartridge Assembly Upper Throat Assembly Paper Feed Rollers Flipper Rollers Low Paper Sensor Distribution Card
Main Frame Assembly Transport Motor Flipper Door Ribbon Door
Flipper Cartridge Ribbon Drive Assembly
Base Frame
Skirt Cover
Grounding Strip
Interface Card
Figure 7. Parts review
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Identifying the cable connections B
C
A
D
E
K
F J
I
H
G
Figure 8. 4610 Models 2CR and 2NR connectors 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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
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:
A
B
Figure 9. Opening the paper door and ribbon door
1. 2. 3. 4.
12
Turn off the power to the 4610. Open the paper door by pressing the blue release button (A in Figure 9). As shown in Figure 9, open the ribbon door (B) by pulling downward. Remove the ribbon. See “Replacing the ribbon” on page 59
SureMark Hardware Service
Removing and replacing FRUs
C
D
Figure 10. Removing the logic card
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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
Removing the interface card The interface card is a customer replaceable unit. 1. Disconnect all power from the 4610.
C
Figure 11. Removing the interface card
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.
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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).
1
2
3
Figure 12. Removing the thermal printhead assembly
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. To replace, reverse these procedures. Note: When you replace the thermal printhead, run the offline test to reset the statistics. See “Firmware offline tests” on page 70.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
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:
P
Figure 13. Opening the paper door
1. Open the paper door: Press and release the blue release button (P in Figure 13). U
U
Figure 14. Removing the paper door
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.
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Removing and replacing FRUs 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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
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.
F
Figure 15. Removing 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.
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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. A
C
B
1
2
Figure 16. Removing the main cover
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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
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).
Figure 17. Removing the flipper door
2. Pull the cover from the printer.
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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.
A
Figure 18. Removing the skirt cover
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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
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.
R
R
Figure 19. Removing 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.
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Removing the flipper cartridge The flipper cartridge is a customer-replaceable part. Follow these steps to remove the flipper cartridge:
1
2 Figure 20. Removing 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. To replace, reverse these steps.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
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.
6mm (.24 in)
N Figure 21. Removing the thermal printhead cable
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.
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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.
A Figure 22. Removing the printhead assembly
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
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
K Figure 23. Removing the right transport shaft adjuster screw
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 1. 2. 3. 4.
replace, Replace the printhead and carriage assembly into the frame. To locate the new cable, position the carriage at its full left position. Make sure that the loop in the cable just touches the left frame wall 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.
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Removing the impact printer transport Figure 24 shows the components of the impact printer transport.
L
O
M
N
Figure 24. Impact printer transport. L
Transport shaft
M
Belt tensioner spring
N
Belt tensioner assembly
O
Carriage timing belt
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:
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
A Figure 25. Left transport shaft adjuster
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.
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Removing and replacing FRUs
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.
S
Figure 26. Removing the transport motor
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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
M Figure 27. Lifting the frame to access 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. To replace, reverse these steps. Note: After you replace the transport motor, follow the procedures to adjust the printhead gap. See “Adjusting the printhead gap” on page 53.
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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
B
A Figure 28. Locating the wear plate and the throat release button
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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
A1
A2 Figure 29. Removing the upper throat assembly
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).
T
Figure 30. Locating the flipper actuator
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Removing and replacing FRUs 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. To replace, reverse these steps.
Removing the impact platen assembly To remove the impact platen assembly (C in Figure 31), follow these procedures:
C
D B E A
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
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.
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Removing and replacing FRUs 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.
L
M
O Figure 32. Locating the platen bracket, platen spring and platen screw. L
Platen bracket
M
Platen spring
O
Platen screw
7. See Figure 32. Remove the screw (O) from the impact platen. 8. Remove the impact platen bracket (L), and the tensioner spring (M.
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S
Figure 33. Removing the e-clip
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.
A
Figure 34. Removing the impact platen
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. To replace, reverse these steps. Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs Note: After you replace the impact platen assembly, follow the procedures to adjust the printhead gap. See “Adjusting the printhead gap” on page 53.
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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.
A
Figure 35. Removing the thermal latch assembly
3. See A in Figure 35. Lift to remove the blue latch button.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
A
Figure 36. Unhooking the spring latch
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. To replace, reverse these steps.
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Removing and replacing FRUs
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
T Figure 37. Removing the ribbon drive assembly
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. To replace, reverse these steps.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
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.
M
N L
Figure 38. Removing the e-clip
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. To replace, reverse these steps.
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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,
B
Figure 39. Removing the tear bar assembly
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). To replace, reverse these steps.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
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.
Figure 40. Identifying the lift spring
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.
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R
Figure 41. Removing the rollers
Removing the receipt rollers 6. 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. To replace, reverse these procedures.
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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
A
B
Figure 42. Locating the shoulder stop
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 To replace, reverse these steps.
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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 “Removing the covers” on page 16,
I
H
K
J
Figure 43. Removing the thermal paper feed motor
3. Open the thermal cutter assembly. 4. Remove the screw (J in Figure 43) holding the thermal paper feed motor. Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs 5. 6. 7. 8. 9.
Rotate the motor (I) to the right to remove. Unplug the motor from the connector (H ). Remove the e-clip holding the gear. Lift out the gear (K). 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.
Figure 44. View with paper-motion sensor assembly open
2. Flip down the paper-motion sensor assembly cover. See Figure 44.
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C S
Figure 45. Removing the paper-out (paper-motion) sensor assembly
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. To replace, reverse these procedures.
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.
Chapter 2. Removing and replacing FRUs
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Removing and replacing FRUs
A B
Figure 46. Removing the low-paper sensor
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. To replace, reverse these procedures.
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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 “Removing the covers” on page 16,
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Removing and replacing FRUs
G
G Figure 47. Removing the grounding strap from beneath the frame
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.
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Removing and replacing FRUs
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.
A Figure 48. Removing the back rollers
4. Turn the printer over and remove the back set of rollers (A in Figure 48) by pulling out the spring. To replace, reverse these procedures.
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.
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Chapter 3. Adjusting and maintaining the 4610 Adjusting the printhead gap . . . . . Using and maintaining the 4610 . . . Replenishing consumable supplies . Loading and replacing the paper roll Installing large paper rolls . . . . Replacing the ribbon . . . . . . Correctly inserting documents . . . Cleaning recommendations . . . . Cleaning the MICR read head . . Cleaning the thermal printhead . . Clearing jams in the check flipper area
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53 55 55 56 59 59 62 63 63 65 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
© Copyright IBM Corp. 2008
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Adjusting and maintaining the 4610 3. Loosen the screw (A in Figure 49 on page 53) on the left side of the printer.
A
Figure 50. Inserting the printhead gap gauge
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.
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K Figure 51. Loosening the right-side screw
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 cartridges Make sure that you have the correct supplies for the 4610.
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Adjusting and maintaining the 4610
Loading and replacing the paper roll Ensure that you have the correct paper for the 4610. See “Supported paper types” on page 57.
P
Figure 52. Opening the paper door
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.
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Figure 53. Paper roll placement
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 paper’s 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: Chapter 3. Adjusting and maintaining the 4610
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Adjusting and maintaining the 4610 Width 79.5 ± 0.5 mm (3.13 ± 0.02 in.) Outside Diameter 102 mm (4.0 in.) maximum Thickness 60 µm (0.00225 in.) Range: 41 µm minimum to 99 µm 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.
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Adjusting and maintaining the 4610 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:
68–90 g/m2 (18–24 #)
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:
75–95 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.
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Adjusting and maintaining the 4610
Figure 54. Opening the ribbon cover
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.
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Adjusting and maintaining the 4610
Figure 55. Ribbon cartridge loading
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.
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Adjusting and maintaining the 4610
A
B
Incorrect
Correct
Figure 56. Ribbon path around the printhead. Correct placement of the ribbon (A) around the printer guides (B).
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:
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Adjusting and maintaining the 4610 Insertion of Check for Printing the Face
Federal Reserve Bank Regulation CC
Do Not Sign / Write / Stamp Below This Line For Financial Usage Only
Endorse Here
Insertion of Check for MICR Reading and Franking
4001 19
Pay To The Order Of
$ Dollars
Memo
041117847096 095867238671
4001
Figure 57. Inserting checks
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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Adjusting and maintaining the 4610
M
Figure 58. Cleaning the MICR read head
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.
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Adjusting and maintaining the 4610
Cleaning the thermal printhead The thermal printhead can be cleaned whenever print quality deteriorates. 1. Open the paper cover. Detailed View of Thermal Printhead Thermal Print Line
Paper Cover
Figure 59. Cleaning the thermal printhead
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.
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Adjusting and maintaining the 4610
Clearing jams in the check flipper area If a check jams in the check flipper mechanism:
Figure 60. Removing the flipper door (lower document insert cover)
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 61. Lifting up on the thumb tab
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Adjusting and maintaining the 4610 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.)
Figure 62. Removing the check flipper cartridge
5. Reach inside the document insert station and carefully remove the jammed check. 6. Reinstall the check flipper cartridge and the flipper door.
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Adjusting and maintaining the 4610
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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.
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Firmware offline tests To enter the firmware offline test and setup procedures follow these steps:
A
Figure 63. Paper feed and document feed buttons
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).
Figure 64. Pressing the power button and the R button
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.
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Running tests and diagnostics 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 Thermal Receipt test Choose Emulation Mode Model Selection EIA-232/RS-232 Flow Control More Selections
Codes 1 2 3 4 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.
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
1. Thermal receipt test
Prints a receipt
2. Choose emulation mode
Displays the sub-menus (see next column)
3. Model selection
Sub-menu (if applicable)
Definition
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.
You specify the printer type: MICR reading or non-MICR reading model.
4. EIS-232/RS-232 flow Provides a list of available baud rates and flow controls. control 5. More selections
Provides additional menus:
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Running tests and diagnostics 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 Starts printhead test 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:
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Running tests and diagnostics A card in the printer has been replaced Main Logic’s S/N is 41-MVT02 Interface Card’s 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/.
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Running tests and diagnostics
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: Note: IBM recommends that you use the offline menus to initiate this 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: Note: IBM recommends that you use the offline menus to initiate this 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.
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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.
Figure 66. Locating the diagnostic LEDs Table 8. Lightpath LED conditions LED
Failing Component
1
Main logic card
2
Interface card
3
Thermal printhead
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Running tests and diagnostics
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. v If using USB communication with a powered USB cable, check that the system is powered ON.
Printer-ready indicator is blinking.
v Check that the customer receipt station has paper loaded correctly. Close the cover and push the Customer Receipt Feed button to feed a small amount of paper. v Check the document insert station printhead and paper path for any obstructions. v Check that the paper and ribbon doors are closed.
Checks not flipping
1. Check for printer jams. Go to “Clearing jams in the check flipper area” on page 66. 2. Print the offline menu and verify that the printer is configured correctly for a MICR/flipper printer. See “Firmware offline tests” on page 70.
Checks not reading
1. Go to “Cleaning the MICR read head” on page 63. 2. Print the offline menu and verify that the printer is configured correctly for a MICR/flipper printer. See “Firmware offline tests” on page 70.
Customer receipt station is feeding v Ensure that the paper roll is not upside down. Go to “Loading and replacing paper, but is not printing. the paper roll” on page 56. v Clean the printhead. See “Cleaning the thermal printhead” on page 65. Document insert station is not printing
v Check the paper path. v Check to see if the ribbon is installed correctly. v Change the ribbon, go to “Replacing the ribbon” on page 59.
Notes: 1. Record all symptoms before calling for service. 2. If you receive software error messages, refer to the software manual of the application. 3. Call your service representative.
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Appendix A. Product specifications This section describes the Models 2CR and 2NR physical specifications.
Physical dimensions Figure 67 describes the physical dimensions:
19 (7. 8 mm 8i n.)
25 5 (10 mm in. )
mm ) 5 . 0 n. 2 0 .89 i (7
14 (5. 0 mm 5i n.)
m 2 m in.) 0 2 01 8 (7. Figure 67. SureMark 4610 Models 2CR and 2NR dimensions Table 10. Summary of dimensions Width:
202 mm (7.801 in.) footprint 200.5 mm (7.89″) with overhanging edge
Height:
Front: 140 mm (5.5 in.) Rear: 198 mm (7.8 in.)
Depth:
277 mm (10.914 in.)
Weight:
4.8kg (10.582 lb)
Temperature and humidity limits Shipping
-40° to 60° C (-40° to 140° F) with 5% to 100% relative humidity including condensation, but excluding rain
Storage
0° to 60° C (32° to 140° F)
Operating
5° to 40° C (42.8° to 104° F) with 8% to 80% relative humidity
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Product specifications
Connector pin assignments The following sections describe the connector pin assignments for the external connectors
Power supply Table 11. Power supply pin designations Pin
Signal
1
+24 V DC
2
Not connected
3
Ground
USB 1 2 3 4
Table 12. USB pin designations Pin
Signal
1
Vbus (+5 V DC)
2
Minus data
3
Plus data
4
Ground
Powered USB Table 13. Powered USB pin designations Pin
Signal
1
Ground (+24 VDC)
2
(+24 VDC)
3
Ground (Vbus)
4
Plus data
5
Minus data
6
Vbus +5VDC
7
+24 VDC
8
Ground (+24 VDC)
RS-232 Table 14. RS-232 pin designations
78
Pin
Signal
1
Not connected
2
Transmit
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Product specifications Table 14. RS-232 pin designations (continued) Pin
Signal
3
Receive
4
DTR
5
Signal ground
6
DSR
7
Not connected
8
RTS
9
Not connected
RS-485 Table 15. RS-485 pin designations. Note: The 24V version is available in Japan; all 38 V DC's change to 24 V DC for that card. Pin
Signal
1
+5 V DC
2
Ground (5 V DC)
3
+5 V DC
4
Ground (5 V DC)
5
+5 V DC
6
Ground (5V DC)
7
Data "B"
8
Data "A"
9
Ground (38 V DC)
10
+38 V DC
11
Ground (38 V DC)
12
+38 V DC
13
Ground (38 V DC)
14
+38 V DC
15
Ground (38 V DC)
16
+38 V DC
Cash drawer
4
1
A single connector can drive either a single cash drawer or two cash drawers using a special cable. The connector provides a status line if one of the cash drawers is open. The cash drawer cannot be activated while the printer is operating.
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Product specifications Table 16. Cash drawer connector pin designations Pin
Signal
1
Not connected
2
Solenoid 1 drawer
3
Cash drawer status
4
+24 VDC
5
Solenoid 2 drawer
6
Ground
Printing width, speed, and acoustics Table 17. Station characteristics Characteristic
Customer Receipt Station
Document Insert Station
Speed (see note following table)
80 lps
4.1 lps wide station
Paper Width
All models: 80 mm (3.54 in.)
Print Width
34 characters at 12 cpi, 44 characters at 15 cpi, 48 characters at 17 cpi 57 characters at 20 cpi
37 characters at 12 cpi, 47 characters at 15 cpi, 52 characters at 17 cpi.
Pitch
12, 15, 17, 20 cpi
12, 15, 17 cpi
4.7 lps narrow station (8 lpi)
Note: To conserve power, the Models 2CR and 2NR reduce their throughput when printing high print densities, such as logo messages or full black lines. Because these types of print messages are used on a limited basis, the overall performance when printing a customer receipt is not noticeably affected. The reduced print speed is based on the number of print dots that are turned on for a given print line, which is defined as dot utilization. Dot utilization is typically low for normal character printing and up to 100% for full black line printing. The SureMark printer operates at 80 lps at low dot utilization, and at slower speeds as the dot utilization increases. Table 18. Sound characteristics Type
Description
LwAd Operating (bels)
SureMark
Printer
5.7
LpAm
Idling (bels) Operating (dB) N/A
61.5
m
Idling (dB) N/A
Operating (dB) 47
Idling (dB) N/A
Notes: LwAd The declared upper limit of the sound power level for a random sample of machines. LpAm The mean value of the A-weighted sound pressure levels at the operator position (if any) for a random sample of machines.
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Product specifications m The mean value of the A-weighted sound pressure levels at the one-meter (bystander) positions for a random sample of machines. N/A
Indicates not applicable.
All measurements were made in accordance with ISO 7779 and reported in conformance with ISO 9296. Figure 68 and Figure 69 on page 82 show the printable area on an inserted document for both portrait and landscape.
Figure 68. Printable area of an inserted document (portrait)
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Product specifications
Figure 69. Printable area of an inserted document (landscape)
Bar codes SureMark printers can generate these bar codes: v UPC A/E v JAN 8 (EAN) v JAN 13 (EAN) v Code 39 v ITF v Code 128 A, B, C v Code 93 v Codabar v PDF417
Resident code pages These code pages are resident in the printer: v Generic v 437 (US) v 858 (International) v 860 (Portuguese) v 863 (Canadian French) v 865 (Norwegian) The firmware supports the following in the thermal station: v Proportional fonts v Scalable fonts v Color printing: black plus one accent on two-color thermal paper (thermal station only) v Upside-down printing
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Appendix B. Parts listing This section contains FRU part number information.
How to use the FRU catalog This parts listing contains reference drawings and a corresponding index for all field replaceable parts. The index provides the part number, the quantity required (units), and a description of the part. Listed below is additional information about the parts assembly index. SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts, they are broken down on the same list. Common parts are shown by one index number. Parts specific to one or the other of the assemblies are listed separately and identified by description. AR
(As Required) in the Units column indicates that the quantity is not the same for all machines.
NP
(Non-Procurable) in the Units column indicates that the part is non-procurable and that the individual parts or the next higher assembly should be ordered.
NR
(Not Recommended) in the Units column indicates that the part is procurable, but not recommended for field replacement, and that the next higher assembly should be ordered.
R
(Restricted) in the Units column indicates the part has a restricted availability.
INDENTURE The indenture is marked by a series of dots located before the parts description. The indenture indicates the relationship of a part to the next higher assembly. No Dot Main assembly One Dot Detail parts of a main assembly One Dot Subassembly of the main assembly Two dots Detail part of a one-dot subassembly Two dots Subassembly of a one-dot subassembly Three dots Detail part of a two-dot subassembly
© Copyright IBM Corp. 2008
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Assembly 1: Models 2CR and 2NR 1
2
3
4 5
6
7
27
8 10
9 19 19 17
11 12 18
13 14
19 20 21 22
15
23 16
24
25
26
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Assembly 1: (continued) Asm– Index
Part Number
1– – – – – –1 –1 –2 –2 –3 –4 –5 –5 –6 –7 –8 –9 –10 –11 –12 –13 –14 –14 –14
44D0145 44D0155 44D0165 44D0175 44D0162 44D0164 44D0166 44D0167 44D0148 44D0194 44D0152 44D0154 44D0186 44D0187 44D0189 44D0188 44D0156 46N2641 44D0206 44D0184 44D0171 44D0172 44D0174
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
–14
44D0176
1
–15 –15 –16 –17 –18 –18 –19 –20 –21 –22 –23 –24 –25 –26 –26 –26 –26 –27 – – – – – – –
44D0168 44D0169 44D0178 46N2640 44D0151 44D0149 44D0196 46N2639 44D0195 44D0179 44D0177 44D0161 44D0204 44M2417 44D0158 44D0159 44D0157 44D0185
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
44D0198 44D0197 44D0199 44D0208
Units Description Note: Refer to Figure 7 on page 10 for the part names and locations Model 2NR with pearl white covers Model 2CR with pearl white covers Model 2NR with iron gray covers Model 2CR with iron gray covers Paper door, pearl white Paper door, iron gray Main cover, pearl white Main cover, iron gray Thermal cutter assembly Document paper feed motor and gear Impact platen assembly (Models 2CR) Impact platen assembly (Models 2NR) Tear bar assembly Thermal latch assembly Thermal printhead Paper out sensor assembly Main logic card Impact printhead/carriage assembly Main frame assembly Transport motor assembly Flipper door, pearl white (Model 2CR) Flipper door, iron gray (Model 2CR) Flipper door, pearl white (Model 2NR) Note: Model 2NR doors have no magnet, rollers, or springs Flipper door, iron gray (Model 2NR) Note: Model 2NR doors have no magnet, rollers, or springs Ribbon door, pearl white Ribbon door, iron gray Ribbon drive assembly Thermal paper feed motor and gears Upper throat assembly (Model 2NR) Upper throat assembly (Model 2CR) Paper stage, rollers, and lift spring Flipper rollers and springs Low-paper sensors Distribution card Flipper cartridge assembly (Model 2CR) Skirt, iron gray Ground strap RS-485 interface card (Japan) RS-232 interface card USB interface RS-485 interface card Transport shaft and adjusters: v Belt tensioner assembly v Belt tensioner spring v Carriage timing belt DI and paper out sensors cable Flipper, ribbon, transport cable CR paper feed motor cable Thermal head cable with clamp
Appendix B. Parts listing
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Assembly 1: (continued)
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Appendix C. Notices This information was developed for products and services offered in the U.S.A. IBM may not offer the products, services, or features discussed in this document in other countries. Consult your local IBM representative for information on the products and services currently available in your area. Any reference to an IBM product, program, or service is not intended to state or imply that only that IBM product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any IBM intellectual property right may be used instead. However, it is the user’s responsibility to evaluate and verify the operation of any non-IBM product, program, or service. IBM may have patents or pending patent applications covering the subject matter in this document. The furnishing of this document does not give you any license to these patents. You can send license inquiries, in writing, to: IBM Director of Licensing IBM Corporation North Castle Drive Armonk, NY 10504-1785 U.S.A. For license inquiries regarding double-byte character set (DBCS) information, contact the IBM Intellectual Property Department in your country or send inquiries, in writing, to: IBM World Trade Asia Corporation Licensing 2-31 Roppongi 3-chome, Minato-ku Tokyo 106, Japan The following paragraph does not apply to the United Kingdom or any other country where such provisions are inconsistent with local law: INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION "AS IS" WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you. This information could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in new editions of the publication. IBM may make improvements and/or changes in the product(s) and/or program(s) described in this publication at any time without notice. IBM may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. Any references in this information to non-IBM Web sites are provided for convenience only and do not in any manner serve as an endorsement of those Web sites. The materials at those Web sites are not part of the materials for this IBM product and use of those Web sites is at your own risk.
© Copyright IBM Corp. 2008
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Information concerning non-IBM products was obtained from the suppliers of those products, their published announcements or other publicly available sources. IBM has not tested those products and cannot confirm the accuracy of performance, compatibility or any other claims related to non-IBM products. Questions on the capabilities of non-IBM products should be addressed to the suppliers of those products. This information is for planning purposes only. The information herein is subject to change before the products described become available.
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Electronic emission notices Federal Communications Commission (FCC) statement This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. IBM is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the user’s authority to operate the equipment. This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation.
European Union EMC Directive conformance statement This product is in conformity with the protection requirements of EU Council Directive 2004/108/EC on the approximation of the laws of the Member States relating to electromagnetic compatibility. IBM cannot accept responsibility for any failure to satisfy the protection requirements resulting from a non-recommended modification of the product, including the fitting of non-IBM option cards. This product has been tested and found to comply with the limits for Class A Information Technology Equipment according to CISPR 22/European Standard EN 55022. The limits for Class A equipment were derived for commercial and industrial environments to provide reasonable protection against iinterferencewith licensed communication equipment. Attention: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. European Community contact: IBM Technical Regulations Pascalstr. 100, Stuttgart, Germany 70569 Telephone: 0049 (0)711 785 1176 Fax: 0049 785 1283 E-mail:
[email protected]
Appendix C. Notices
89
Industry Canada Class A Emission Compliance statement This Class A digital apparatus complies with Canadian ICES-003.
Avis de conformité aux normes d’Industrie Canada Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.
Germany Zulassungsbescheinigung laut dem Deutschen Gesetz über die elektromagnetische Verträglichkeit von Geräten (EMVG) vom 30. August 1995 (bzw. der EMC EG Richlinie 89/336). Dieses Gerät ist berechtigt in Übereinstimmung mit dem Deutschen EMVG das EG-Konformitätszeichen - CE - zu führen. Verantwortlich für die Konformitätserklärung nach Paragraph 5 des EMVG ist die IBM Deutschland Informationssysteme GmbH, 70548 Stuttgart Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2: Das Gerät erfüllt die Schutzanforderungen nach EN 50082–1 und EN 55022 Klasse A.
EN 55022 Klasse A Geräte müssen mit folgendem Warnhinweis versehen werden: ″Warnung: dies ist eine Einrichtung der Klasse A. Diese Einrichtung kann im Wohnbereich Funkstörungen verursachen; in diesem Fall kann vom Betreiber verlangt werden, angemessene Maβnahmen durchzuführen und dafür aufzukommen.″ EN 50082–1 Hinweis: ″Wird dieses Gerät in einer industriellen Umgebung betrieben (wie in EN 50082–2 festgelegt), dann kann es dabei eventuell gestört werden. In solch einem Fall ist der Abstand bzw. die Abschirmung zu der industriellen Störquelle zu vergröβern.″ Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte, wie in den IBM Handbüchern angegeben, zu installieren und zu betreiben.
Australia and New Zealand Attention: This is a Class A product. In a domestic environment this product may cause radio interference, in which case the user may be required to take adequate measures.
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Chinese Class A warning statement Attention: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.
Japanese power line harmonics compliance statement
Japanese Voluntary Control Council for Interference (VCCI) statement Attention: This product is a Class A Information Technology Equipment and conforms to the standards set by the Voluntary Control Council for Interference by Technology Equipment (VCCI). In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.
Korean communications statement Please note that this device has been approved for business purposes with regard to electromagnetic interference. If you find this is not suitable for your use, you may exchange it for a non-business purpose one.
Appendix C. Notices
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Taiwanese Class A warning statement
Taiwan contact information
IBM Taiwan Product Service Contact Info: IBM Taiwan Corporation 3F, No 7, Song Ren Road, Taipei Taiwan Telephone: 0800-016-888
Cable ferrite requirement All cable ferrites are required to suppress radiated EMI emissions and must not be removed.
Electrostatic Discharge (ESD) Attention: ESD damage can occur when there is a difference in charge between the part, the product, and the service person. No damage will occur if the service person and the part being installed are at the same charge level.
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ESD Damage Prevention Anytime a service action involves physical contact with logic cards, modules, back-panel pins, or other ESD sensitive (ESDS) parts, the service person must be connected to an ESD common ground point on the product through the ESD wrist strap and cord. The ESD ground clip can be attached to any frame ground, ground braid, green wire ground, or the round ground prong on the AC power plug. Coax or connector outside shells can also be used. Handling Removed Cards Logic cards removed from a product should be placed in ESD protective containers. No other object should be allowed inside the ESD container with the logic card. Attach tags or reports that must accompany the card to the outside of the container.
Product Recycling and disposal This unit must be recycled or discarded according to applicable local and national regulations. IBM encourages owners of information technology (IT) equipment to responsibly recycle their equipment when it is no longer needed. IBM offers a variety of product return programs and services in several countries to assist equipment owners in recycling their IT products. Information on IBM product recycling offerings can be found on IBM’s Internet site at http://www.ibm.com/ibm/ environment/products/prp.shtml. Español: Esta unidad debe reciclarse o desecharse de acuerdo con lo establecido en la normativa nacional o local aplicable. IBM recomienda a los propietarios de equipos de tecnología de la información (TI) que reciclen responsablemente sus equipos cuando éstos ya no les sean útiles. IBM dispone de una serie de programas y servicios de devolución de productos en varios países, a fín de ayudar a los propietarios de equipos a reciclar sus productos de TI. Se puede encontrar información sobre las ofertas de reciclado de productos de IBM en el sitio web de IBM http://www.ibm.com/ibm/environment/products/prp.shtml.
Notice: This mark applies only to countries within the European Union (EU) and Norway. Appliances are labeled in accordance with European Directive 2002/96/EC concerning waste electrical and electronic equipment (WEEE). The Directive determines the framework for the return and recycling of used appliances as applicable throughout the European Union. This label is applied to various products to indicate that the product is not to be thrown away, but rather reclaimed upon end of life per this Directive. In accordance with the European WEEE Directive, electrical and electronic equipment (EEE) is to be collected separately and to be reused, recycled, or recovered at end of life. Users of EEE with the WEEE marking per Annex IV of the Appendix C. Notices
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WEEE Directive, as shown above, must not dispose of end of life EEE as unsorted municipal waste, but use the collection framework available to customers for the return, recycling, and recovery of WEEE. Customer participation is important to minimize any potential effects of EEE on the environment and human health due to the potential presence of hazardous substances in EEE. For proper collection and treatment, contact your local IBM representative. Disposal of IT products should be in accordance with local ordinances and regulations.
Battery return program This product may contain sealed lead acid, nickel cadmium, nickel metal hydride, lithium, or lithium ion battery. Consult your user manual or service manual for specific battery information. The battery must be recycled or disposed of properly. Recycling facilities may not be available in your area. For information on disposal of batteries outside the United States, go to http://www.ibm.com/ibm/environment/ products/batteryrecycle.shtml or contact your local waste disposal facility. In the United States, IBM has established a return process for reuse, recycling, or proper disposal of used IBM sealed lead acid, nickel cadmium, nickel metal hydride, and other battery packs from IBM equipment. For information on proper disposal of these batteries, contact IBM at 1-800-426-4333. Please have the IBM part number listed on the battery available prior to your call.
For Taiwan:
Please recycle batteries.
For the European Union:
Notice: This mark applies only to countries within the European Union (EU) Batteries or packaging for batteries are labeled in accordance with European Directive 2006/66/EC concerning batteries and accumulators and waste batteries and accumulators. The Directive determines the framework for the return and recycling of used batteries and accumulators as applicable throughout the European Union. This label is applied to various batteries to indicate that the battery is not to be thrown away, but rather reclaimed upon end of life per this Directive.
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In accordance with the European Directive 2006/66/EC, batteries and accumulators are labeled to indicate that they are to be collected separately and recycled at end of life. The label on the battery may also include a chemical symbol for the metal concerned in the battery (Pb for lead, Hg for mercury and Cd for cadmium). Users of batteries and accumulators must not dispose of batteries and accumulators as unsorted municipal waste, but use the collection framework available to customers for the return, recycling and treatment of batteries and accumulators. Customer participation is important to minimize any potential effects of batteries and accumulators on the environment and human health due to the potential presence of hazardous substances. For proper collection and treatment, contact your local IBM representative.
For California: Perchlorate material – special handling may apply Refer to http://www.dtsc.ca.gov/hazardouswaste/perchlorate. The foregoing notice is provided in accordance with California Code of Regulations Title 22, Division 4.5, Chapter 33: Best Management Practices for Perchlorate Materials. This product/part includes a lithium manganese dioxide battery which contains a perchlorate substance.
Flat panel displays The fluorescent lamp in the liquid crystal display contains mercury. Dispose of it as required by local ordinances and regulations.
Monitors Connecticut - Please see the web site of the Department of Environmental Protection at http://www.ct.gov/dep for information about recycling covered electronic devices in the State of Connecticut, or telephone the Connecticut Department of Environmental Protection at 1-860-424-3000. Washington - Please see the web site of the Department of Ecology at http://1800recycle.wa.gov/ for information about recycling covered electronic devices in the State of Washington, or telephone the Washington Department of Ecology at 1-800Recycle.
Trademarks The following are trademarks of International Business Machines Corporation in the United States or other countries, or both: AnyPlace Kiosk(tm) AnyPlace POS Hub(tm) DB2 DB2 Universal Database IBM and the IBM logo PS/2 SureMark SurePoint SurePOS Wake on LAN WebSphere Appendix C. Notices
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Microsoft, Windows, Windows NT, and the Windows logo are trademarks of Microsoft Corporation in the United States, other countries, or both. Celeron and Intel are trademarks of Intel corporation in the United States, or other countries. Java and all Java-based trademarks and logos are trademarks or registered trademarks of Sun Microsystems, Inc. in the United States, or other countries, or both. Other company, product, or service names may be trademarks or service marks of others.
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Index A
electronic emissions notices (continued) Taiwan 92 electrostatic discharge (ESD) 92 end of life disposal 93 equipment disposal 93
accessibility of publications xi adjusting the printhead gap 53
B F
bar codes, supported 82 battery return program 94 battery, European Union 94
C cable ferrite requirement 92 calling for service 7 changing the interface card or logic card check verification, printing 62 checks, clearing jams 66 Class A compliance statement Australia and New Zealand 90 China 91 European Union 89 FCC (USA) 89 Germany 90 Industry Canada 90 Japan 91 Taiwan 92 cleaning recommendations 63 cleaning the MICR read head 63 clearing jams, DI station 66 code pages, resident 82 communication interfaces 3 RS-232 interface card 4 USB interface card 3 connector pin assignments 78 covers ribbon cover 60
D damage from electrostatic discharge 92 dimensions, physical 77 disposal of equipment 93 document insert forms 58 document sensor threshold, resetting 74
72
ferrite requirement 92 firmware offline tests 70 flat panel displays 95 flippable document specifications 59 forms, document insert, specifications 58 FRU catalog how to use 83
H handling static-sensitive devices 9 hardware adjustment procedures 53 hardware requirements 6 height, all models 77 humidity requirements 77
I identifying the cable connections 11 installing large paper rolls 59 thermal printhead assembly 15 installing the logic card 12 interfaces, communication 3 introduction 1
J Japanese power line harmonics compliance statement 91 Japanese Voluntary Control Council for Interference statement 91
K Korean communications statement
E
L
electronic emissions notices 89 Australia and New Zealand 90 China 91 European Union 89 FCC (USA) 89 Germany 90 Industry Canada 90 Japan 91 Korea 91
lightpath LEDs 75 loading and replacing the paper roll locating the power button 5
© Copyright IBM Corp. 2008
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56
M mercury-added statement 95 MICR test results, understanding 74 model and feature description 2
97
model number location 7 models and features 1
N notices 87 battery recycling 94 cable ferrites 92 electronic emissions 89 electrostatic discharge (ESD) end of life disposal 93 IBM 87
92
O offline tests customer receipt test 74 offline tests, earlier methods 74 opening the paper door 56 opening the paper door and ribbon door 12 opening the ribbon cover 60 operating system requirements 5 overview of removal and replacements parts 9
P paper document insert, specifications 58 large rolls 59 supported types 57 paper roll placement 57 paper, thermal, specifications 57 perchlorate 95 physical dimensions 77 pictorial overview of all FRUs 9 printhead cleaning, thermal head 65 product specifications 77 publications, related xi
R related publications and diskettes xi removal and replacement distribution card 22 document paper-feed motor and gear 40 flipper cartridge 23 flipper door (document insert cover) 20 grounding strap 50 impact platen assembly 33 impact printer transport 27 interface card 14 logic card 12 low-paper sensor card 47 main cover 19 paper door 16 paper stage, rollers and lift spring 42 paper-motion sensor assembly 46 printhead and carriage assembly 25 ribbon door 18 ribbon drive assembly 39
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removal and replacement (continued) skirt cover 21 tear bar assembly 41 thermal cutter assembly 43 thermal latch assembly 37 thermal printhead assembly 15 thermal printhead cable 24 transport motor 29 upper throat assembly 31 removal and replacement procedures thermal paper-feed motor and gear 45 removing belt tensioner assembly 28 upper throat assembly 33 removing the carriage timing belt 27 removing the printhead carriage assembly 25 Resetting the printer and the Document Sensor Threshold 74 resident code pages 82 ribbon path round the printhead 62 supported types 62 ribbon drive assembly, removing 39 ribbon loading 59 ribbon replacement 59 ribbons, print 62 running tests and diagnostics 69
S serial number location 7 static-sensitive devices, handling 9 storing a new serial number in the firmware supported paper types 57
T Taiwanese battery recycling statement temperature requirements 77 testing the 4610 69 thermal paper specifications 57 trademarks 95 transport motor, removing 29
U understanding the lightpath LEDs
W warranty information 3 weight, all models 77
75
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73
Part number index Part Number
Asm– Index
44D0145 44D0148 44D0149 44D0151 44D0152 44D0154 44D0155 44D0156 44D0157 44D0158 44D0159 44D0161 44D0162 44D0164 44D0165 44D0166 44D0167 44D0168 44D0169 44D0171 44D0172 44D0174 44D0175 44D0176 44D0177 44D0178 44D0179 44D0184 44D0185 44D0186 44D0187 44D0188 44D0189 44D0194 44D0195 44D0196 44D0197 44D0198 44D0199 44D0204 44D0206 44D0208 44M2417 46N2639 46N2640 46N2641
1– 1–3 1–18 1–18 1–5 1–5 1– 1–10 1–26 1–26 1–26 1–24 1–1 1–1 1– 1–2 1–2 1–15 1–15 1–14 1–14 1–14 1– 1–14 1–23 1–16 1–22 1–13 1–27 1–6 1–7 1–9 1–8 1–4 1–21 1–19 1– 1– 1– 1–25 1–12 1– 1–26 1–20 1–17 1–11
© Copyright IBM Corp. 2008
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Readers’ Comments — We’d Like to Hear from You SureMark 4610 Printers Hardware Service Guide for Models 2CR and 2NR Publication No. GA27-5004-00 We appreciate your comments about this publication. Please comment on specific errors or omissions, accuracy, organization, subject matter, or completeness of this book. The comments you send should pertain to only the information in this manual or product and the way in which the information is presented. For technical questions and information about products and prices, please contact your IBM branch office, your IBM business partner, or your authorized remarketer. When you send comments to IBM, you grant IBM a nonexclusive right to use or distribute your comments in any way it believes appropriate without incurring any obligation to you. IBM or any other organizations will only use the personal information that you supply to contact you about the issues that you state on this form. Comments:
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