DBCS Hardware Service Manual PDF

SureMark Printers
DBCS Hardware Service Manual
updated March 18, 2002 GY27-0397-00

updated March 18, 2002
Note
Before using this information and the product it supports, be sure to read “Safety Information” on page viii, Appendix D,
“Translated Safety Notices” on page 187, and the general information under Appendix E, “Notices” on page 195.
Third Edition (September 2000)

This edition applies to the IBM SureMark Printers, models TI5 and Models TF7 and TM7. This edition replaces
publication GY18-2406-02.
Order publications through your IBM representative or the IBM branch office serving your locality. Publications are
not stocked at the address given below.
A form for reader’s comments is also provided at the back of this publication. If the form has been removed, address
your comments to:
IBM Corporation,
Information Development, Department CJMA
PO Box 12195
Research Triangle Park, North Carolina, 27709 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 1999,2001. All rights reserved.
US Government Users Restricted Rights – Use, duplication or disclosure restricted by GSA ADP Schedule Contract
with IBM Corp.
Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Who Should Read This Manual . . . . . . . . . . . . . . . . . . . vii
How This Manual Is Organized . . . . . . . . . . . . . . . . . . . vii
Related Publications and Diskettes . . . . . . . . . . . . . . . . . viii
Tell Us What You Think . . . . . . . . . . . . . . . . . . . . . . viii
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . viii
Summary of Changes . . . . . . . . . . . . . . . . . . . . . xix

Web-only Update for GY27-0397-00 (March 2002). . . . . . . . . . . . xix
Web-only Update for GY27-0397-00 (October 2001) . . . . . . . . . . . xix
GY27-0397-00 . . . . . . . . . . . . . . . . . . . . . . . . . xix
GY18-2406-01 . . . . . . . . . . . . . . . . . . . . . . . . . xix
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
Part 1. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 1. Overview . . . . . . . . . . . . . . . . . . . . . .
. 3
Indicators, Controls, and Printing Stations – SureMark ModelS TI5 and TG5 . .
. 3
Indicator, Control, and Printing Station – Single-Station SureMark Printers . .
. 4
Communication Mode Selections. . . . . . . . . . . . . . . . . .
. 5
RS-232 Baud Rate Selection . . . . . . . . . . . . . . . . . .
. 5
RS-232 XON/XOFF Mode Selection . . . . . . . . . . . . . . .
. 7
RS-232/RS-485 Selection . . . . . . . . . . . . . . . . . . .
. 7
| Emulation Mode Selection . . . . . . . . . . . . . . . . . . .
. 8
| Paper Width Selection (Single-Station Printers Only) . . . . . . . . .
. 8
USB Selection . . . . . . . . . . . . . . . . . . . . . . . .
. 8
Power Supply Connections . . . . . . . . . . . . . . . . . . . . 10
Printer Mechanism Overviews . . . . . . . . . . . . . . . . . . . 12
Chapter 2. SureMark Installation, Service, and Utility Software . . . . . . 13

Software Adjustments (Model TI5 and TG5 Only) . . . . . . . . . . . . 13
Using the 4690 Operating System . . . . . . . . . . . . . . . . . 13
Using IBM Point-of-Sale Device Diagnostics . . . . . . . . . . . . . 14
Using Reference/Service Diskettes (RS-485 or RS-232 Only) . . . . . . . 14
4610 DBCS Installation Utility Diskette . . . . . . . . . . . . . . . . 17
DBCS Code Page Download . . . . . . . . . . . . . . . . . . . . 17
4610 DBCS Installation Utility Diskette Code Page Download . . . . . . . 17
DBCS Code Page Download – POSS for Windows (RS-485 and USB only) 19
DBCS User-Defined Character Download . . . . . . . . . . . . . . . 21
Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . 22
4610 DBCS Installation Utility Diskette for Updating SureMark Firmware. . . 22
Using POSS For Windows for Updating SureMark Firmware (RS-485 and
USB Only). . . . . . . . . . . . . . . . . . . . . . . . . 23
Using 4690 OS 4610 Utility to Update SureMark Firmware . . . . . . . . 24
Updating 4610 Firmware Using RS-232 Attachment Cable . . . . . . . . 24
Limitation on Updating Firmware . . . . . . . . . . . . . . . . . 25
Emulating the IBM Model 3 or Model 4 Printers . . . . . . . . . . . . . 25
Enabling Emulation Using 4610 DBCS Installation Utility Diskette . . . . . 25
Enabling Emulation Using 4690 On-Line Terminal Diagnostics . . . . . . 26
Limitations for Emulation . . . . . . . . . . . . . . . . . . . . 26
Printing Saved Data . . . . . . . . . . . . . . . . . . . . . . 27
| Emulating an Epson Single-Station Printer (Single-Station SureMark Only) . . . 27
© Copyright IBM Corp. 1999,2001 iii

| Enabling Epson Emulation. . . . . . . . . . . . . . . . . . . . 28

| Limitations for Epson Emulation. . . . . . . . . . . . . . . . . . 28
Changing the Printer Mode between DBCS and SBCS . . . . . . . . . . 28
| Proportional Font Conversion Utility . . . . . . . . . . . . . . . . . 29
Resources on the Internet . . . . . . . . . . . . . . . . . . . . . 29
Part 2. Models TI5 and TG5. . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 3. Problem Determination . . . . . . . . . . . . . . . . . 33

Offline Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Customer Receipt Test . . . . . . . . . . . . . . . . . . . . . 33
Document Insert Test . . . . . . . . . . . . . . . . . . . . . 34
Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Customer Receipt Paper Movement and Cutter Problems . . . . . . . . . 40
FRU Removal and Replacement . . . . . . . . . . . . . . . . . . 42
Removing and Replacing the Top, Paper, and Ribbon Covers. . . . . . . 42
Removing and Replacing the Top Cover Operator Buttons . . . . . . . . 46
Removing and Replacing the Printhead . . . . . . . . . . . . . . . 47
Removing and Replacing the Home Sensor . . . . . . . . . . . . . 48
Removing and Replacing the Ribbon Drive Assembly. . . . . . . . . . 49
Removing and Replacing the Tensioner . . . . . . . . . . . . . . . 51
Removing and Replacing the Printhead Carriage Assembly . . . . . . . 52
Removing and Replacing the Transport Motor . . . . . . . . . . . . 56
Removing and Replacing the Printhead Cable . . . . . . . . . . . . 59
Removing and Replacing the Document Insert Sensor Assembly . . . . . 60
Removing and Replacing the Document Insert Platen Assembly . . . . . . 63
Removing and Replacing the Lower Forms Entry Frame . . . . . . . . 65
Removing and Replacing the Document Insert Backup Roller and Insert
Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . 68
Removing and Replacing the DI Feed Roller . . . . . . . . . . . . . 71
Removing and Replacing the Switch Card and Printhead Spacer . . . . . 75
Removing and Replacing the Main Logic Card and Connector-Attached
Interface Card . . . . . . . . . . . . . . . . . . . . . . . 76
Removing and Replacing the Thermal Cables and Paper Switch . . . . . 77
Removing and Replacing the Thermal Latch . . . . . . . . . . . . . 79
Removing and Replacing the Thermal Drag Strip . . . . . . . . . . . 81
Removing and Replacing the Thermal Printhead Assembly. . . . . . . . 83
Removing and Replacing the Thermal Platen Assembly . . . . . . . . . 86
Removing and Replacing the Customer Receipt Motor . . . . . . . . . 87
Removing and Replacing the Rotating Cutter Blade and Thermal Guide . . . 88
Removing and Replacing the Cutter Gears and Cutter Clutch . . . . . . . 89
Removing and Replacing the Customer Receipt Paper Guide. . . . . . . 90
Removing and Replacing the Customer Receipt Paper Bucket . . . . . . 91
Removing and Replacing the Document Insert Motor and Gears . . . . . 93
Chapter 4. Hardware Adjustment Procedures. . . . . . . . . . . . . 97

Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . 97
Mechanical Adjustments . . . . . . . . . . . . . . . . . . . . . 98
DI Forms Compensation Adjustment . . . . . . . . . . . . . . . . 98
Printhead Platen Gap Adjustment . . . . . . . . . . . . . . . . 100
DI Open Lever Adjustment . . . . . . . . . . . . . . . . . . . 102
Cutter Blade Run-In . . . . . . . . . . . . . . . . . . . . . 103
Thermal Printhead Adjustment . . . . . . . . . . . . . . . . . . 104
Thermal Paper Switch Adjustment . . . . . . . . . . . . . . . . 106
Document Sensor Threshold Reset . . . . . . . . . . . . . . . . 106
iv SureMark DBCS Hardware Service

Chapter 5. Parts Listing . . . . . . . . . . . . . . . . . . . . 107

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . 108
Assembly 2: Operator Switch and Button Assembly . . . . . . . . . . . 110
Assembly 3: Logic Cards and Shock Mounts . . . . . . . . . . . . . 112
Assembly 4: Document Insert Station . . . . . . . . . . . . . . . . 114
Assembly 5: Thermal Printhead Assembly and Cover . . . . . . . . . . 116
Assembly 6: Printhead Transport and Ribbon Drive Assembly . . . . . . . 118
Assembly 7: Impact Printhead Assembly . . . . . . . . . . . . . . . 120
Assembly 8: Document Insert Station Platen and Lever . . . . . . . . . 122
Assembly 9: Document Insert Drive Shaft Assembly . . . . . . . . . . . 124
Assembly 10: Document Insert Station Gears and Motor . . . . . . . . . 126
Assembly 11: Customer Receipt Drive, Cutter, and Platen . . . . . . . . 128
Assembly 12: Hardware Kits . . . . . . . . . . . . . . . . . . . 130
Assembly 13: Cable Assemblies, Filler Panel, Power Supply. . . . . . . . 132
Chapter 6. Operation . . . . . . . . . . . . . . . . . . . . . . 135

Operating Controls and Indicators . . . . . . . . . . . . . . . . . 135
Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Ribbon Loading . . . . . . . . . . . . . . . . . . . . . . . . 137
Paper Loading . . . . . . . . . . . . . . . . . . . . . . . . 139
Thermal Printhead Cleaning . . . . . . . . . . . . . . . . . . . 141
| Part 3. Models TF7 and TM7 . . . . . . . . . . . . . . . . . . . . . . . . . 143
| Chapter 7. Problem Determination . . . . . . . . . . . . . . . . 145

| Offline Diagnostics . . . . . . . . . . . . . . . . . . . . . . . 145
| Customer Receipt Test . . . . . . . . . . . . . . . . . . . . 145
| Listing the MCT Settings . . . . . . . . . . . . . . . . . . . . 146
| RS-232 Hex Dump . . . . . . . . . . . . . . . . . . . . . . 147
| Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . 148
| Customer Receipt Paper Movement and Cutter Problems. . . . . . . . . 150
| Installing the 58–mm Paper Roll Feature RPQ . . . . . . . . . . . . . 152
| FRU Removal and Replacement . . . . . . . . . . . . . . . . . . 153
| Removing and Replacing the Top Cover and Inner Cover Assembly . . . . 153
| Removing and Replacing the Bottom Cover . . . . . . . . . . . . . 155
| Removing and Replacing the Interface and Main Logic Cards . . . . . . 156
| Removing and Replacing the Thermal Print Mechanism . . . . . . . . 158
| Chapter 8. Hardware Adjustment Procedures . . . . . . . . . . . . 161

| Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . 161
| Thermal Paper Switch Adjustment . . . . . . . . . . . . . . . . . 162
| Chapter 9. Parts Listing . . . . . . . . . . . . . . . . . . . . 163

| Assembly 14: Covers . . . . . . . . . . . . . . . . . . . . . . 164
| Assembly 15: Interface and Logic Cards . . . . . . . . . . . . . . . 166
| Assembly 16: Thermal Printhead . . . . . . . . . . . . . . . . . . 168
| Assembly 17: Hardware Kits . . . . . . . . . . . . . . . . . . . 170
| Assembly 18: Miscellaneous Parts and Accessories . . . . . . . . . . . 172
| Chapter 10. Operation . . . . . . . . . . . . . . . . . . . . . 175

| Operating Controls and Indicators . . . . . . . . . . . . . . . . . 175
| Paper Loading . . . . . . . . . . . . . . . . . . . . . . . . 176
| Thermal Printhead Cleaning . . . . . . . . . . . . . . . . . . . 177
Part 4. Appendixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Contents v
Appendix A. Maintenance Inspection . . . . . . . . . . . . . . . 181

Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . 181
Appendix B. Preventive Maintenance Information . . . . . . . . . . 183

Models TI5 and TG5 . . . . . . . . . . . . . . . . . . . . . . 183
| Models TF7 and TM7 . . . . . . . . . . . . . . . . . . . . . . 183
Appendix C. Tools and Supplies . . . . . . . . . . . . . . . . . 185

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 185
Expendable Supplies . . . . . . . . . . . . . . . . . . . . . . 185
RS-232 Connector Pin Assignments . . . . . . . . . . . . . . . . 185
USB Connector Pin Assignments . . . . . . . . . . . . . . . . . . 185
Cash Drawer Connector Pin Assignments . . . . . . . . . . . . . . 186
Appendix D. Translated Safety Notices. . . . . . . . . . . . . . . 187

Nederlands - België. . . . . . . . . . . . . . . . . . . . . . . 187
Algemene veiligheidsvoorschriften . . . . . . . . . . . . . . . . 187
Français - Belgique . . . . . . . . . . . . . . . . . . . . . . . 187
Consignes de sécurité générales . . . . . . . . . . . . . . . . . 187
Português do Brasil. . . . . . . . . . . . . . . . . . . . . . . 188
Considerações Gerais sobre Seguranç’a . . . . . . . . . . . . . . 188
Dansk. . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Generelle sikkerhedsforskrifter. . . . . . . . . . . . . . . . . . 188
Suomi. . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Yleiset turvaohjeet . . . . . . . . . . . . . . . . . . . . . . 189
Français . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Généralités . . . . . . . . . . . . . . . . . . . . . . . . . 190
Deutsch . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Allgemeine Sicherheitsüberlegungen . . . . . . . . . . . . . . . 190
Italiano . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Sicurezza - Considerazioni generali . . . . . . . . . . . . . . . . 191
Norsk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Generelle sikkerhetsforskrifter . . . . . . . . . . . . . . . . . . 191
Português . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Informaçõles de Segurança Gerais . . . . . . . . . . . . . . . . 191
Español . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Consideraciones Generales de Seguridad . . . . . . . . . . . . . 192
Svenska . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Allmänna säkerhetsföreskrifter . . . . . . . . . . . . . . . . . . 193
Appendix E. Notices . . . . . . . . . . . . . . . . . . . . . . 195

Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . 195
Part Number Index . . . . . . . . . . . . . . . . . . . . . . 197
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
vi SureMark DBCS Hardware Service

Preface
This manual provides information about problem determination, testing, and a parts
listing of field-replaceable units (FRUs) for the IBM SureMark Printers.
Who Should Read This Manual

This manual is intended for use by trained service representatives.
How This Manual Is Organized

Part 1, “General Information” on page 1 contains information for all SureMark
printers:
v Chapter 1, “Overview” – an overview of the features of the SureMark printers.
v Chapter 2, “SureMark Installation, Service, and Utility Software” – information
about using the utilities diskettes.
Part 2, “Models TI5 and TG5” on page 31 contains the following information that is
specific to the thermal/impact SureMark printers – Model TI5:
v Chapter 3, “Problem Determination” – information about testing, messages, and
symptoms for determining any failing components of the SureMark printer. This
chapter also includes procedures for removing and replacing components in the
SureMark printer.
v Chapter 4, “Hardware Adjustment Procedures” – printer adjustment procedures.
v Chapter 5, “Parts Listing” – part numbers of the field replaceable units (FRUs) for
the SureMark printer.
v Chapter 6, “Operation” – information on operating the SureMark printer.
Part 3, “Models TF7 and TM7” on page 143 contains the following information that is
specific to the single-station SureMark printers – models TF7 and TM7:
v Chapter 7, “Problem Determination” – information on testing, messages, and
symptoms for determining any failing components of the SureMark printer. This
chapter also includes procedures for removing and replacing components in the
SureMark printer.
v Chapter 8, “Hardware Adjustment Procedures” – printer adjustment procedures.
v Chapter 9, “Parts Listing” – part numbers of the field replaceable units (FRUs) for
the SureMark printer.
v Chapter 10, “Operation” – information on operating the SureMark printer.
The appendixes contain the following information:

v Appendix A, “Maintenance Inspection” – checklist to be used during an IBM
maintenance inspection.
v Appendix B, “Preventive Maintenance Information” – preventive maintenance
procedures for the SureMark printer.
v Appendix C, “Tools and Supplies” – information about special tools for the
SureMark printer and the pin assignments you need to know if you use non-IBM
cables.
v Appendix D, “Translated Safety Notices” – translations of the safety notices in
this manual.
v Appendix E, “Notices” – electronic emission notices and other general
information.
© Copyright IBM Corp. 1999,2001 vii

Related Publications and Diskettes

v IBM SureMark Printers: DBCS User’s Guide, GA27-4256
v IBM SureMark Printers: User’s Guide, GA27-4151
v IBM SureMark Printers: Hardware Service Manual, GY27-0355
v IBM Safety Information – Read This First, GA27-4004
v IBM SurePOS 700 Series: Hardware Service Guide, GA27-0363
v IBM SurePOS 700 Series: Options and I/0 Devices Service Guide, SY27-0392
v IBM SurePOS 700 Series: System Reference, SA27-4224
v IBM SurePOS 500 Series: System Reference, SA27-4255
v POSS Programming Reference and User’s Guide, SC30-3560
v IBM SureMark Printers: DBCS Installation Utility Diskette
v IBM 4693 Point-of-Sale Terminals Reference Diskette
v IBM 4694/4695 Point-of-Sale Terminals Service Diskette
The diskettes are only available by download from the Internet. See “Resources on
the Internet” on page 29 for more information.
For information about ordering IBM publications not shipped with the SureMark
Printers, contact your IBM representative or your place of purchase.
SureMark publications are available on the Internet as PDF files. See “Resources
on the Internet” on page 29 for more information.
Tell Us What You Think

Your feedback is important in helping to provide the most accurate and high-quality
information. Please take a few moments to tell us what you think about this book.
The only way for us to know if you are satisfied with our books, or how we might
improve their quality, is through feedback from customers like you. If you have any
comments about this book, there is a comment form at the back of this book. You
can also get a copy of the form from the PDF version of the book on the Web.
To access a PDF version of this book, visit the Retail Store Solutions Web site at:
http://www.ibm.com/solutions/retail/store
From there, select Support at the left, then select Publications.
After you have filled out the form, return it by mail, by fax, or by giving it to an IBM
representative. If applicable, include a reference to the specific location of the text
on which you are commenting. For instance, include the page or table number.
Between major revisions of this manual we may make minor technical updates. The
latest softcopy version of this manual is available under Publications on the IBM
Retail Store Solutions Web site.
Safety Information
viii SureMark DBCS Hardware Service

Danger:
Before you begin to install this product, read the safety information in IBM
Safety Information — Read This First, GA27–4004. This booklet describes
safe procedures for cabling and plugging in electrical equipment.
Gevaar:
Voordat u begint met de installatie van dit produkt, moet u eerst de
veiligheidsinstructies lezen in de brochure Veiligheidsinstructies—Lees dit
eerst, GA27–4004. Hierin wordt beschreven hoe u electrische apparatuur op
een veilige manier moet bekabelen en aansluiten.
Preface ix
Perigo:
Antes de começar a instalar este produto, leia as informações de segurança
contidas em Informações Sobre Seguranaça—Leia Isto Primeiro, GA27–4004.
Esse folheto descreve procedimentos de segurança para a instalação de
cabos e conexões em equipamentos elétricos.
Fare!
Før du installerer dette produkt, skal du læse sikkerhedsforskrifterne i
Sikkerhedsforskrifter—Lœs dette først GA27–4004. Vejledningen beskriver den
fremgangsmåde, du skal bruge ved tilslutning af kabler og udstyr.
Gevaar
Voordat u begint met het installeren van dit produkt, dient u eerst de
veiligheidsrichtlijnen te lezen die zijn vermeld in de publikatie IBM Safety
Information — Read This First, GA27–4004. In dit boekje vindt u veilige
procedures voor het aansluiten van elektrische appratuur.
x SureMark DBCS Hardware Service

VAARA
Ennen kuin aloitat tämän tuotteen asennuksen, lue julkaisussa
Turvaohjeet—Luetämä ensin, GA27–4004, olevat turvaohjeet. Tässä
kirjasessa on ohjeet siitä, miten sähkölaitteet kaapeloidaan ja kytketään
turvallisesti.
Danger
Avant d’installer le présent produit, consultez le livret Informations pour la
sécurité–Lisez-moi d’abord, GA27–4004, qui décrit les procédures à respecter
pour effectuer les opérations de câblage et brancher les équipements
électriques en toute sécurité.
Vorsicht
Bevor mit der Installation des Produktes begonnen wird, die
Sicherheitshinweise in Sicherheitsinformationen—Bitte zuerst lesen, IBM Form
GA27–4004. Diese Veröffentlichung beschreibt die Sicherheitsvorkehrungen
für das Verkabeln und Anschlieβen elektrischer Geräte.
Vigyázat
Mielôtt megkezdi a berendezés üzembe helyezését, olvassa el a IBM Safety
Information — Read This First, GA27–4004 könyvecskében leírt biztonsági
információkat. Ez a könyv leírja, milyen biztonsági intézkedéseket kell
megtenni az elektromos berendezés huzalozásakor illetve csatlakoztatásakor.
Preface xi
Pericolo
prima di iniziare l’installazione di questo prodotto, leggere le informazioni
relative alla sicurezza riportate nell’opuscolo Informazioni di sicurezza—Prime
informazioni da leggere in cui sono descritte le procedure per il cablaggio ed il
collegamento di apparecchiature elettriche.
Fare
Før du begynner å installere dette produktet, må du lese
sikkerhetsinformasjonen i Sikkerhetsinformasjon—Les dette først, GA27–4004
som beskriver sikkerhetsrutinene for kabling og tilkobling av elektrisk utstyr.
Perigo
Antes de iniciar a instalação deste produto, leia as informações de segurança
Informações de Segurança—Leia Primeiro, GA27–4004. Este documento
descreve como efectuar, de um modo seguro, as ligações eléctricas dos
equipamentos.
Peligro
Antes de empezar a instalar este producto, lea la información de seguridad en
Información de Seguridad—Lea Esto Primero, GA27–4004. Este documento
describe los procedimientos de sequridad para cablear y enchufar equipos
eléctricos.
xii SureMark DBCS Hardware Service

Varning—livsfara
Innan du börjar installera den här produkten bör du läsa
säkerhetsinformationen i dikumentet Säkerhetsföreskrifter—Läs detta först,
GA27–4004. Där beskrivs hur du på ett säkert sätt ansluter elektrisk
utrustning.
Preface xiii
IBM
IBM
GA27-4004
GA27-4004
xiv SureMark DBCS Hardware Service

Preface xv
xvi SureMark DBCS Hardware Service

Preface xvii
xviii SureMark DBCS Hardware Service

Summary of Changes
This section summarizes the changes included in the latest editions of this manual.
Web-only Update for GY27-0397-00 (March 2002)

This update includes the following changes:
v Added part numbers to the parts catalog information for miscellaneous kits on
models TM7 and TF7. Refer to “Assembly 17: Hardware Kits” on page 170.
v Updated the paper loading procedure for models TM7 and TF7. See “Paper
Loading” on page 176.
Web-only Update for GY27-0397-00 (October 2001)

This update corrects the parts catalog information for the covers on models TM7
and TF7. Refer to “Assembly 14: Covers” on page 164 for revision bars that indicate
the changed information.
GY27-0397-00
This edition includes information about new SureMark models TF7 and TM7, and
also includes updates for Model TI5. Changed or new information is indicated by a
revision bar (|) in the left margin. (There are no revision bars in the margin of
figures. Refer to “Figures” on page xxi for revision bars that show which figures
have been changed.)
There are both similarities and important differences between the thermal/impact
SureMark printer (Model TI5) and the single-station SureMark printers (models TF7
and TM7) that support DBCS. For that reason, this document has been reorganized
and divided into parts.
v Part 1, “General Information” on page 1 contains overview information for
SureMark printers and also information about using installation diskettes and
utilities.
v Part 2, “Models TI5 and TG5” on page 31 contains information about Model TI5.
This information has few changes from the previous edition.
v Part 3, “Models TF7 and TM7” on page 143 contains information about the
single-station printers. All information in this part is new in this edition.
GY18-2406-01
This edition contains information about USB connections, which are now supported
by the SureMark Model TI5.
© Copyright IBM Corp. 1999,2001 xix

xx SureMark DBCS Hardware Service

Figures
1. Indicators, Controls, and Printing Stations – Thermal/Impact SureMark Printer . . . . . . . . . 4
2. Indicator, Control, and Printing Station – Single-Station SureMark Printers . . . . . . . . . . 4
3. Cable Connectors and RS-232 Settings Switch for Thermal/Impact SureMark Printers . . . . . . 5
| 4. Cable Connectors for Single-Station SureMark Printers . . . . . . . . . . . . . . . . . 6
| 5. RS-232 Mode Switch for Single-Station SureMark Printers . . . . . . . . . . . . . . . . 6
| 6. RS-232 and RS-485 Cable Routing for Single-Station SureMark Printers. . . . . . . . . . . 7
7. USB Ports for Thermal/Impact SureMark Printers . . . . . . . . . . . . . . . . . . . 9
| 8. USB Ports for Single-Station SureMark Printers . . . . . . . . . . . . . . . . . . . . 9
| 9. USB Cable Routing for Single-Station SureMark Printers . . . . . . . . . . . . . . . . 10
10. Printer Mechanism Overview – SureMark Model TI5 or TG5 . . . . . . . . . . . . . . . 12
11. Printer Mechanism Overview – SureMark Models TF7 and TM7 . . . . . . . . . . . . . 12
12. Adjustment and Alignment Printouts . . . . . . . . . . . . . . . . . . . . . . . . 16
| 13. Switch for Epson Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
| 14. Offline Printer Test Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
15. Customer Receipt Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
16. Removing the Paper and Ribbon Covers . . . . . . . . . . . . . . . . . . . . . . 44
17. Removing the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
18. Removing the Operator Buttons in the Top Cover . . . . . . . . . . . . . . . . . . . 46
19. Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
20. Removing the Ribbon Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . 50
21. Removing the Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
22. Removing the Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
23. Removing the Printhead/Home Sensor Cable . . . . . . . . . . . . . . . . . . . . 53
24. Removing the Carriage Assembly, Front or Rear Transport Shafts . . . . . . . . . . . . . 54
25. Removing the Front Transport Carrier Bearing . . . . . . . . . . . . . . . . . . . . 55
27. Turning the Bushing and Removing the Transport Shaft . . . . . . . . . . . . . . . . 57
28. Removing the Transport Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 58
29. Disconnecting the Printhead Cable and Home Sensor . . . . . . . . . . . . . . . . . 59
31. Removing the Front Transport Shaft . . . . . . . . . . . . . . . . . . . . . . . . 61
32. Disconnecting the Sensor Spring and Removing the DI Insert Assembly . . . . . . . . . . 62
33. Removing the Document Insert Platen Assembly . . . . . . . . . . . . . . . . . . . 64
34. Disconnecting the Main Logic Card Cables . . . . . . . . . . . . . . . . . . . . . 66
35. Removing the Front Shock Mount . . . . . . . . . . . . . . . . . . . . . . . . 66
36. Removing the Lower Forms Entry Frame . . . . . . . . . . . . . . . . . . . . . . 67
37. Removing the Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
38. Removing the DI Backup Roller . . . . . . . . . . . . . . . . . . . . . . . . . 69
39. Removing the DI Lever Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 70
40. Disconnecting the Main Logic Card Cables . . . . . . . . . . . . . . . . . . . . . 72
42. Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
43. Removing the Document Insert Feed Roller . . . . . . . . . . . . . . . . . . . . . 74
44. Removing the Switch Card and Printhead Spacer . . . . . . . . . . . . . . . . . . . 75
45. Removing the Interface Card Assembly . . . . . . . . . . . . . . . . . . . . . . 76
46. Removing the Thermal Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 77
47. Removing the Spiral Wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
48. Disconnecting the Thermal Cable from the Main Logic Card . . . . . . . . . . . . . . . 78
49. Thermal Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
50. Removing the Thermal Latch Spring. . . . . . . . . . . . . . . . . . . . . . . . 80
51. View of Drag Strip from Back of Printer . . . . . . . . . . . . . . . . . . . . . . 81
52. Removing the Drag Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
53. Thermal Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 84
© Copyright IBM Corp. 1999,2001 xxi

54. Removing the Spiral Wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

55. Removing the Cutter Stud, Stationary Blade, and Printhead Shaft . . . . . . . . . . . . . 85
56. Removing the Thermal Platen Assembly . . . . . . . . . . . . . . . . . . . . . . 86
57. Removing the Customer Receipt Motor . . . . . . . . . . . . . . . . . . . . . . 87
58. Removing the Rotating Blade and Thermal Guide . . . . . . . . . . . . . . . . . . . 88
59. Removing the Cutter Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
60. Removing the Customer Receipt Paper Guide . . . . . . . . . . . . . . . . . . . . 90
61. Disconnecting the Cable Connected to the Main Logic Card . . . . . . . . . . . . . . . 91
63. Customer Receipt Paper Bucket . . . . . . . . . . . . . . . . . . . . . . . . . 92
64. Disconnecting the Logic Card Cables . . . . . . . . . . . . . . . . . . . . . . . 93
66. Removing the Motor Gear and Idler Gear . . . . . . . . . . . . . . . . . . . . . . 94
67. Removing the Document Insert Feed Motor . . . . . . . . . . . . . . . . . . . . . 95
68. DI Forms Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
69. Placement of Gap Setting Tool . . . . . . . . . . . . . . . . . . . . . . . . . 101
70. Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
71. DI Open Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
72. Cutter Blade Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
73. Thermal Printhead Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 105
74. Thermal Paper Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 106
75. Printable Area of an Inserted Document (Portrait) . . . . . . . . . . . . . . . . . . 135
76. Printable Area of an Inserted Document (Landscape) . . . . . . . . . . . . . . . . . 136
77. Opening the Ribbon Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
78. Ribbon Cartridge Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
79. Ribbon Path around the Printhead . . . . . . . . . . . . . . . . . . . . . . . . 138
80. Paper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
81. Paper Loading Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
82. Printhead and Print Line Area. . . . . . . . . . . . . . . . . . . . . . . . . . 141
| 83. Offline Printer Test Pattern (Models TF7 and TM7) . . . . . . . . . . . . . . . . . . 146
| 84. Thermal Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
| 85. Paper Out Switch and Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . 151
| 86. Mode Switches for Single-Station SureMark Printers . . . . . . . . . . . . . . . . . 152
| 87. Removing the Top Cover and Inner Cover Assembly . . . . . . . . . . . . . . . . . 154
| 88. Removing the Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 155
| 89. Removing the Interface and Main Logic Cards – Models TF7 and TM7 . . . . . . . . . . 156
| 90. Separating the Interface and Main Logic Cards – Models TF7 and TM7 . . . . . . . . . . 157
| 91. Thermal Print Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
| 92. Thermal Paper Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 162
| 93. Paper Loading Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
| 94. Printhead and Print Line Area. . . . . . . . . . . . . . . . . . . . . . . . . . 177
xxii SureMark DBCS Hardware Service

Part 1. General Information

This section contains information that applies to all DBCS SureMark printers.
The following table shows the warranty information for each printer model.
Table 1. Warranty Information
Machine type Description Warranty Warranty
service upgrade
4610-TI3 Attaches to the IBM 4694/4800. IOR 24x7 none
RS232, RS485, USB (Pearl white
covers)
4610-TI4 Attaches to the IBM 4694/4800. IOR 24x7 none
covers)
4610-TI5 (DBCS Attaches to the IBM 4694/4800. IOR 24x7 none
– AP only) RS232, RS485, USB (Pearl white
covers)
4610-TM6 Attaches to the IBM 4694/4800. IOR 24x7 none
covers)
4610-TM7 Attaches to the IBM 4694/4800. IOR 24x7 none
(DBCS – AP RS232, RS485, USB (Pearl white
only) covers)
4610-TF6 TM6 with iron gray covers to match Depot repair IOR 24x7 IOR
4840 9x5
4610-TF7 TM7 with iron gray covers to match Depot repair IOR 24x7, IOR
4840 9x5
4610-IF6 Functionally equivalent to TF6 with IOR 24x7 none
iron gray covers but with IOR
warranty
4610-TG3 Functionally equivalent to Model TI3 IOR 24x7 none
with iron gray covers to match the
IBM 4840
with iron gray covers to match the
IBM 4840
(DBCS – AP with iron gray covers to match the
only) IBM 4840
4610-DG3 Functionally equivalent to Model Depot repair IOR 24x7, 9x5
TG3 but with Depot warranty
4610-DG4 Functionally equivalent to Model Depot repair IOR 24x7, 9x5
TG4 but with Depot warranty
4610-DI3 Functionally equivalent to Model TI3 Depot repair IOR 24x7, 9x5
but with Depot warranty
4610-DI4 Functionally equivalent to Model TI4 Depot repair IOR 24x7, 9x5
but with Depot warranty
4610-DM6 Functionally equivalent to Model Depot repair IOR 24x7, 9x5
TM6 but with Depot warranty
© Copyright IBM Corp. 1999,2001 1

Note: IOR 24x7 is IBM onsite repair 24 hours times seven days per week. 9x5 is
nine hours per day for five days per week.
2 SureMark DBCS Hardware Service

Chapter 1. Overview
Indicators, Controls, and Printing Stations – SureMark ModelS TI5 and TG5 . . . 3
Indicator, Control, and Printing Station – Single-Station SureMark Printers . . . 4
Communication Mode Selections. . . . . . . . . . . . . . . . . . . 5
RS-232 Baud Rate Selection . . . . . . . . . . . . . . . . . . . 5
RS-232 XON/XOFF Mode Selection . . . . . . . . . . . . . . . . 7
RS-232/RS-485 Selection . . . . . . . . . . . . . . . . . . . . 7
| Emulation Mode Selection . . . . . . . . . . . . . . . . . . . . 8
| Paper Width Selection (Single-Station Printers Only) . . . . . . . . . . 8
USB Selection . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power Supply Connections . . . . . . . . . . . . . . . . . . . . 10
Printer Mechanism Overviews . . . . . . . . . . . . . . . . . . . 12
Indicators, Controls, and Printing Stations – SureMark ModelS TI5 and

TG5
There are two triangular-shaped buttons and two LED indicators located on the top
of the printer. The buttons serve multiple functions.
When the Printer Ready LED indicator is on continuously, the printer is online
(connected to the system) and ready for printing.
When the indicator blinks, one of the following conditions exists:

| v The printer is offline (offline testing is enabled).
v The printer is out of thermal paper.
v The ribbon cover and/or CR paper cover is open.
v The printer has a nonrecoverable home error.
The second LED is the document present indicator. It lights when a document is
inserted far enough into the Document Insert (DI) station to reach the DI sensor.
When this LED blinks, the DI station is waiting for you to insert a document.
The topmost button is the Customer Receipt (CR) paper feed button. Press this
button to advance the CR paper. The lower button is the document feed button.
Press this button to advance the document.
If you simultaneously press both buttons momentarily and then release them, the DI
throat opens. The throat must be open to insert a document from the side. Press
and then release both buttons again to close the throat.
Both buttons are also used to test the printer. See “Offline Tests” on page 33 for
additional button functions.

Paper Cover
Customer Receipt Printer
Ribbon Cover
Document Printer
Printer Ready LED

Customer Receipt Feed Button
Document Present LED
Document Feed Button
Figure 1. Indicators, Controls, and Printing Stations – Thermal/Impact SureMark Printer
Indicator, Control, and Printing Station – Single-Station SureMark

Printers
There is one triangular-shaped button and one LED indicator located on top of the
printer.
When the indicator is on continuously, the printer is powered on and ready for
printing. When the indicator blinks, one of the following conditions exists:
v The printer is offline (offline testing is enabled).
v The printer is out of paper.
v The cover is open.
v The cutter has jammed.
The button is the Customer Receipt (CR) paper feed button. Press this button to
advance the CR paper.
See “Offline Diagnostics” on page 145 for additional button functions.
Top cover
Printer ready
LED
Customer receipt
feed button
Figure 2. Indicator, Control, and Printing Station – Single-Station SureMark Printers

Communication Mode Selections
RS-232 Baud Rate Selection

The SureMark printer supports two RS-232 baud rates, 9600 and 19 200 baud.
The baud rate is selected using SW1-1 on the main logic card. The switch is
located on the lower left corner of the logic card and is accessible without removing
the printer covers. Set the switch as follows:
SW1-1 OFF - 9600 baud

SW1-1 ON - 19 200 baud
The card is normally set with SW1-1 in the OFF position, which selects the 9600
baud rate. See Figure 3 for thermal/impact SureMark printers. See Figure 4 on
page 6 and Figure 5 on page 6 for single-station SureMark printers.
1
OFF
RS 232 Cash Power Supply RS 232 RS 485 Port

Mode Drawer Port (RS 232 Port
Switch Port Only)
Figure 3. Cable Connectors and RS-232 Settings Switch for Thermal/Impact SureMark Printers. (View is from the
bottom rear of the printer)
Chapter 1. Overview 5
Power supply port (RS-232 only)
RS-232 port
RS-485 port
Cash drawer connector
|
| Figure 4. Cable Connectors for Single-Station SureMark Printers. (View is from the bottom rear of the printer)
Power supply port (RS-232 only)
RS-232 port
RS-485 port
|
| Figure 5. RS-232 Mode Switch for Single-Station SureMark Printers. (View is from the bottom rear of the printer)

|
Cash drawer cable Cash drawer cable
Power cord RS-485 cable
RS-232 cable
|
| Figure 6. RS-232 and RS-485 Cable Routing for Single-Station SureMark Printers
RS-232 XON/XOFF Mode Selection

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

SW1-2 ON - XON/XOFF Control (Required with a 3-wire RS-232 cable)
The card is normally set with SW1-2 in the OFF position, which selects DTR/DSR
mode of operation. See Figure 3 on page 5.
RS-232/RS-485 Selection
The SureMark printer will operate using either RS-232 or RS-485 communications
protocol. RS-232 is typically associated with PC systems. The printer contains a
9-pin D-shell connector for RS-232 communications. This connector is located on
the interface card and is accessible under the printer without the need to remove
the printer covers. The connector has the following pin functions:
Pin Signal Pin Signal

1 Not Connected 6 DSR
2 Transmit 7 Not Connected
3 Receive 8 Not Connected
4 DTR 9 Not Connected
5 Signal Ground
RS-485 mode is an IBM proprietary mode of communication. This form of

communication is obtained when attaching the appropriate cable to Port 7 on an
IBM POS system.
| Emulation Mode Selection

| Single-station SureMark printers in SBCS mode can emulate an Epson
| single-station printer.
| The printer’s mode is selected using SW1-3 on the main logic card (see Figure 4 on
| page 6). The switch is located on the logic card next to the cash drawer connector
| and is accessible without removing the printer covers. Set the switch as follows:
| SW1-3 OFF - SureMark native mode

| SW1-3 ON - Epson emulation mode
| For more information about emulation mode, see “Emulating an Epson

| Single-Station Printer (Single-Station SureMark Only)” on page 27.
| Paper Width Selection (Single-Station Printers Only)

| Single-station SureMark printers support thermal paper that is 80 mm wide. An
| available RPQ allows single-station SureMark printers to support thermal paper that
| is 58 mm wide. If the RPQ is installed, a switch must be set on the SureMark to
| indicate the narrower paper is being used.
| Use SW1-4 to set the paper width for the printer. The switch is located on the main
| logic card next to the cash drawer connector and is accessible without removing the
| printer cover. Set the switch as follows:
| SW1-4 OFF - 80 mm paper

| SW1-4 ON - 58 mm paper
|
USB Selection
Universal serial bus (USB) is an industry standard communication interface. It is
used to attach devices, such as printers, displays, and keyboards to personal
computers or IBM POS systems that have USB ports. The standard USB port (with
a power brick) is used to attach the SureMark to personal computers. The powered
USB port is used to attach the SureMark to IBM POS systems. See Figure 7 on
page 9 for the thermal/impact SureMark printers and Figure 8 on page 9 for the
single-station SureMark printers.

Cash Power Powered Standard

Drawer Supply USB Port USB Port
Port Port
Figure 7. USB Ports for Thermal/Impact SureMark Printers. (View is from the bottom rear of
the printer)
Power supply port
Powered USB port
Standard USB port
|
| Figure 8. USB Ports for Single-Station SureMark Printers. (View is from the bottom rear of
| the printer)
|
Cash drawer cable Cash drawer cable
Standard USB cable Powered USB cable
Power cord
|
| Figure 9. USB Cable Routing for Single-Station SureMark Printers
Power Supply Connections

| The SureMark printer does not contain a power supply. When the RS-232 or USB
| port is used, an external power supply must be attached to the power supply port of
| the interface card of the SureMark (see Figure 7 on page 9 or Figure 8 on page 9
| for USB mode, and Figure 3 on page 5 or Figure 4 on page 6 for RS-232 mode).
| This connector is located under the printer and is accessible without removing the
| printer covers. Connector J2 has the following pin functions:
|| Pin Signal Pin Signal
| 1 +24 V dc 2 Not Connected
| 3 Ground
When the SureMark printer is operating in RS-485 or powered USB mode, power is
supplied to the printer from the IBM POS system.
DANGER
Never work on equipment or connect or disconnect signal cables during
periods of lightning activity.
CAUTION:
For your safety, connect equipment requiring electrical power to a correctly
wired and grounded outlet.
Note: For translations of these safety notices, see Appendix D, “Translated Safety
Notices” on page 187.

| To protect the printer from electrical damage, never plug or unplug the RS-232 or
| the RS-485 connector without deactivating the power first. (You can deactivate the
| power by either turning off the system unit, or by unplugging the power supply from
| the electrical outlet. You can also deactivate a single-station SureMark by turning off
| the printer’s power switch.)
Printer Mechanism Overviews
Operator Switch and

Button Assembly
Thermal Printhead Assembly
Customer Receipt Ribbon Guide
Drive Gears
Impact Printhead Assembly
Document Insert Station Ribbon Drive Assembly
Platen
Document Insert Station

Drive Shaft Assembly
Figure 10. Printer Mechanism Overview – SureMark Model TI5 or TG5
Inner cover assembly

Tear bar
Logic card
Light-emitting diode
Drive gear (LED)
On/off switch
Interface card
Figure 11. Printer Mechanism Overview – SureMark Models TF7 and TM7

Chapter 2. SureMark Installation, Service, and Utility Software

Software Adjustments (Model TI5 and TG5 Only) . . . . . . . . . . . . 13
Using the 4690 Operating System . . . . . . . . . . . . . . . . . 13
Using IBM Point-of-Sale Device Diagnostics . . . . . . . . . . . . . 14
Using Reference/Service Diskettes (RS-485 or RS-232 Only) . . . . . . . 14
4610 DBCS Installation Utility Diskette . . . . . . . . . . . . . . . . 17
DBCS Code Page Download . . . . . . . . . . . . . . . . . . . . 17
4610 DBCS Installation Utility Diskette Code Page Download . . . . . . . 17
DBCS Code Page Download – POSS for Windows (RS-485 and USB only) 19
DBCS User-Defined Character Download . . . . . . . . . . . . . . . 21
Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . 22
4610 DBCS Installation Utility Diskette for Updating SureMark Firmware. . . 22
Using POSS For Windows for Updating SureMark Firmware (RS-485 and
USB Only). . . . . . . . . . . . . . . . . . . . . . . . . 23
Using 4690 OS 4610 Utility to Update SureMark Firmware . . . . . . . . 24
Updating 4610 Firmware Using RS-232 Attachment Cable . . . . . . . . 24
Limitation on Updating Firmware . . . . . . . . . . . . . . . . . 25
Emulating the IBM Model 3 or Model 4 Printers . . . . . . . . . . . . . 25
Enabling Emulation Using 4610 DBCS Installation Utility Diskette . . . . . 25
Enabling Emulation Using 4690 On-Line Terminal Diagnostics . . . . . . 26
Limitations for Emulation . . . . . . . . . . . . . . . . . . . . 26
Printing Saved Data . . . . . . . . . . . . . . . . . . . . . . 27
Printing Buffer Data – Thermal/Impact SureMark Models TI5 and TG5 27
Printing Buffer Data – Single-Station SureMark Printers . . . . . . . . 27
| Emulating an Epson Single-Station Printer (Single-Station SureMark Only) . . . 27
| Enabling Epson Emulation. . . . . . . . . . . . . . . . . . . . 28
| Limitations for Epson Emulation. . . . . . . . . . . . . . . . . . 28
Changing the Printer Mode between DBCS and SBCS . . . . . . . . . . 28
| Proportional Font Conversion Utility . . . . . . . . . . . . . . . . . 29
Resources on the Internet . . . . . . . . . . . . . . . . . . . . . 29
| This chapter describes how to make software adjustments using the 4690 OS, IBM
| POS Device Diagnostics (POSS for Windows, RS-485 and USB only), or diskettes
| and other resources that are available from the Retail Store Solutions Web site.
| See “Resources on the Internet” on page 29 for more information.
Software Adjustments (Model TI5 and TG5 Only)

Depending on your operating system and whether the printer is operating in SBCS
or DBCS mode, you can use the following to make software adjustments to a
SureMark printer:
v 4690 Operating System
v IBM POS Device Diagnostics
v Reference/service diskettes
Using the 4690 Operating System

| Note: This procedure is applicable only in SBCS mode, when DBCS is supported
| by customer engagement, or with 4690 OS V2R4, when it is available.
1. Start Utility Mode by pressing S1, typing 9 5, and then pressing S2.
2. When “enter request” is displayed, enter the keying sequence from the table for
the procedure you want to do.

3. Press S2 to advance through the various parts of the printer adjustment steps.
4. Type 9 9 and then press S2 to exit.
Table 2. Adjustment Procedures Using 4690 Operating System
Procedure Keying Sequence
Print Current Adjustment Values - see Figure 12 on page 16. 7, 2, 1, S2
Character Alignment Procedure - see Figure 12 on page 16. 7, 2, 2, S2
DI Front Load Print Line Adjustment - see Figure 12 on 7, 2, 3, S2
page 16.
Backlash Adjustment (Landscape) 7, 2, 5, S2
Engineering Use Only 7, 2, 7, S2
Hardware Setup Option 7, 2, 8, S2
Update Printer Firmware 7, 2, 9, S2
Using IBM Point-of-Sale Device Diagnostics

| This utility is for RS-485 and USB only.
1. Start the IBM Point-of-Sale Device Diagnostics application from the Windows
Start menu.
2. Click 4610 Printer.
3. Click Device Utility.
4. Select the appropriate tab for the desired adjustment:
| Table 3. Adjustment Procedures Using the Point-of-Sale Device Diagnostics
| Procedure Tab
| Character Alignment Adjustments
| DI Front Load Adjustment Adjustments
| Backlash Adjustment (Landscape) Adjustments
| Engineering Use Only Read MCT
| Firmware Update Firmware Update
| Reset Thermal Print Head Statistics Reset Stats
| Reset CR Motor Statistics Reset Stats
| Reset Impact Print Head Statistics Reset Stats
| Reset DI Motor Statistics Reset Stats
| Reset Transport Motor Statistics Reset Stats
|
Using Reference/Service Diskettes (RS-485 or RS-232 Only)

1. Load the reference/service diskette. See the hardware service manual for your
system for reference/service diskette procedures.
| 2. Select Test Menu.
| 3. Select Run POS Device Tests for an RS-485 connection. Select RS232 4610
| Printer Test for an RS-232 connection.
4. If another system is attached, select the system whose printer you want to
adjust. This is unnecessary when there is no other system attached.
| 5. Select Printer Utilities.
6. Select the adjustment you want to make from the menu.

v Print current adjustment values - see Figure 12 on page 16.

v Character alignment procedure - see Figure 12 on page 16.
v DI front load print line adjustment - see Figure 12 on page 16.
| v Document landscape adjustment - see Figure 12 on page 16.
v Engineering use only
v Change 4610 Model Configuration
| v Reset printer statistics
Note: Because the first four adjustments affect only the document insert
station, they are not displayed as selectable options if the printer is a
single-station SureMark.
| 7. Follow the instructions that are printed on the printer or displayed on the screen.
8. Press S1 (Esc on the Enhanced A/N Keyboard) to return to the previous menu.
Chapter 2. SureMark Installation, Service, and Utility Software 15

TL1
TL2
TL3 TL4
TL5
TL6
CURRENT ADJUSTMENT VALUES TL7
TL8
TL9
H 5 = Character alignment
TL5 = Top line front insert
BL3 = Bottom line top insert Measure from the top edge of this
paper to the top of each print line.
Press the key (1-9) that corresponds
to the print line that is closest to 5MM.
CHARACTER ALIGNMENT PROCEDURE
Press the key (1-9) that corresponds

to the pair of H's that appear to be
most aligned
5 = selected line
Figure 12. Adjustment and Alignment Printouts

4610 DBCS Installation Utility Diskette

This utility is for both RS-232 and RS-485 operation. It includes:
v The latest level of firmware for the printer
v A README file that describes how to use the utility program.
v A utility program that performs the following functions:
– Update printer firmware
– Configure the printer model
– Create, edit, and download SBCS user-defined character font, logo image,
and messages
– Edit and download DBCS code pages and DBCS user-defined character font
– Convert fonts and logo files from impact to thermal
v Sample files for the utility program:
– An SBCS user-defined character file
– A message file
– A logo file
v Utility program to enable/disable Model 4 Printer emulation (SBCS mode only)
v Utility program to change the printer mode between DBCS and SBCS
DBCS Code Page Download

| SureMark models TI5, TG5, TF7, and TM7 can receive a DBCS code page from an
| attached host system connected by an RS-485 cable (cable 7), an RS-232 cable, or
| a USB cable.
The following mediums can be used to download a DBCS code page:

| v 4610 DBCS Installation Utility Diskette code page download (RS-485 or RS-232
| connection)
| v POSS for Windows DBCS code page download (RS-485 or USB connection)
| v 4690 OS V2R4 font download, when available
After downloading the latest level software from the Retail Store Solutions Web site
(see “Resources on the Internet” on page 29), use the appropriate procedure that
follows to download a DBCS code page.
4610 DBCS Installation Utility Diskette Code Page Download

Use the 4610 DBCS Installation Utility Diskette to download a DBCS code page to
a SureMark that is connected to a system unit by either an RS-232 or RS-485
cable.
To download a diskette font, perform the following steps:

| 1. Download the fonts diskette from the Retail Store Solutions Web site (see
| “Resources on the Internet” on page 29).
| 2. Download the latest level of the 4610 DBCS Installation Utility Diskette from
| the Retail Store Solutions Web site (see “Resources on the Internet” on
| page 29). Place the file that you download, which is 4610dbcs.exe, in a
| temporary directory. Run 4610dbcs.exe in a DOS window to create the
| diskette. If you are using Windows NT, you might need to use FORCEDOS.
3. Insert the 4610 DBCS Installation Utility Diskette in drive A.
4. Power on the system unit to which the SureMark is connected.
5. Select Run Printer Utility for the RS-232 or RS-485 connection.
6. Follow the displayed instructions to complete the font download.

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

b. Select the connection type (RS-485 or RS-232).
For the RS-232 connection, also select the following:
v Communications port (COM1, COM2, COM3, COM4)
v Baud rate (9600 or 19 200)
v Control flow (DTR/DSR or XON/XOFF)
| v IRQ test
Refer to the communication mode selection switches located at the bottom

rear of the SureMark printer when making the above selection.
c. Press Enter (OK).
| d. Select the printer model, then select Enter (OK).
e. Select F10 (Menu).
f. Select O (Operations).
g. Select F (Download Fonts).
| h. If you want to selectively download code pages, go to Step 6j. Otherwise,
| select one of the font sets from the font set menu, then select D
| (Download). Use this option with POSS for Windows, OPOS, or JavaPOS
| drivers.
| The following DBCS font files are downloaded to the printer when you
| select Yes (you can change the list of files in a:\utility\fontset.dat before
| selecting Yes):
| v DBCS for thermal printhead
| v DBCS for impact printhead
| v SBCS for user-defined thermal code page 1
| v SBCS for user-defined impact code page 1
| v DBCS user-defined character for thermal printhead
| v DBCS user-defined character for impact printhead
| i. When prompted, insert the appropriate DBCS Font Diskette in drive A (see
| “Resources on the Internet” on page 29 for information about downloading
| the diskette), then select OK.
| Go to Step 7.
j. Select S (Selective Download).
| Note: If you are using the 4610 DBCS Installation Utility Diskette with a
| printer that will be used with POSS for Windows, OPOS, or
| JavaPOS drivers, then do not use the selective download. If you
| use the selective download with those drivers, the drivers will not
| recognize what DBCS code page has been downloaded.
| k. Select E (Erase EPROM).
l. Select the code set (SBCS or DBCS), code page, station (Thermal or
Impact), and characters (Normal or User-Defined).
m. Select B (Browse) and specify the font file, if required.
n. Select D (Download).
| o. Select Yes. When prompted, insert the appropriate DBCS Font Diskette in
| drive A (see “Resources on the Internet” on page 29 for information about
| downloading the diskette), then select OK.
| p. Go to Step 7.
7. After the font download has completed,

| a. Press Done for confirmation if Download (Step 6h on page 18) was used.
| Press OK for confirmation if Selective Download (Step 6j on page 18) was
| used.
b. Press C (Close) to close the dialog.
c. Press Alt-X (Exit) to exit the menu.
d. Press Enter to exit the utility.
| 8. When prompted, reinsert the 4610 DBCS Installation Utility Diskette, then
| press Enter.
9. Remove the diskette from drive A.
10. Press Ctrl-Alt-Delete to reboot the system.
DBCS Code Page Download – POSS for Windows (RS-485 and USB
only)
DBCS fonts must be manually loaded into the SureMark printer. The process
requires files that are downloaded from the IBM Retail Store Solutions Web site,
including the 4610CVNT.EXE and AIPFNT46.EXE programs. For details, refer to the
POSS Programming Reference and User’s Guide.
Note: This utility requires POS Suite V1.0.0 or greater. POS Suite includes POSS
for Windows.
1. Download the latest DBCS font files from the IBM Retail Store Solutions Web
site to the same directory in which POSS for Windows is installed, which is
usually the C:\POS\BIN directory. To access the files on the Web:
a. Go to the IBM Retail Store Solutions Web site at
b. Select Support at the left edge of the main page.
c. Under IBM SurePOS Systems and Peripherals, select IBM SureMark
Printer.
d. Select the link to the Model TI5/TG5 support page.
e. Select the font files that you want to download.
The files for each DBCS code page are shown in Table 4.
Table 4. Font Files for DBCS Code Pages
Code Page File Name Codeset Station Where to Download
932 jpngh16.fnt SBCS Impact Impact code page 1
Japan jpngz16.fnt DBCS Impact Impact DBCS
Gothic Style jpngh24.fnt SBCS Thermal Thermal code page 1
jpngz24.fnt DBCS Thermal Thermal DBCS
judcz16.fnt DBCS Thermal Impact DBCS UDC
judcz24.fnt DBCS Thermal Thermal DBCS UDC
932 jpnmh16.fnt SBCS Impact Impact code page 1
Japan jpnmz16.fnt DBCS Impact Impact DBCS
Mincho Style jpnmh24.fnt SBCS Thermal Thermal code page 1
jpnmz24.fnt DBCS Thermal Thermal DBCS
judcz16.fnt DBCS Thermal Impact DBCS UDC
judcz24.fnt DBCS Thermal Thermal DBCS UDC

Table 4. Font Files for DBCS Code Pages (continued)

Code Page File Name Codeset Station Where to Download
949 kormh16.fnt SBCS Impact Impact code page 1
Korea kormz16.fnt DBCS Impact Impact DBCS
kormh24.fnt SBCS Thermal Thermal code page 1
kormz24.fnt DBCS Thermal Thermal DBCS
kudcz16.fnt DBCS Thermal Impact DBCS UDC
kudcz24.fnt DBCS Thermal Thermal DBCS UDC
1381 prcmh16.fnt SBCS Impact Impact code page 1
Chinese prcmz16.fnt DBCS Impact Impact DBCS
PRC prcmh24.fnt SBCS Thermal Thermal code page 1
(Simplified) prcmz24.fnt DBCS Thermal Thermal DBCS
pudcz16.fnt DBCS Thermal Impact DBCS UDC
pudcz24.fnt DBCS Thermal Thermal DBCS UDC
950 rocmh16.fnt (Note 1) SBCS Impact Impact code page 1
Chinese rocmz16.fnt DBCS Impact Impact DBCS
Taiwan rocmh24.fnt SBCS Thermal Thermal code page 1
(Traditional) rocmz24a.fnt (Note 2) DBCS Thermal Thermal DBCS
rocmz24b.fnt (Note 2) DBCS Thermal Thermal DBCS
rudcz16.fnt DBCS Thermal Impact DBCS UDC
rudcz24.fnt DBCS Thermal Thermal DBCS UDC
950 rocmh16b.fnt (Note 1) SBCS Impact Impact code page 1
Chinese rocmz16.fnt DBCS Impact Impact DBCS
Taiwan rocmh24.fnt SBCS Thermal Thermal code page 1
(Traditional) rocmz24a.fnt (Note 2) DBCS Thermal Thermal DBCS
rocmz24b.fnt (Note 2) DBCS Thermal Thermal DBCS
rudcz16.fnt DBCS Thermal Impact DBCS UDC
rudcz24.fnt DBCS Thermal Thermal DBCS UDC
Notes:
a. The file rocmh16b.fnt contains bold fonts and the file rocmh16.fnt contains
normal fonts.
b. The file rocmz24a.fnt contains the BIG-5 code set and the IBM Selected
non-Chinese character set (first byte A1-F9 and second byte 40-7E, A1-FE).
The file rocmz24b.fnt contains the IBM Selected non-Chinese/Chinese
character set (first byte F2-F9 and second byte 81-A0).
2. Download the 4610CVNT.EXE program and the configuration files that it uses.
To access the program and its files:
a. Go to the IBM Retail Store Solutions Web site at
b. Select Support at the left edge of the main page.
c. Under SurePOS Peripherals, select IBM SureMark Printer.
d. Select the link to the Model TI5/TG5 support page.
e. Select Font Utility Package to download the zipped file that contains the
program and the configuration files.
f. Unzip the program and the configuration files into the same directory that
contains the font files that you previously downloaded.
3. Enter the 4610CVNT config_file command to create the font file that will be
loaded into the printer. config_file is the name of the appropriate configuration
file from the following list:
JPNGS932.CFG
Code page 932, Japan, Gothic style

JPNMS932.CFG
Code page 932, Japan, Mincho style
KORMS949.CFG
Code page 949, Korea
CHNM1381.CFG
Code page 1381, Chinese – PRC
CHNM950N.CFG
Code page 950, Chinese – Taiwan, normal impact SBCS
CHNM950B.CFG
Code page 950, Chinese – Taiwan, bold impact SBCS
4. The font file is created. The file name is XXX.FON, where XXX is the same as
the configuration file. For example, when you run the 4610CVNT program with
JPNMS932.CFG, the font file is JPNMS932.FON.
5. Enter the following command to download the font set to the printer
(AIPFNT46.EXE should be in the same directory in which POSS for Windows is
installed, which is usually C:\POS:\BIN)
AIPFNT46 -s slot_number -p port_number -f font_file
where:
slot_number
The SureMark slot number. This is usually 1.
port_number
The SureMark port number. This is usually 17.
font_file
The name of the file created by the 4610CVNT.EXE program.
6. Wait a while. The SureMark font download takes several minutes.
DBCS User-Defined Character Download

To create a new character, use the 4610 DBCS Installation Utility Diskette with a
SureMark that is connected to a system unit by either an RS-232 or RS-485 cable.
The system unit must have a diskette drive, a PC keyboard, and a display.
To download a user-defined character:

1. Download the latest level of the 4610 DBCS Installation Utility Diskette from the
Retail Store Solutions Web site (see “Resources on the Internet” on page 29).
3. Power on the system unit to which the SureMark is connected.
4. Select Run Printer Utility for the RS-232 or RS-485 connection.
5. Follow the displayed instructions to complete the font download.
v Baud rate (9600 or 19 200)
Refer to the communication mode selection switches located at the bottom

rear of the SureMark printer when making the above selection.

c. Press Enter (OK).

d. Select F10 (Menu).
e. Select E (Edit).
f. Select D (Edit Font File).
g. Insert the font diskette, which includes the DBCS UDC font files. The DBCS
UDC font file names for each code page and type of station are shown in
Table 5.
Table 5. UDC Font File Names for DBCS Code Pages
Code Page File Name Station
932 (Japan) judcz16.fnt Impact
judcz24.fnt Thermal
949 (Korea) kudcz16.fnt Impact
kudcz24.fnt Thermal
1381 (PRC) pudcz16.fnt Impact
pudcz24.fnt Thermal
950 (Taiwan) rudcz16.fnt Impact
rudcz24.fnt Thermal
h. Select a font file and press Enter (OK).

i. Edit the font and save it.
6. To download the file, see “DBCS Code Page Download” on page 17.
Firmware Update
The SureMark printer has the capability to receive firmware updates from the host
system unit to which it is attached for RS-485, RS-232, or USB connections.
The following mediums can be used to update the SureMark firmware:

v 4610 DBCS Installation Utility Diskette Firmware Update
v POSS for Windows 4610 Printer Firmware Update Program
v 4690 OS 4610 Utility
v Alternative SureMark firmware update method via RS-232 attachment cable
Use the appropriate procedure that follows to update the SureMark firmware, after
downloading the latest level software from the Retail Store Solutions Web site (see
“Resources on the Internet” on page 29).
4610 DBCS Installation Utility Diskette for Updating SureMark

Firmware
To update the firmware in SureMark configurations, use the 4610 DBCS Installation
Utility Diskette with a SureMark that is connected to a system unit by an RS-232 or
RS-485 cable. The system unit must have a diskette drive, a PC keyboard, and a
display.
To update the firmware:

1. Download the latest level 4610 DBCS Installation Utility Diskette from the Retail
Store Solutions Web site (see “Resources on the Internet” on page 29).
3. Power on the system unit that has the SureMark attached by an RS-232 or
RS-485 cable.

4. Select Run Printer Utility for RS-485 or RS-232 connection.

5. Follow the displayed messages to complete the firmware update.
v Baud rate (9600 or 19 200)
Refer to the communication mode selection switches, which are located at

the bottom rear of the SureMark printer, when making the above selection.
c. Press Enter (OK) to proceed.
d. Select F10 (Menu).
e. Select O (Operations).
f. Select A (Advanced Options).
g. Select U (Update Firmware).
h. Press Enter twice to select the desired firmware image file (usually only the
latest firmware image file is available for selection).
i. Press Enter (Yes) again to commit to firmware update.
j. The Information screen will display the firmware update percent completed.
Note: The SureMark flash update will take several minutes. Do not power
off the host system or SureMark printer after the update has started.
6. After the firmware update is complete, the SureMark printer will be reset.
a. Press Enter (OK) to confirm.
b. Press Alt-X (Exit).
c. Press Enter to exit.
7. Remove the diskette from drive A.
8. Press Ctrl-Alt-Delete to reboot the system.
Using POSS For Windows for Updating SureMark Firmware (RS-485

and USB Only)
If you use a Windows operating system with the SureMark, you can use the POSS
for Windows 4610 Printer Firmware Update program (AIPFLD46.EXE) to update
SureMark firmware. For additional information, refer to the POSS Programming
Reference and User’s Guide.
Note: This utility requires POS Suite V1.0.0 or greater. POS Suite includes POSS
for Windows.
| 1. Download the latest SureMark firmware update image file from the IBM Retail
| Store Solutions Web site (see “Resources on the Internet” on page 29) to the
| C:\POS\BIN directory. The file is AIP46MC5.HEX for models TI5, TG5, TF7, and
| TM7. Because the file in the directory is more current than the old file, the
| firmware will be automatically updated when the system is powered off, then
| powered on.
2. To update the SureMark firmware manually, enter the following command:
AIPFLD46.EXE -S slot_number -P port_number -F microcode_file [-Q]
where:

slot_number
The SureMark slot number, which is usually 1. The slot number must be
specified with decimal values only; hexadecimal values are not
accepted.
port_number
The SureMark port number, which is usually 17. The port number must
be specified with a decimal value.
microcode_file
Must be C:\POS\BIN\AIP46MC5.HEX.
-Q Quiet mode installation (no progress information)
3. The SureMark flash update will take several minutes.
Note: USB printers connected to one of the SurePOS 700 Series systems can also
use the IBM Point-of-Sale Device Diagnostics, which is included in the POS
Suite, to update firmware. See IBM SurePOS 700 Series System Reference
for information about the IBM Point-of-Sale Device Diagnostics.
Using 4690 OS 4610 Utility to Update SureMark Firmware

4690 OS users with SureMark printers that use RS-485 or USB connections to
attach to medialess systems can update SureMark firmware (flash) by using the
4690 OS 4610 Utility Program function of 4690 OS.
Note: 4690 OS level 9910 or greater is required to use this utility.

1. To invoke the utility, press Ctrl S1, 95, Ctrl S2.
2. Press 729, Ctrl, S2 at the ENTER REQUEST prompt.
3. Press 1, Ctrl S2 to continue.
4. Message T7175 will display to confirm that the flash update has started.
5. The SureMark flash update will take several minutes. Message ″T9514 Enter
Request″ displays after the 4610 flash update completes.
6. Enter 99, Ctrl S2 to end the SureMark utility.
Updating 4610 Firmware Using RS-232 Attachment Cable

To use the 4610 DBCS Installation Utility Diskette to update SureMark firmware for
configurations that do not have a diskette drive and display and PC keyboard, you
must provide a temporary RS-232 attachment to a host PC that does have a
diskette drive.
Before starting the firmware update, you must obtain the following parts:
v RS-232 attachment cable, either 2 meters in length (P/N 86H2192) or 4 meters in
length (P/N 86H2195).
v SureMark Power Supply (for RS-232 configurations only), P/N 42H1176.
If the SureMark is currently attached to a host system unit that does not support a
diskette drive, use the following procedure to temporarily connect the SureMark to a
host PC that has a diskette drive, RS-232 port, PC keyboard and display.
1. Disconnect the SureMark (RS-485 #7) attachment cable and temporarily
connect an RS-232 attachment cable to the SureMark.
2. Connect the SureMark via the RS-232 port connector to an alternate host PC
that has a diskette drive.

3. Follow the procedure in “4610 DBCS Installation Utility Diskette for Updating
SureMark Firmware” on page 22, starting with Step 1, to complete the printer
firmware update.
4. Reconnect the SureMark to the original host system unit using the original
attachment cables.
Limitation on Updating Firmware

The following limitation must be considered when updating firmware on the
SureMark printer:
v SureMark firmware update cannot be performed if the printer currently has Model
4 emulation enabled. If emulation is enabled, temporarily disable Model 4
emulation, then start the SureMark firmware update. After the firmware update is
complete, re-enable Model 4 emulation. See “Emulating the IBM Model 3 or
Model 4 Printers” for additional information.
Emulating the IBM Model 3 or Model 4 Printers

Note: This procedure only applies to SBCS mode.
It is possible to emulate the IBM Model 3 or Model 4 printer with the SureMark
printer. You must change the configuration to enable the SureMark to emulate the
Model 3 or Model 4 printers.
The following mediums can be used to set up Model 3 or Model 4 emulation:

v For systems with diskette drives, use the 4610 DBCS Installation Utility Diskette
(see “Enabling Emulation Using 4610 DBCS Installation Utility Diskette”).
Download the latest level diskette from the Retail Store Solutions Web site (see
“Resources on the Internet” on page 29).
v For medialess systems using the 4690 OS, use the 4690 OS Online Terminal
Diagnostics (see “Enabling Emulation Using 4690 On-Line Terminal Diagnostics”
on page 26).
Enabling Emulation Using 4610 DBCS Installation Utility Diskette

The following information is also available in the 4610MOD4.TXT file on the
diskette.
Notes:
| 1. All SureMark firmware levels for models TI5, TG5, TF7, and TM7 support
| emulation.
2. 4610 DBCS Installation Utility Diskette V1.00 or later is required.
To set up Model 3 or Model 4 emulation using the 4610 DBCS Installation Utility
Diskette:
2. Power on the system unit.
3. Select MOD4 when the menu is displayed.
4. Perform the specified steps to either enable or disable emulation.
To enable when emulation is currently disabled:

1. Select one of the following:
v Model 4 emulation with Offline mode disabled
v Model 4 emulation with Offline mode enabled

The printer is reconfigured.

2. Press Ctrl-Alt-Delete to reboot the system. The system IPLs.
To disable when emulation is currently enabled:

1. Select Disable Model 4 emulation.
2. Press Ctrl-Alt-Delete to reboot the system. The system IPLs.
Enabling Emulation Using 4690 On-Line Terminal Diagnostics

Note: 4690 OS Version 1 level 9740 or greater is required to use this utility.
To set up Model 3 or Model 4 emulation using the 4690 On-Line Terminal

Diagnostics:
1. To invoke the utility, press Ctrl S1, 95 Ctrl S2.
2. At the ENTER REQUEST prompt, press 728, Ctrl, S2. This brings up the
function to switch the mode of the printer.
3. Perform the specified steps to either enable or disable emulation. The operating
system recognizes the current state of printer emulation and displays the
appropriate prompts.
To enable emulation:
1. Select TI3.
2. At the Activate Model 3/4 Emulation 1=N, 2=Y, S2 prompt, enter 2 to enable
Model 3/4 emulation.
3. At the Using EJ in Offline Mode? 1=N, 2=Y, S2 prompt, select Y if you want to
store all the journal data in the printer’s flash memory.
To disable emulation:
1. At the Disable Mod 3/4 Emulation 1=N, 2=Y, S2 prompt, enter 2 to disable
Model 3/4 emulation.
Limitations for Emulation

The following limitations must be considered when using the SureMark printer to
emulate the Model 3 or Model 4 printer.
v Emulation mode is supported only in SBCS mode.
v Printing the face of checks requires application changes (franking the back of
checks should not).
v Printing wide documents may require changes. The document station on the
Model 4 printer supports 86 characters, the SureMark supports 47 characters.
v Journal commands can be ignored or stored in the printer’s flash memory. This
needs to be decided when the printer is initially configured.
v There is no top document registration (documents must be inserted from the
front).
v User-defined special characters are not supported.
v Emulation mode does not support the Model 4A double-byte character set.
v For RS-485, emulation mode is currently only supported on 4690 OS and DOS
systems. For USB, emulation mode is currently only supported on 4690 OS.
Emulation is not supported for RS-232.

Printing Saved Data

When the printer is offline in Model 3/4 emulation mode and the option for storing
data to the printer was selected, it is possible to fill up the printer flash memory.
When the memory is full, a printer error indicates the journal station is out of paper.
You can empty the printer buffer by printing out the data that is stored in the flash
memory. The data prints on the customer receipt station. The data in the buffer is
erased only after the last line of data is printed.
Printing Buffer Data – Thermal/Impact SureMark Models TI5 and

TG5
To print the buffer data from the beginning:
1. Press and hold both buttons. When the printer ready indicator begins blinking,
release both buttons.
2. Press and release both buttons again.
Notes:
1. If the SureMark printer encounters an error (for example, the paper runs out or
the cover is opened) while printing the data, the data remains intact.
2. To stop printing the data, open and close the ribbon cover. When you are ready
to print the data, use the procedure above to restart printing from the beginning.
3. To stop printing and restart at the current position, open and close the paper
cover. Printing immediately restarts.
Printing Buffer Data – Single-Station SureMark Printers

To print the buffer data from the beginning:
1. Open the top cover. The LED will flash quickly.
2. Press and hold the paper feed button for 5 seconds.
3. The LED will show one short blink, accompanied by a beep, followed by a
1-second pause.
4. Press and hold the paper feed button for 5 seconds.
5. The LED will change to a long blink. The beeper will sound continuously.
6. Close the cover to begin printing the electronic journal data.
Notes:
1. If the SureMark printer encounters an error (for example, the paper runs out or
the cover is opened) while printing the data, the data remains intact.
2. To stop printing the data, open the top cover, turn the printer power switch ON,
turn the printer power switch OFF, and close the top cover. When you are ready
to print the data, use the procedure above to restart printing from the beginning.
3. To stop printing and restart at the current position, open and close the top cover.
Printing immediately restarts.
4. Pressing and releasing the paper feed button a third time before closing the top
cover will cause the printer to return to normal mode.
| Emulating an Epson Single-Station Printer (Single-Station SureMark

| Only)
| Emultation of an Epson single-station printer is supported on the single-station
| SureMark printers in SBCS mode.

| Enabling Epson Emulation

| To enable emulation of an Epson single-station printer on a single-station SureMark
| printer, you must set switch 3 on the main logic card. See Figure 13.
|
|
OFF
4
1 2 3
RS-232 mode switches
|
| Figure 13. Switch for Epson Emulation
|
| Limitations for Epson Emulation
| The following limitations must be considered when using the SureMark printer to
| emulate an Epson single-station printer.
| v Logos and downloadable characters are supported in emulation mode. However,
| because the Epson printer prints at 150 dpi and the SureMark prints at 200 dpi,
| the emulated printout will be smaller.
| v Emulation of page mode is not supported on the SureMark.
| v Epson supports the Select paper sensor to stop printing command. IBM does not
| support a low paper sensor.
Changing the Printer Mode between DBCS and SBCS

To disable DBCS printing (that is, to enter SBCS mode), use the 4610 DBCS
Installation Utility Diskette.
Note: This procedure requires 4610 DBCS Installation Utility Diskette V1.00 or
later.
2. Power on the system unit.
3. Select Change Printer Mode when the menu is displayed.
4. Perform the specified steps to change the printer mode.
To set to DBCS Mode:
a. Select DBCS Mode.
b. Press Ctrl-Alt-Delete to reboot the system. The system IPLs.
To set to SBCS Mode:

a. Select SBCS Mode.

b. Press Ctrl-Alt-Delete to reboot the system. The system IPLs.
| Proportional Font Conversion Utility

| As part of its support for proportional fonts, IBM provides three TrueType fonts and
| a utility that you can use to convert the fonts to files that the SureMark printer can
| use.
| The application and instructions for downloading the converted fonts are available
| from the Retail Store Solutions Web site. See “Resources on the Internet” for more
| information.
| Note: You might have TrueType fonts other than those supplied by IBM on your
| system. Before using the conversion utility to convert and download any
| non-IBM fonts for use by the SureMark printer, you must confirm that you
| have received authorization from the owner of the fonts to convert and
| download the fonts.
Resources on the Internet

The IBM Retail Store Solutions Web site at
http://www.ibm.com/solutions/retail/store contains publications for the
SureMark Printer. The Web site also provides access to diskettes, drivers, and
miscellaneous documentation, such as README files and OEM paper certification
information.
Select Support at the left on the main page of the Web site, then select IBM
SureMark Printer. The displayed page contains links both to documentation and to
diskettes and drivers that you can download for the SureMark printers.


Part 2. Models TI5 and TG5

This part contains repair/replacement, adjustment, and daily operational procedures
for Models TI5 and TG5. It also contains the parts catalog for this model.


Chapter 3. Problem Determination

Offline Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Customer Receipt Test . . . . . . . . . . . . . . . . . . . . . 33
Document Insert Test . . . . . . . . . . . . . . . . . . . . . 34
Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Customer Receipt Paper Movement and Cutter Problems . . . . . . . . . 40
FRU Removal and Replacement . . . . . . . . . . . . . . . . . . 42
Removing and Replacing the Top, Paper, and Ribbon Covers. . . . . . . 42
Removing and Replacing the Top Cover Operator Buttons . . . . . . . . 46
Removing and Replacing the Printhead . . . . . . . . . . . . . . . 47
Removing and Replacing the Home Sensor . . . . . . . . . . . . . 48
Removing and Replacing the Ribbon Drive Assembly. . . . . . . . . . 49
Removing and Replacing the Tensioner . . . . . . . . . . . . . . . 51
Removing and Replacing the Printhead Carriage Assembly . . . . . . . 52
Removing and Replacing the Transport Motor . . . . . . . . . . . . 56
Removing and Replacing the Printhead Cable . . . . . . . . . . . . 59
Removing and Replacing the Document Insert Sensor Assembly . . . . . 60
Removing and Replacing the Document Insert Platen Assembly . . . . . . 63
Removing and Replacing the Lower Forms Entry Frame . . . . . . . . 65
Removing and Replacing the Document Insert Backup Roller and Insert
Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . 68
Removing and Replacing the DI Feed Roller . . . . . . . . . . . . . 71
Removing and Replacing the Switch Card and Printhead Spacer . . . . . 75
Interface Card . . . . . . . . . . . . . . . . . . . . . . . 76
Removing and Replacing the Thermal Cables and Paper Switch . . . . . 77
Removing and Replacing the Thermal Latch . . . . . . . . . . . . . 79
Removing and Replacing the Thermal Drag Strip . . . . . . . . . . . 81
Removing and Replacing the Thermal Printhead Assembly. . . . . . . . 83
Removing and Replacing the Thermal Platen Assembly . . . . . . . . . 86
Removing and Replacing the Customer Receipt Motor . . . . . . . . . 87
Removing and Replacing the Rotating Cutter Blade and Thermal Guide . . . 88
Removing and Replacing the Cutter Gears and Cutter Clutch . . . . . . . 89
Removing and Replacing the Customer Receipt Paper Guide. . . . . . . 90
Removing and Replacing the Customer Receipt Paper Bucket . . . . . . 91
Removing and Replacing the Document Insert Motor and Gears . . . . . 93
Offline Tests
The following offline tests are used as diagnostic tools to ensure the printer is
operating correctly.
Customer Receipt Test

1. Press and hold both buttons to enter offline mode. When the Printer Ready
indicator begins blinking, release both buttons.
2. Press and release the Customer Receipt Feed button to start this test.
3. See Figure 14 on page 35 and verify that your printer has printed correct
information for your model and configuration:
v Double-byte character sets enabled (Models TI5 and TG5)
v 2 MB card with user flash storage enabled (Models TI3 and TI4)
v 2 MB card in single-byte mode (Models TI5 and TG5)
v RS-232, RS-485 or USB serial interface

v Applicable parameters for RS-232 communications:

– 9600 or 19 200 baud rate
– DTR/DSR or XON/XOFF control
v A solid line should appear as the last line of the test pattern.
If any characters that appear in Figure 14 on page 35 are missing from the test
pattern you print, or if the solid line is missing, go to “Symptoms” on page 36.
Document Insert Test

1. Insert a document in the Document Insert station. The Document Present
indicator should come on.
v If the Document Present indicator does not come on, realign the document. If
the Document Present indicator still does not come on, go to “Document
Sensor Threshold Reset” on page 106.
v If pressing the Document Feed button does not feed the document, go to
“Symptoms” on page 36.
2. Press and hold both buttons to enter offline mode. When the Printer Ready
indicator begins blinking, release both buttons.
3. Press and release the document feed button to print the test pattern. The test
pattern includes all printable characters in the resident code page, printed in the
default font.
v Model type (double-byte enabled, for Models TI5 and TG5).
v Communication options (RS-232 or RS-485).
v RS-232 parameters, if applicable.

T
The Printers S/N is 12345678 1
Microcode EC level is 30 2
Serial Interface: RS232 3
Serial Interface : 19.2K Baud, XON / XOFF 4 ,5
Double Byte Character Sets 6
|"#$%&'()*+,-./0123456789:;<->?ABCDEFGHIKJK
LMNOPQRSTUVWXYZ[\]^_ abcdefghijklmnopqrstuvw
xyz{|}~.CüéâäàåcêëèïîìÄÅÉæÆôöòûùÿÖÜø£ØSsáíóú 7
ÁÑGg¿ · · · · ¡ · · ÁÂÀ I · ¢ · · · · · · · · ãÃ ·
H I III · · · · · · · · · · · · · õ Ð ÊËÈÍÎÏÌÓßOO ^ ` õÕµþÞUUUyY±÷ ` ^` ` ` ·
Cuts: 139
CR Characters Printed: 142834
CR Motor Steps: 659340
CR Cover Openings: 593
DI Characters Printed: 11589
DI Feed Motor Steps: 68453
DI Transpor t Motor Passes: 5174 8
DI Home Errors: 2
DI Cover Openings: 3
DI Documents Inser ted: 58
9
|
| Figure 14. Offline Printer Test Pattern. This pattern is from the customer receipt (CR) station.
Test Pattern Notes:

1. The serial number that prints will be the actual serial number of your printer. (If
the logic card has been replaced, this number must be reset to the original
serial number.)
2. The microcode level will be the actual level of your printer’s microcode.
3. The serial interface will be specified as RS232, RS485, or USB, depending on
which interface is used to attach the printer to the system unit.
4. The line speed information appears only when the RS-232 interface is used.
The value can be either 9.6K baud or 19.2K baud, depending on the RS-232
switch settings. (See “Communication Mode Selections” on page 5.)
5. The RS-232 control mode information appears only when the RS-232 interface
is used. The value can be either DTR/DSR or XON/XOFF, depending on the
RS-232 switch settings. (See “Communication Mode Selections” on page 5.)
6. The feature enabled lines will appear only when the feature is installed.
7. These lines break at different points for the test pattern printed in the document
insert (DI) station.
| 8. This section contains printer usage statistics that you can use for problem
| determination.
9. The line across the bottom should be solid with no blank spaces.
Chapter 3. Problem Determination 35

Symptoms
Review the following symptoms or messages and take the suggested actions.
Table 6. Printer Symptoms or Messages
Symptom Repair Actions Listed in Most Likely Order of Failure
Printer does not power ON (Both 1. Check for a good connection and that the printer is plugged in.
LEDs are off).
2. Replace the power supply or system unit.
3. Exchange the printer interface card. Go to “Removing and Replacing the
Main Logic Card and Connector-Attached Interface Card” on page 76.
4. Exchange the main logic card. Go to “Removing and Replacing the Main
Logic Card and Connector-Attached Interface Card” on page 76.
Printer indicators do not come on. 1. Check that the printer is plugged in and has power.
2. Check for a broken LED.
3. Exchange the switch card. Go to “Removing and Replacing the Switch Card
and Printhead Spacer” on page 75.
Printer Ready LED is blinking. 1. Press the customer receipt feed button.
2. Check the paper supply to ensure that the receipt paper is loaded correctly.
3. Ensure that the covers are closed.
4. Adjust the thermal paper switch. Go to “Thermal Paper Switch Adjustment”
on page 106.
5. Run the printer offline tests. Go to “Offline Tests” on page 33.
Customer receipt (thermal) does 1. Check to see if the thermal paper is jammed or loaded incorrectly.
not advance paper.
2. Go to “Customer Receipt Paper Movement and Cutter Problems” on page 40
to isolate the problem.
Customer receipt (thermal) is 1. Check to see if the thermal paper is correctly installed.
missing character dots.
2. Check to see if the printhead cables are seated correctly. Go to “Removing
and Replacing the Thermal Cables and Paper Switch” on page 77.
3. Check and clean the printhead area, if contaminated.
4. Adjust the printhead. Go to “Thermal Printhead Adjustment” on page 104.
5. Exchange the CR (thermal) latch and print assembly. Go to “Removing and
Replacing the Thermal Latch” on page 79.
Customer receipt (thermal) Problem is caused by operator pulling the receipt out of the printer. Instruct
randomly missing rows of print, operators to use the CR feed button to advance the paper, instead of pulling the
accompanied by one thin line on paper.
receipt.
Cutter does not work correctly. 1. Check that the paper is loaded correctly.
2. Check that the clear plastic paper guide is in the correct position.
3. Perform the Cutter Blade Run-In Procedure. Go to “Cutter Blade Run-In” on
page 103.
4. If paper is folded or partially cut, go to “Customer Receipt Paper Movement
and Cutter Problems” on page 40.

Table 6. Printer Symptoms or Messages (continued)

DI print has missing dots. 1. Ensure the nose of the printhead is clear of debris.
2. Check the printhead platen gap adjustment. Go to “Printhead Platen Gap
Adjustment” on page 100.
3. Check the printhead cable for continuity. Unplug the cable at the printhead
and logic card for access.
4. Check the printhead for bent print wires. Remove the printhead (see
“Removing and Replacing the Printhead” on page 47) for access.
5. Exchange the printhead. Go to “Removing and Replacing the Printhead” on
page 47.
6. Exchange the logic card. Go to “Removing and Replacing the Main Logic
Card and Connector-Attached Interface Card” on page 76.
7. Exchange any or all of the following components: DI gears, DI feed roll shaft
assembly, and feedroll assembly. Go to “Removing and Replacing the
Printhead Carriage Assembly” on page 52 and “Removing and Replacing the
Cutter Gears and Cutter Clutch” on page 89.
DI station does not advance 1. Check the paper feed throat for an obstruction.
document.
2. Ensure that the gear train is free.
3. Check the DI open lever adjustment. Go to “DI Open Lever Adjustment” on
page 102.
4. Ensure DI forms compensation is correctly set. Go to “DI Forms
Compensation Adjustment” on page 98.
5. Exchange the DI motor. Go to “Removing and Replacing the Document
Insert Motor and Gears” on page 93.
6. Exchange the DI gears, DI feed roll shaft assembly, and feedroll assembly.
Go to “Removing and Replacing the Printhead Carriage Assembly” on
page 52 and “Removing and Replacing the Cutter Gears and Cutter Clutch”
on page 89.
7. Replace the main logic card. Go to “Removing and Replacing the Main Logic
DI (impact) printhead does not 1. Ensure that the printhead path is free.
move correctly.
2. Check that the transport shafts are not loose.
3. Check the timing belt assembly. If you need to exchange it, go to “Removing
and Replacing the Printhead Carriage Assembly” on page 52.
4. Check the tensioner. If you need to exchange it, go to “Removing and
Replacing the Tensioner” on page 51.
5. Check the home sensor cable for continuity.
6. Exchange the home sensor (see “Removing and Replacing the Home
Sensor” on page 48).
7. Exchange the transport motor. Go to “Removing and Replacing the Transport
Motor” on page 56.
8. Replace the main logic card. Go to “Removing and Replacing the Main Logic


Ribbon does not advance. 1. Exchange the ribbon cartridge. Go to “Ribbon Loading” on page 137.
2. Ensure that the ribbon drive is connected to the main logic card (see
Figure 29 on page 59).
3. Check the printhead gap and ribbon guide. Go to “Printhead Platen Gap
4. Exchange the ribbon drive assembly. Go to “Removing and Replacing the
Transport Motor” on page 56.
Printer Ready and Document 1. Press the customer receipt feed button.
Present LEDs are blinking.
2. Check the paper supply.
3. Ensure that both covers are closed.
4. Run the printer offline tests. Go to “Offline Tests” on page 33.
5. Insert a document.
6. Reflash microcode.
DI not moving documents Perform the DI forms compensation adjustment procedure. Go to “DI Forms
correctly. Compensation Adjustment” on page 98.
Uneven print on receipt. Go to “Thermal Printhead Adjustment” on page 104.
T7151 Printer card or cable is 1. Check or exchange the printer interface cable.
failing.
2. Exchange the printer main logic card. Go to “Removing and Replacing the
T7152 home sensor error. 1. Remove any obstruction to printhead movement.
2. Check the printhead gap.
3. Check the home sensor cable continuity. Replace, if necessary.
4. Replace the home sensor. Go to “Removing and Replacing the Printhead
Carriage Assembly” on page 52.
5. Exchange the logic card.
6. Exchange the transport motor.
T7153 Ribbon cover is open. 1. Close the cover.
2. Exchange the ribbon cover. Go to “Removing and Replacing the Top, Paper,
and Ribbon Covers” on page 42.
T7156 Document is inserted in the 1. Check for obstructions.
printer and printer fails.
2. Rerun the diagnostic test.
3. Exchange the DI sensor, then reset the sensor threshold. Go to “Removing
and Replacing the Document Insert Sensor Assembly” on page 60, then
“Document Sensor Threshold Reset” on page 106.
T7157 Document was not 1. Exchange the document and run the test again.
removed when expected or DI
2. Exchange the DI sensor. Reset the sensor threshold. Go to “Removing and
sensor is failing.
Replacing the Document Insert Sensor Assembly” on page 60, then
“Document Sensor Threshold Reset” on page 106.
T7159 EEPROM error. Exchange the main logic card. Go to “Removing and Replacing the Main Logic
T7161 Command reject. An invalid command was sent to the printer.


T7165 CR paper is empty or cover 1. Ensure that paper is in the printer and both covers are closed.
is open.
2. Press the customer receipt feed button to advance about 76 mm (3 in.) of
paper.
3. Check to see if the paper is installed correctly in the customer receipt station.
4. Open the customer receipt cover and manually press the switch.
5. Adjust the switch. Go to “Thermal Paper Switch Adjustment” on page 106.
T7166 Firmware error. 1. Update the SureMark firmware by downloading a new image from the utility
diskette. Go to Chapter 2, “SureMark Installation, Service, and Utility
Software” on page 13.

Customer Receipt Paper Movement and Cutter Problems

This procedure helps isolate customer receipt (thermal) paper movement or paper
cutting problems.
If paper is ″accordioned″ or wrapped around the platen, the paper guide may be
caught under the main cover or something may have blocked the paper from freely
exiting the printer.
1. Remove the covers. Go to “Removing and Replacing the Top, Paper, and
Ribbon Covers” on page 42.
2. Ensure that the thermal paper is loaded and the thermal printhead is latched.
3. Turn the thermal idler gear clockwise (see Figure 15 on page 41). All four gears
should turn and the platen should move the paper forward.
Note: It is normal for there to be a time lag of more than 1/2 rotation of the
gear before the paper starts moving.
v If all the gears did not turn, exchange the failing gear.
v If the platen did not turn the paper, exchange the platen and the bearings.
See “Removing and Replacing the Document Insert Platen Assembly” on
page 63.
v If it is difficult to turn the gears and advance the paper, replace the clutch.
See “Removing and Replacing the Cutter Gears and Cutter Clutch” on
page 89.
4. Turn the thermal idler gear counterclockwise 1-1/4 rotations, then clockwise
1-1/4 rotations. All four gears should turn and the two gears on the inside of the
frame should turn and move the lever on the rotating blade to cut the paper.
v If the blades closed, but did not cut the paper, replace both blades.
v If it was difficult to close the blades or there was a noticeable hang-point
during the cut, replace both blades. Go to “Cutter Blade Run-In” on page 103.
v If the blades did not close, replace the failing gear.
v If the blades closed, but did not open, replace the clutch.
5. If all of the above hardware worked correctly:
a. Temporarily restore power to the printer. With the customer receipt cover
open, press the customer receipt feed button to ensure that the motor
rotates the platen. Remove power from the printer by either unplugging it
from the wall outlet or turning off the system unit.
b. If the platen does not rotate, exchange the customer receipt motor. See
“Removing and Replacing the Customer Receipt Motor” on page 87. Ensure
that the thermal paper is loaded and the paper cover is latched.
c. If the platen still does not rotate, exchange the main logic card. Depending
on how the main logic card is attached, see “Removing and Replacing the

Figure 15. Customer Receipt Gears

FRU Removal and Replacement

This section includes removal and replacement procedures for the SureMark printer
field replaceable units (FRUs).
Removing and Replacing the Top, Paper, and Ribbon Covers
Important
This procedure shows you how to remove the printer covers (FRUs). Stop
when you get to the failing FRUs, exchange the FRUs, and reassemble. The
FRUs are highlighted.
Note: It is possible to remove the top cover, paper cover, and ribbon cover as one
unit by opening the paper cover and ribbon cover and removing the top
cover.
1. Power off the printer by either powering off the system or unplugging the
external power source from the wall outlet.
2. Open the paper cover. Place the top of the screwdriver handle between the
side of the printer and the top cover. Then close the top cover on the
screwdriver, one side at a time. This frees the pivots on both sides. Slide the
paper cover forward and out. See Figure 16 on page 44.
3. Open the ribbon cover using the lift tab. From the right side, push the ribbon
cover towards the left side while pressing the lock tab, and remove.
4. Remove the top cover. Pull the front of the top cover forward and off the
mounting post. See Figure 17 on page 45.
5. Reach in and release the rear latch in the CR paper well.
Note: Make sure that the front shock is correctly seated in the top cover before
installing a new top cover.
6. Lift the front of the top cover outward and upward until it clears the post.
7. Pull the bottom left side of the top cover locking latch outward and upward until
the side is clear of the track guide. See Figure 17 on page 45. Pull the latch
forward while pulling up on the rear of the top cover until the latch clears. Lift
the top cover clear.
8. Reassemble.
Attention: When reassembling, be sure that the clear plastic paper guide is
inserted through the slot in the paper cover.
Choose one of the following links to return to the procedure from which you came:
v “Removing and Replacing the Top Cover Operator Buttons” on page 46
v “Removing and Replacing the Printhead” on page 47
v “Removing and Replacing the Ribbon Drive Assembly” on page 49
v “Removing and Replacing the Tensioner” on page 51
v “Removing and Replacing the Printhead Carriage Assembly” on page 52
v “Removing and Replacing the Transport Motor” on page 56
v “Removing and Replacing the Document Insert Sensor Assembly” on page 60
v “Removing and Replacing the Document Insert Platen Assembly” on page 63
v “Removing and Replacing the DI Feed Roller” on page 71

v “Removing and Replacing the Main Logic Card and Connector-Attached Interface
Card” on page 76
v “Removing and Replacing the Thermal Cables and Paper Switch” on page 77
v “Removing and Replacing the Thermal Drag Strip” on page 81
v “Removing and Replacing the Thermal Platen Assembly” on page 86
v “Removing and Replacing the Customer Receipt Motor” on page 87
v “Removing and Replacing the Customer Receipt Paper Guide” on page 90
v “Removing and Replacing the Document Insert Motor and Gears” on page 93

Paper Cover
Lift Tab
Ribbon Cover
Clear Plastic
Guide
Top Cover
Lock Tab
Top Cover
Ribbon Cover
Paper Cover
Screwdriver
Top Cover
Figure 16. Removing the Paper and Ribbon Covers

Figure 17. Removing the Top Cover

Removing and Replacing the Top Cover Operator Buttons
Important
This procedure shows you how to remove the top cover and the operator
button (FRUs). Stop when you get to the failing FRUs, exchange the FRUs,
and reassemble. The FRUs are highlighted.
2. On the under side of the cover, press both sides of the key button latch inward
and lift the button out. See Figure 18.
3. Reassemble.
Key Buttons
Top Cover
Figure 18. Removing the Operator Buttons in the Top Cover

Removing and Replacing the Printhead
Important
This procedure shows you how to remove the printhead FRU. Stop when you
get to the failing FRU, exchange the FRU, and reassemble. The FRUs are
highlighted.
1. Power OFF the printer by either powering off the system or unplugging the
2. Open the ribbon cover. Go to “Removing and Replacing the Top, Paper, and
3. Remove the ribbon cartridge.
4. Remove the mounting screw from the printhead. See Figure 19.
5. Lift the printhead out of the carrier and disconnect the printhead cable.
6. Remove any dust from the home sensor.
7. Reassemble.
8. Adjust the printhead gap. Go to “Printhead Platen Gap Adjustment” on
page 100.
| 9. When you replace the impact printhead, run the service diskette and select
| Reset Statistics for the FRU. See “Software Adjustments (Model TI5 and TG5
| Only)” on page 13.
Figure 19. Replacing the Printhead

Removing and Replacing the Home Sensor
Important
This procedure shows you how to remove the home sensor FRU. Stop when
you get to the failing FRU, exchange the FRU, and reassemble. The FRUs are
highlighted.
2. Open the ribbon cover. Go to “Removing and Replacing the Top, Paper, and
3. Remove the ribbon cartridge.
4. Disconnect the home sensor cable. See Figure 19 on page 47.
5. Move the impact printhead assembly to the middle of the printer.
6. Loosen the home sensor mounting screw.
7. Remove the home sensor from beneath the impact printhead carriage (see
Figure 25 on page 55).
8. Reassemble.

Removing and Replacing the Ribbon Drive Assembly
Important
This procedure shows you how to remove the ribbon drive FRUs. Stop when
you get to the failing FRUs, exchange the FRUs, and reassemble. The FRUs
are highlighted. Use the following link to return to the procedure from which
you came:
v “Removing and Replacing the Transport Motor” on page 56.
2. Remove the front shock mount. Turn the front shock mount 1/4 turn
counterclockwise (end rib will be horizontal), then pull it out. See Figure 20 on
page 50.
3. Disconnect the ribbon drive assembly cable from the main logic card. See
Figure 20 on page 50.
4. Disconnect the printhead cable before lifting the printer assembly.
5. Remove the ribbon drive assembly. Lift the frame upward and pull the ribbon
drive assembly locking arm out.
6. Pull the ribbon drive toward the front of the printer and move it down and out.
Note: Ensure that the logic card is completely seated in the base when
reassembling.
7. Reassemble.
8. Check cables for good seat on logic card.

Figure 20. Removing the Ribbon Drive Assembly

Removing and Replacing the Tensioner
Important
This procedure shows you how to remove the tensioner FRUs. Stop when you
get to the failing FRUs, exchange the FRUs, and reassemble. The FRUs are
highlighted.
1. Open the ribbon cover.

2. Position the carriage assembly in the center. See Figure 21.
3. Push the tensioner inward and remove the timing belt from the transport motor
pulley.
4. Remove the tensioner spring.
5. Remove the tensioner by sliding it towards the right and lifting it out.
6. Reassemble.
7. Run one of the SureMark diagnostic and adjustment utilities. See “Software
Adjustments (Model TI5 and TG5 Only)” on page 13.
Tensioner
Tensioner Spring
Timing Belt
Transport Motor
Figure 21. Removing the Tensioner

Removing and Replacing the Printhead Carriage Assembly
Important
This procedure shows you how to remove the printhead carriage assembly
FRUs. Stop when you get to the failing FRUs, exchange the FRUs, and
reassemble. The FRUs are highlighted.
2. Position the carriage assembly on the right side of the printer.
3. Push the tensioner inward and remove the timing belt from the transport
motor pulley. See Figure 22 on page 53.
4. Disconnect the printhead/home sensor cable from the printhead and home
sensor. Thread the cable through the printhead carrier. See Figure 23 on
page 53.
5. Turn the bushing on the right side of the printer transport shaft
counterclockwise until locking tabs align with the release slots, which are
visible on the inside of the frame. Remove the rear transport shaft. If
necessary, replace the bushing. See Figure 24 on page 54.
6. Remove the printhead carriage assembly. See Figure 24 on page 54.
Note: Steps 7, 8, and 9 describe removals of individual FRUs. You can

remove each FRU separately without removing other FRUs. Choose
one or all of these steps to remove the failing FRUs, and then proceed
with step 10.
7. Remove the screw holding the home sensor to the printhead carriage
assembly. Remove the home sensor. See Figure 25 on page 55.
8. Remove the two screws from the ribbon guide, pivot the platen toward the
rear, and remove the ribbon guide. See Figure 23 on page 53.
9. Remove the timing belt from the printhead carriage assembly. See
Figure 22 on page 53 and Figure 24 on page 54.
10. Remove the screw from the front transport shaft and slide it out from the left
side. See Figure 24 on page 54.
11. Remove the front transport carrier bearing. See Figure 24 on page 54.
12. Reassemble.
13. Adjust the printhead.

Tensioner
Tensioner Spring
Timing Belt
Transport Motor
Figure 22. Removing the Timing Belt
Figure 23. Removing the Printhead/Home Sensor Cable

Backup Roller
Screw
Ribbon Guide
Printer Carriage Assembly
Right Eccentric
Rear Transport Shaft Front Carrier Bearing
Front Transport Shaft

Left
Printhead
Gap Eccentric
Printhead Gap
Eccentric Detail Slot
Figure 24. Removing the Carriage Assembly, Front or Rear Transport Shafts

Figure 25. Removing the Front Transport Carrier Bearing

Removing and Replacing the Transport Motor
Important
This procedure shows you how to remove the transport motor FRU. Stop
2. Remove the ribbon drive assembly. Go to “Removing and Replacing the
Ribbon Drive Assembly” on page 49.
3. Disconnect the printhead cable from the main logic card. Go to “Removing and
Replacing the Printhead Cable” on page 59.
4. Position the carriage assembly on the right side of the printer. See Figure 26
on page 57. Push the tensioner inward and remove the timing belt from the
transport motor pulley.
5. Turn the bushing on the right side of the printer transport shaft
counterclockwise until locking tabs align with the release slots. Remove the
rear transport shaft. If necessary, replace the bushing. See Figure 27 on
page 57.
Note: If the rear transport motor screw can be removed and secured with the
transport shaft in place, this step can be omitted.
6. Disconnect the transport motor cable from the main logic card.
7. Remove the two screws holding the transport motor to the frame.
8. Lift the printer frame upward enough to remove the transport motor. Remove
the transport motor. See Figure 28 on page 58.
9. Reassemble.
10. If the transport shaft was removed, adjust the printhead gap. Go to “Printhead
Platen Gap Adjustment” on page 100.
| 11. When you replace the transport motor, run the service diskette and select

Tensioner
Tensioner Spring
Timing Belt
Transport Motor
Backup Roller
Screw
Ribbon Guide
Right Eccentric

Left
Printhead
Gap Eccentric
Printhead Gap
Figure 27. Turning the Bushing and Removing the Transport Shaft

Transport Motor
Front Shock Mount
Figure 28. Removing the Transport Motor

Removing and Replacing the Printhead Cable
Important
This procedure shows you how to remove the printhead cable FRU. Stop
2. Remove the ribbon drive assembly. Go to “Removing and Replacing the
Ribbon Drive Assembly” on page 49.
3. Disconnect the printhead cable from the main logic card.
4. Disconnect the printhead cable and the home sensor from the printhead and
pull it through and out of the carriage assembly. See Figure 29.
5. Make an alignment mark across the edge of the cable, partly on the cable and
partly on the frame. (See Figure 29.)
6. Peel the adhesive loose from the frame.
7. Lift the printer frame upward and unsnap the two front latches, which hold the
upper document guide, by pressing forward and down with a screwdriver to
loosen the upper document guide (see Figure 23 on page 53).
8. Pull the printhead cable through and out of the frame.
Note: Take note of how the cable is routed through the frame. The cable is
affixed to the frame with adhesive.
9. Lay the old and new printhead cable side by side. Copy the alignment mark
from the old printhead cable to the same location on the new printhead cable.
10. Reassemble.
Note: Route and connect the printhead cable at both ends before using the
adhesive strip to affix the cable to the frame. Use the alignment mark to
position the printhead cable.
Figure 29. Disconnecting the Printhead Cable and Home Sensor

Removing and Replacing the Document Insert Sensor Assembly
Important
This procedure shows you how to remove the document insert assembly
Choose one of the following links to return to the procedure from which you
came:
v “Removing and Replacing the DI Feed Roller” on page 71.
v “Removing and Replacing the Document Insert Backup Roller and Insert
Lever Assembly” on page 68.
1. Remove the covers and the ribbon cartridge.

2. Disconnect the document sensor assembly cable (red five-pin connector) from
the top of the main logic card.
3. Remove the sensor spring.
v If the DI sensor will rotate forward past the carriage assembly, go to the next
step.
v If the DI sensor will not rotate forward past the carriage assembly, remove
the pressure pad holder and wear plate to provide the required clearance.
See Figure 32 on page 62.
4. Position the carriage assembly on the right side of the printer.
5. Pivot the document insert sensor assembly towards the front and pull it
forward to remove.
6. Reassemble.
7. Perform the document threshold reset procedure. Go to “Document Sensor
Threshold Reset” on page 106.
Tensioner
Tensioner Spring
Timing Belt
Transport Motor

Backup Roller
Screw
Ribbon Guide
Right Eccentric

Left
Printhead
Gap Eccentric
Printhead Gap
Figure 31. Removing the Front Transport Shaft

Figure 32. Disconnecting the Sensor Spring and Removing the DI Insert Assembly

Removing and Replacing the Document Insert Platen Assembly
Important
This procedure shows you how to remove the platen FRUs. Stop when you
get to the failing FRUs, exchange the FRUs, and reassemble. The FRUs are
highlighted.
came:
v “Removing and Replacing the DI Feed Roller” on page 71.
v “Removing and Replacing the Cutter Gears and Cutter Clutch” on page 89.
v “Removing and Replacing the Customer Receipt Paper Guide” on page 90.
2. Open the thermal printhead assembly up.
3. Disconnect the clip springs on both sides of the platen shaft. See Figure 33 on
page 64.
Note: The clip spring on the right side is installed reversed from the clip spring
on the left side.
4. Disengage the platen spring and remove the platen assembly and the platen
spring.
5. Reassemble.
6. Check the printhead gap. Go to “Printhead Platen Gap Adjustment” on
page 100.

E-Clips
Platen Shaft
Clip Spring
Platen
Platen Spring
Figure 33. Removing the Document Insert Platen Assembly

Removing and Replacing the Lower Forms Entry Frame
Important
This procedure shows you how to remove the lower forms entry frame FRUs.
Stop when you get to the failing FRUs, exchange the FRUs, and reassemble.
The FRUs are highlighted.
2. Gently remove the cables connected to the main logic card. See Figure 34 on
page 66.
3. Twist the front shock mount to the horizontal position and pull it out.
SeeFigure 35 on page 66.
4. If you need to replace the upper DI forms entry, do so at this point. See
Note: Snaps for the upper DI forms entry are inside the frame under the front
transport shaft. (See Figure 19 on page 47.)
5. Lift the frame out of the bottom cover.
6. Remove the document insert platen assembly. Go to “Removing and Replacing
the Document Insert Platen Assembly” on page 63.
7. Remove the document insert sensor spring. Go to “Removing and Replacing
the Document Insert Sensor Assembly” on page 60.
8. Remove the E-clips from each side of the drive shaft. Slide and remove the
drive shaft. See Figure 36 on page 67.
9. Remove the document insert lower forms entry frame by maneuvering the
bail through the DI backup roller and the feed roller and unsnapping the
document insert sensor from the right side of the forms entry frame. See
10. Remove the bail from the document insert lower forms entry frame assembly.
Press the bail downward in the center until the bail clears the locking posts
and pull outward. See Figure 37 on page 67.
11. Reassemble.
page 100.

Thermal Paper-Out Sensor Connector (Green)

Document Insert Sensor Connector (Red)
Thermal Printhead Document Insert Motor Connector (Green)
Connector Cutter Motor Connector (White)
Switch Card Connector (Yellow)
Impact Ribbon Drive

Connector (Yellow)
Transport Motor
Connector (Red)
Impact Printhead Connector
Interface Card Connector
Figure 34. Disconnecting the Main Logic Card Cables
Main Logic Card
Printer Assembly
Frame
Front Shock Mount

Bottom Cover
Figure 35. Removing the Front Shock Mount

Toggle Actuator
DI Backup Roller
DI Feed Roller
Upper Document
Insert Forms Entry
E Clip
Flipper Drive Gear

Bail
E Clip
Flipper
Drive Shaft
Figure 36. Removing the Lower Forms Entry Frame
Bail
Hooked Tabs
Flipper Assembly
Figure 37. Removing the Bail

Removing and Replacing the Document Insert Backup Roller and

Insert Lever Assembly
Important
This procedure shows you how to remove the document insert backup roller
1. Remove the document insert sensor assembly. Go to “Removing and

Replacing the Document Insert Sensor Assembly” on page 60.
2. Remove the pressure spring between the frame and shaft eccentric bearing.
3. Remove the E-clip from the document insert backup roller.
4. Slide the document insert backup roller to the left side and pull forward to
remove.
Note: Be careful not to misplace the bushing on the right-side.

5. Remove the rear transport shaft.
6. Remove the E-clip from the document insert lever assembly. See Figure 39 on
page 70.
7. Remove the document insert lever assembly.
8. Reassemble.
9. Reset the pressure shaft eccentric bushing. Go to “DI Forms Compensation
10. Reset the DI open lever adjustment. Go to “DI Open Lever Adjustment” on
page 102.
page 100.

Figure 38. Removing the DI Backup Roller

Figure 39. Removing the DI Lever Assembly

Removing and Replacing the DI Feed Roller
Important
This procedure shows you how to remove the DI feed roller FRU. Stop when
are highlighted.
3. Remove the ribbon.
4. Gently remove the cables connected to the main logic card. See Figure 40 on
page 72.
5. Twist the front shock mount to the horizontal position and pull it out. See
6. Remove the document insert platen assembly. Go to “Removing and Replacing
the Document Insert Platen Assembly” on page 63.
7. Remove the document insert sensor assembly. Go to “Removing and
Replacing the Document Insert Sensor Assembly” on page 60.
8. Follow steps 8 through 9 for “Removing and Replacing the Lower Forms Entry
Frame” on page 65.
9. Remove the document insert backup roller. Go to “Removing and Replacing
the Document Insert Backup Roller and Insert Lever Assembly” on page 68.
10. Remove the DI gear. See Figure 42 on page 73.
11. Remove the E-clip from the left side of the document insert feed roller. See
12. Move the left feed bearing to the right side enough to clear it from the frame.
Pull forward and remove the left end of the feed roller.
13. Align the retention pin on the right side of the feed roller with the opening in
the frame and remove the feed roller.
14. Reassemble.
page 100.
16. Run one of the 4610 diagnostic and adjustment utilities. See “Software


Impact Ribbon Drive

Connector (Yellow)
Transport Motor
Connector (Red)
Figure 40. Disconnecting the Main Logic Card Cables
Main Logic Card
Printer Assembly
Frame
Front Shock Mount

Bottom Cover

DI Gear
E-Clip
DI Motor
DI Motor Gear
E-Clip
Idler Gear
E-Clip
Figure 42. Gear Removal

Figure 43. Removing the Document Insert Feed Roller

Removing and Replacing the Switch Card and Printhead Spacer
Important
This procedure shows you how to remove the switch card and printhead
spacer. Stop when you get to the failing FRUs, exchange the FRUs, and
Use the following link to return to the procedure from which you came:
v “Removing and Replacing the Ribbon Drive Assembly” on page 49.
2. Disconnect the switch card cable from the main logic card.
3. Unfasten the screw and remove the switch card. See Figure 44.
4. Remove the printhead spacer from the frame.
5. Reassemble.
Figure 44. Removing the Switch Card and Printhead Spacer


Interface Card
Important
This procedure shows you how to remove the logic FRUs. Stop when you get
to the failing FRUs, exchange the FRUs, and reassemble. The FRUs are
highlighted.
1. Invert the fully assembled printer.

2. Turn the screw that is fastened to the interface card assembly
counterclockwise until it is loose.
3. Pull down on the interface card assembly at the end nearest to the screw.
4. Slide the interface card assembly out of the bottom cover.
5. Remove the top cover. Go to “Removing and Replacing the Top, Paper, and
6. Remove all cables from the main logic card.
7. Lift the main logic card out of the bottom cover.
8. Reassemble.
9. Whenever you exchange the main logic card, you must configure the printer
model and then update the firmware. Make a note of the printer model and
serial number, which are located on the label that is either on or under the front
cover of the printer, then go to “Software Adjustments (Model TI5 and TG5
Only)” on page 13.
Figure 45. Removing the Interface Card Assembly

Removing and Replacing the Thermal Cables and Paper Switch
Important
This procedure shows you how to remove the thermal cover, thermal cables,
and the thermal paper switch FRUs. Stop when you get to the failing FRUs,
exchange the FRUs, and reassemble. The FRUs are highlighted.
2. Remove the thermal cover. See Figure 46.
3. Remove the tie wraps and spiral wraps from the thermal printhead cables. Take
note of the cable and spiral wrap locations. See Figure 47 on page 78.
4. Disconnect the cable from the main logic card and from the thermal printhead.
5. Remove the thermal cables.
6. Unfasten the screw and remove the thermal paper switch.
7. Reassemble.
8. Check thermal paper switch operation and adjust as necessary. Go to “Thermal
Paper Switch Adjustment” on page 106.
Figure 46. Removing the Thermal Cover

Figure 47. Removing the Spiral Wraps

Impact Ribbon Drive

Connector (Yellow)
Transport Motor
Connector (Red)
Figure 48. Disconnecting the Thermal Cable from the Main Logic Card

Removing and Replacing the Thermal Latch
Important
This procedure shows you how to remove the thermal latch FRUs. Stop when
are highlighted.
1. Remove the paper cover. Go to “Removing and Replacing the Top, Paper, and
2. Remove the thermal cover, see Figure 49.
3. Remove the latch return spring from the platen latch.
4. Push outward on the platen latch and remove. See Figure 49.
5. Pull locking tabs on both sides of the latch spring outward from the printhead
mounting bracket.
6. Slide the thermal latch spring to one side and remove it. See Figure 50 on
page 80.
7. Reassemble.
Figure 49. Thermal Latch Assembly

Figure 50. Removing the Thermal Latch Spring

Removing and Replacing the Thermal Drag Strip
Important
This procedure shows you how to remove the thermal drag strip FRUs. Stop
1. Remove the paper cover. Go to “Removing and Replacing the Top, Paper, and
2. Remove the E-clip and disconnect the drag strip from the printhead shaft. See
3. Remove the drag strip by pulling it through the drag shaft housing. Take note
of the orientation for reassembling.
4. Reassemble. You must flex the tip of the drag strip to get it back into position.
Figure 51. View of Drag Strip from Back of Printer

E-clip
Drag Strip
Customer Receipt Paper Guide
Figure 52. Removing the Drag Strip

Removing and Replacing the Thermal Printhead Assembly
Important
This procedure shows you how to remove the thermal printhead assembly
came:
v “Removing and Replacing the Customer Receipt Motor” on page 87.
2. Disconnect the thermal cables from the main logic card.
3. Follow steps 2 and 3 in “Removing and Replacing the Thermal Drag Strip” on
page 81.
4. Cut the tie wraps securing the thermal cables to the thermal frame. See
5. Remove the hinge by rotating it approximately 45° and squeezing the hinge
post through the pivot openings. See Figure 53 on page 84.
6. Remove the thermal printhead assembly.
7. Remove the E-clip from the cutter stud.
8. Remove the cutter stud by removing the E-clip, sliding the cutter blade to the
left, and pulling the right side of the blade from the frame.
9. Remove the stationary blade. See Figure 55 on page 85.
10. Remove the thermal cover.
11. Remove the E-clips from the left side of the printhead shaft. Remove the
printhead shaft by sliding it through the printhead bracket. See Figure 55 on
page 85.
12. Remove the leaf spring.
13. The thermal paper switch will be attached to either the thermal frame or the
thermal printhead assembly. Remove and replace the switch, if necessary.
14. Reassemble.
15. Check the thermal paper switch operation and adjust if necessary. Go to
“Thermal Paper Switch Adjustment” on page 106.
| 16. When you replace the thermal printhead, run the service diskette and select

Figure 53. Thermal Printhead Assembly
Figure 54. Removing the Spiral Wraps

Figure 55. Removing the Cutter Stud, Stationary Blade, and Printhead Shaft

Removing and Replacing the Thermal Platen Assembly
Important
This procedure shows you how to remove the thermal platen assembly FRUs.
2. Open the thermal printhead assembly.
3. Rotate the right thermal platen bearing 90° and lift the right side of the platen so
that the locating tab on the platen stripper is above the locating notch in the
right frame.
4. Unsnap and remove the platen stripper.
Note: Handle the platen stripper carefully. The edges may be sharp.
5. Remove the E-clip from the idler gear. Remove the thermal idler gear and
thermal drive gear.
6. Lift the right side of the thermal platen and slide the left side of the platen out
of the frame.
7. Reassemble.
Figure 56. Removing the Thermal Platen Assembly

Removing and Replacing the Customer Receipt Motor
Important
This procedure shows you how to remove the customer receipt motor FRUs.
2. Disconnect the motor connector from the logic card.
3. Open the thermal frame and remove the paper.
4. Slide the left wall of the paper bucket as far to the left as it will go.
Note: This may be difficult. You must pull up on the bucket wall while pushing
down on the tabs that latch the bottom of the guide.
5. Remove the two screws from the customer receipt motor and remove the motor
by sliding it under the edge of the paper guide and then out through the paper
bucket area.
6. Reassemble.
7. Slide the left wall of the paper bucket back to its original position.
Note: This may be difficult. You must pull up on the bucket wall while pushing
down on the tabs that latch the bottom of the guide.
| 8. When you replace the customer receipt motor, run the service diskette and
| select Reset Statistics for the FRU. See “Software Adjustments (Model TI5 and
| TG5 Only)” on page 13.
Figure 57. Removing the Customer Receipt Motor

Removing and Replacing the Rotating Cutter Blade and Thermal Guide
Important
This procedure shows you how to remove the rotating cutter blade FRUs. Stop
2. Remove the rotating cutter blade and thermal guide by prying outward with a
screwdriver on the right side of the frame. See Figure 58.
3. Reassemble.
Figure 58. Removing the Rotating Blade and Thermal Guide

Removing and Replacing the Cutter Gears and Cutter Clutch
Important
This procedure shows you how to remove the cutter gear FRUs. Stop when
are highlighted.
2. Remove the spiral pin holding the cutter gear and remove the cutter gear. See
Figure 59.
3. Remove the cutter clutch assembly.
4. Remove the rotating cutter blade. Go to “Removing and Replacing the Rotating
Cutter Blade and Thermal Guide” on page 88.
5. Remove the E-clip holding the pin gear and remove the pin gear.
6. Remove the cutter stop spring (see Figure 57 on page 87).
7. Reassemble.
Figure 59. Removing the Cutter Gears

Removing and Replacing the Customer Receipt Paper Guide
Important
This procedure shows you how to remove the customer receipt paper guide
2. Remove the rotating cutter blade. Go to “Removing and Replacing the Rotating
Cutter Blade and Thermal Guide” on page 88.
3. Remove the thermal printhead assembly. Go to “Removing and Replacing the
Thermal Printhead Assembly” on page 83.
4. Remove the thermal platen. Go to “Removing and Replacing the Thermal Platen
Assembly” on page 86.
5. Remove the document insert platen. Go to “Removing and Replacing the
Document Insert Platen Assembly” on page 63.
6. Release the two locking posts from the frame and remove the customer
receipt paper guide. See Figure 60.
Attention: Be careful that you do not break the locking posts.
7. Reassemble.
Figure 60. Removing the Customer Receipt Paper Guide

Removing and Replacing the Customer Receipt Paper Bucket
Important
This procedure shows you how to remove the customer receipt paper bucket
2. Gently remove the cables connected to the main logic card, except the cable
attached to the interface card. See Figure 61.
3. Twist the front shock mount to the horizontal position and pull it out. See
5. Unlock the locking tabs from the underside of the frame and remove the
customer receipt paper bucket. See Figure 63 on page 92.
6. The right side of the bucket will have to be snapped by the triangular guide rib
on the paper guide.
7. Reassemble.

Impact Ribbon Drive

Connector (Yellow)
Transport Motor
Connector (Red)
Figure 61. Disconnecting the Cable Connected to the Main Logic Card

Main Logic Card
Printer Assembly
Frame
Front Shock Mount

Bottom Cover
Figure 63. Customer Receipt Paper Bucket

Removing and Replacing the Document Insert Motor and Gears
Important
This procedure shows you how to remove the document insert motor and gear
2. Remove the customer receipt paper guide. Go to “Removing and Replacing
the Customer Receipt Paper Guide” on page 90.
3. Gently remove the cables connected to the main logic card, except the cable
attached to the interface card. See Figure 64.
4. Remove the front shock mount. See Figure 65 on page 94.
6. Remove the E-clip holding the motor gear to the motor. See Figure 66 on
page 94.
7. Remove the motor gear.
8. Remove the two screws and then remove the document insert feed motor.
9. Reassemble.

Impact Ribbon Drive

Connector (Yellow)
Transport Motor
Connector (Red)
Figure 64. Disconnecting the Logic Card Cables

Main Logic Card
Printer Assembly
Frame
Front Shock Mount

Bottom Cover
Screw
E-Clips
Screw Motor Gear

Idler Gear
Figure 66. Removing the Motor Gear and Idler Gear

Document Insert Feed Motor
Screws
Figure 67. Removing the Document Insert Feed Motor


Chapter 4. Hardware Adjustment Procedures

Mechanical Adjustments . . . . . . . . . . . . . . . . . . . . . 98
DI Forms Compensation Adjustment . . . . . . . . . . . . . . . . 98
Printhead Platen Gap Adjustment . . . . . . . . . . . . . . . . 100
DI Open Lever Adjustment . . . . . . . . . . . . . . . . . . . 102
Cutter Blade Run-In . . . . . . . . . . . . . . . . . . . . . 103
Thermal Printhead Adjustment . . . . . . . . . . . . . . . . . . 104
Thermal Paper Switch Adjustment . . . . . . . . . . . . . . . . 106
Document Sensor Threshold Reset . . . . . . . . . . . . . . . . 106
DANGER
CAUTION:
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, the product, and the part being installed are at the same charge level.
ESD Damage Prevention:
Anytime a service action involves physical contact with logic cards, modules,
back-panel pins, or other ESD sensitive (ESDS) parts, the service person must be
connected to an ESD common ground point on the product through the ESD wrist
strap and cord.
The ESD ground clip can be attached to any frame ground, ground braid, green
wire ground, or the round ground prong on the ac power plug. Coax or connector
outside shells can also be used.
Handling Removed Cards:
Logic cards removed from a product should be placed in ESD-protective containers.

No other object should be allowed inside the ESD container with the logic card.
Attach tags or reports that must accompany the card to the outside of the container.

Mechanical Adjustments
The following adjustment procedures are included in this section.
Important: Procedures 1 through 3 must be done is sequence.

1. DI Forms Compensation Adjustment
2. Printhead/Platen Gap Adjustment
3. DI Open Lever Adjustment
4. Cutter Blade Run In
5. Thermal Printhead Adjustment
6. Thermal Switch Adjustment
7. Document Sensor Threshold Reset
DI Forms Compensation Adjustment

Before making this adjustment, make sure the printhead is not pushed against the
platen.
1. Turn the printhead gap adjustment bushings away from the platen (clockwise
when looking at the left side of the printer). Ensure that the printhead is not in
the far-right position. See Figure 68 on page 99.
2. Rotate the shaft eccentric bearing until the DI backup roll is away from the DI
feed roll shaft (clockwise). A single sheet of paper should be able to slip
between the backup roll and the feed roll.
3. Rotate the shaft eccentric bearing counterclockwise so that the backup roll
moves toward the feed roll. Make sure that the paper is removed before
continuing the adjustment.
4. Rotate the shaft eccentric bearing until the feed roll shaft end nearest to the
eccentric moves away from the pressure roll shaft 0.05 mm (0.002 in). You can
measure this by using a feeler gauge between the frame and the left feed roll
bearing.
6. Continue with “Printhead Platen Gap Adjustment” on page 100.

Figure 68. DI Forms Adjustment
Chapter 4. Adjustments – Models TI5 and TG5 99

Printhead Platen Gap Adjustment

The printhead platen gap needs to be adjusted to 0.508 mm (0.02 in.) nominally
across the length of the platen. This is accomplished by adjusting the printhead gap
bushings located at the left and right ends of the carriage shaft. The gap setting tool
FRU part number is 42H1190. A sealant might be required to reseal the 4610 cover
set.
1. The printer mechanism must be installed in the printer base and resting on a
flat and level surface.
For printers with a flipper installed, the flipper cover must be installed.
The thermal print mechanism must be closed. The thermal paper cover does
not have to be in place.
2. Remove the ribbon from the printer (see “Ribbon Loading” on page 137).
3. Move the printhead carriage to the left. Check the printhead gap by sliding the
gap setting tool between the printhead and the ribbon guide. See Figure 69 on
page 101.
v The gap setting tool only needs to be pushed down until it reaches the print
wires on the printhead.
v The force used to move the gap setting tool up and down in the gap needs
to be very light.
v There should be no movement of the printhead.
4. Move the printhead carriage to the right and check the printhead gap as
described in step 3.
5. If both adjustments are correct, no further action is required. If either
adjustment is incorrect, return the printhead carriage to the left.
6. Adjust the left printhead gap eccentric using a screwdriver. The gap between
the ribbon guide and the print wires on the printhead should be 0.388 +/- 0.02
mm (0.0153 +/- 0.0008 in). Adjust it with the printhead gap setting tool that is
provided with the printhead FRU.
7. For right printhead gap adjustment, remove the 4610 cover set.
8. Move the printhead carriage to the right and adjust the right printhead gap
eccentric using a screwdriver (see step 6).
9. Check the left side and the right side again. Re-adjust if necessary.
10. If the eccentrics appear snug during the adjustment phase (steps 6 through 8),
replace the 4610 cover set and proceed. If the eccentrics did not appear snug
during the adjustment phase, apply a small amount of an appropriate sealant
(nail polish, a sealant from Glyptal, Inc., etc.) across the original seals. If the
eccentrics appear excessively loose, they may require replacement.
Note: Loctite® is not an acceptable sealant.

11. Replace the 4610 cover set.
12. Check the left side and the right side again. Replacing the cover may introduce
variations. Readjust if necessary.
13. Reinstall the ribbon and perform a print test to check function and print quality.
See “Customer Receipt Test” on page 33 for information on performing a CR
print test.

Figure 69. Placement of Gap Setting Tool
Backup Roller
Screw
Ribbon Guide
Right Eccentric

Left
Printhead
Gap Eccentric
Printhead Gap
Figure 70. Platen Gap Adjustment

DI Open Lever Adjustment

1. Move the impact printhead carriage to the right until it is 2 mm from the right
wall of the frame.
2. Use a screwdriver to adjust the DI open adjustment bushing. Adjust until the left
end of the backup roll shaft has moved 2.5 mm (0.098 in. or 0.1 in.) from the
closed position. This can be measured by the distance the left backup roll
bearing moves back relative to the frame (see Figure 71).
Figure 71. DI Open Lever Adjustment

Cutter Blade Run-In

Note: This procedure needs to be done whenever the cutter blades are replaced.
1. Make sure the thermal bracket is closed and there is no paper in the printer.
2. Manually rotate the cutter blade for 5 cycles by rotating the thermal feed gears.
This ensures that the blades are correctly run-in. See Figure 72.
3. Metal debris left on the blades must be removed by manually operating
additional cycles.
Figure 72. Cutter Blade Run-In

Thermal Printhead Adjustment

Note: The thermal printhead should be adjusted prior to adjusting the thermal
switch.
1. The thermal printhead must be mounted in the printer and the customer receipt
cover removed.
2. With the thermal bracket open, loosen both of the shoulder screws until the
thermal printhead and the shoulder screws slide smoothly within the thermal
printhead mounting bracket slots. See Figure 73 on page 105.
3. Close the thermal bracket.
4. Use a small screwdriver to press on the shaft of the shoulder screw, between
the mounting bracket and the printhead bracket.
5. Slide the printhead to the end of the slots, towards the back of the printer.
6. Run the CR offline test (see “Customer Receipt Test” on page 33). Observe the
thermal print density as it prints.
7. Slide the thermal printhead using steps 4 and 5, one side at a time, towards
the front of the printer. As you move the printhead, the printing will become
darker. When the print is most dense and uniform across the entire print line,
the thermal printhead adjustment is complete.
8. Tighten the two shoulder screws till they are snug. Do not overtighten the
shoulder screws.
9. Test the printer to ensure continued print quality. Go to “Offline Tests” on
page 33. Re-adjust if necessary.
10. Check the thermal paper switch adjustment. Go to “Thermal Paper Switch

Shoulder Screws
Printhead Mounting Bracket
Latch Return Spring
Thermal Latch Spring
Platen Latch
Thermal Printer Cover
Shoulder Screws
Figure 73. Thermal Printhead Adjustment

Thermal Paper Switch Adjustment

1. Loosen the bracket mounting screw until the switch and the bracket assembly
slide smoothly into the switch mounting bracket slot. See Figure 74.
2. Slide the switch in the slot so that the switch is closest to the front of the printer
and successively move the switch rearward until the printer passes the following
test steps.
3. Test the printer by installing about 150 mm (6 in.) of paper and closing the
cover. The blinking CR light should go to a steady state. If the light does not,
press the CR paper feed button to advance the receipt paper a few inches. The
printer ready LED should then go to a steady state.
4. With the paper cover still closed, feed the paper out of the printer. The printer
ready LED should start to blink, indicating an out-of-paper condition.
Figure 74. Thermal Paper Switch Adjustment
Document Sensor Threshold Reset

Set the document sensor threshold reset (adjustment), if the printer does not sense
an inserted document.
To reset the sensor threshold values to the original default values:

1. Press and hold both buttons to enter offline mode.
2. While the printer is offline, open and close the customer receipt cover.

Chapter 5. Parts Listing

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . 108
Assembly 2: Operator Switch and Button Assembly . . . . . . . . . . . 110
Assembly 3: Logic Cards and Shock Mounts . . . . . . . . . . . . . 112
Assembly 4: Document Insert Station . . . . . . . . . . . . . . . . 114
Assembly 5: Thermal Printhead Assembly and Cover . . . . . . . . . . 116
Assembly 6: Printhead Transport and Ribbon Drive Assembly . . . . . . . 118
Assembly 7: Impact Printhead Assembly . . . . . . . . . . . . . . . 120
Assembly 8: Document Insert Station Platen and Lever . . . . . . . . . 122
Assembly 9: Document Insert Drive Shaft Assembly . . . . . . . . . . . 124
Assembly 10: Document Insert Station Gears and Motor . . . . . . . . . 126
Assembly 11: Customer Receipt Drive, Cutter, and Platen . . . . . . . . 128
Assembly 12: Hardware Kits . . . . . . . . . . . . . . . . . . . 130
Assembly 13: Cable Assemblies, Filler Panel, Power Supply. . . . . . . . 132
Operator Switch and

Button Assembly
Thermal Printhead Assembly
Customer Receipt Ribbon Guide
Drive Gears
Impact Printhead Assembly
Document Insert Station Ribbon Drive Assembly
Platen

Drive Shaft Assembly

Assembly 1: Covers

updated March 18, 2002 Assembly 1: (continued)
Asm– Part
Index Number Units Description
1–1 42H1136 1 v Cover, Customer Receipt Paper
–2 42H1132 1 v Cover, Ribbon
–3 42H1131 1 v Cover, Top
–4 42H1138 1 v Paper Guide, Customer Receipt (Thermal)
–6 42H1125 1 v Bucket, Paper, Customer Receipt
–7 NP Frame
– 10J0153 1 4610 Models TI5 and TG5 with RS-485/RS-232 interface
Chapter 5. Parts Listing – Models TI5 and TG5 109

Assembly 2: Operator Switch and Button Assembly

Asm– Part
2–1 42H1139 2 v Button, Operator (2x)
–2 42H1135 1 v Switch Asm, Operator
Includes Screw (Asm Index 2-3) and Insulator (Asm Index 2-4)
–3 NP v v Screw (see kit 42H1063)
–4 NP v v Insulator, Switch
–5 NP Frame

Assembly 3: Logic Cards and Shock Mounts
3
4
8

Asm– Part
3–1 NP Frame
– 42H1140 1 v Kit, Shock Mounts
(Includes Asm Index 3-2, 3-3, 3-4 , and 3-5)
–2 NP v v Shock, Front, Mount
–3 NP v v Shock, Front
–4 NP v v Shock, Rear (X2)
–5 NP v v Support, Front
–6 10J0152 1 Card Asm, Main Logic, Models TI5 and TG5
–7 10J0153 1 Card Asm, Interface (RS-232 and RS-485), Models TI5 and TG5
–7 02L0821 1 Card Asm, Interface (USB)
–8 30L6406 NP Shield
– 02L0769 1 Spill Shield
Includes Asm Index 3-7.
–9 NP Cover, Base
Includes trap door

Assembly 4: Document Insert Station

Asm– Part
4–1 NP Frame
–2 42H1133 NP DI Forms Entry, Upper

Assembly 5: Thermal Printhead Assembly and Cover
11
8
4
5
6
10

Asm– Part
5–1 30L6442 v Cable, Thermal, High Speed
–2 42H1137 1 v Hinge
Includes Asm Index 5-4, 5-5, and 5-6.
–3 30L6441 v Thermal Printhead Assembly, High Speed
Includes Asm Index 5-4, 5-5, 5-6, 5-11, and additional non-illustrated parts.
– 42H1059 1 v v Thermal Latch Asm.
–4 NP v v Spring, Thermal
–5 NP v v Spring, Latch Return
–6 NP v v Latch, Platen
–7 42H1180 1 v Cover, Thermal Printhead
Includes Label.
–8 42H1129 1 v Drag Strip
Includes E-clip
–9 42H1128 1 v Sensor, Thermal Paper
Includes Screws and Mounting Bracket.
–10 NP Frame
–11 08L1843 Thermal Printhead FRU, High Speed

Assembly 6: Printhead Transport and Ribbon Drive Assembly
6
7
10
12
11

Asm– Part
6–1 42H1107 1 v Bushing, Gap Adjust (2X)
–2 42H1106 1 v Shaft, Transport, Rear
Includes Gap Adjust Bushings (Asm Index 6-1)
–3 42H1044 1 v Shaft, Transport, Front
Includes Screw (Asm Index 6-4)
–5 42H1110 1 v Belt, Timing
–6 42H1109 1 v Spring, Tensioner
–7 42H1108 1 v Tensioner Asm.
Includes Tension Spring (Asm Index 6-6)
–8 42H1145 1 v Spacer, Printhead
–9 NP Frame
–10 42H1114 1 v Ribbon Drive Asm.
–11 42H1045 1 v Motor, Transport
Includes Screws (Asm Index 6-12)
–12 1 v v Screws (2X)
See Hardware Kit, 42H1063, Miscellaneous Fasteners.)

Assembly 7: Impact Printhead Assembly
9
8
10

Asm– Part
7–1 42H1047 1 v Guide, Ribbon
Includes Screws (Asm Index 7-2)
–2 NP v v Screws (2X)
Part of Hardware Kit, 42H1063, Miscellaneous Fasteners.
–3 42H1046 1 v Printhead Asm, Impact
Includes Printhead, Screw (Asm Index 7-4), Printhead Gap Gage
–5 42H1112 1 v Carriage Asm.
–6 42H1111 1 v Cable, Printhead
–7 42H1113 1 v Bearing, Carrier, Front
–8 42H1048 1 v Sensor, Home
Includes Screw (Asm Index 7-9)
–9 NP v v Screw
Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.
–10 NP Frame
– 42H1190 1 Printhead Gap Gage

Assembly 8: Document Insert Station Platen and Lever

Asm– Part
8– 42H1062 1 v Platen Asm, DI Station
Includes Asm Index 8-1, 8-2, 8-3, 8-4, and 8-5.
–1 NP v v E-Clips (2X) (part of 42H1063)
–2 NP v v Shaft, Platen
–3 NP v v Spring, Clip (2X) (part of 42H1144)
–4 NP v v Platen
–5 NP v v Spring, Platen (part of 42H1144)
– 42H1051 1 v Pressure Pad Asm.
Includes Asm Index 8-6, 8-7, and Sample Checks
– 42H1052 1 v DI Sensor Asm.
Includes Asm Index 8-6, 8-7, 8-8, 8-9, and Sample Checks
–6 NP v v Holder, Pressure Pad
–7 NP v v Pressure Pad
–8 NP v v Spring, Sensor (part of 42H1144)
–9 NP v v Sensor, DI Upper/Lower
–12 NP v v Wear Plate
–10 42H1121 1 v DI Lever Asm
Includes Bushing, E-clip, DI Lever
–11 NP Frame

Assembly 9: Document Insert Drive Shaft Assembly
3
4
6
7

Asm– Part
9–1 NP Frame
– 42H1119 1 v DI Feedroller Asm.
–2 NP v v DI Feedroller
–3 NP v v E-Clip (part of 42H1063)
–4 NP v v Bearing, Feed, Left
–5 42H1118 1 v Bail
– 42H1134 1 v DI Lower Forms Entry
Includes Asm Index 9-6, 9-7, and 9-8..
–6 NP v v Shaft
–7 NP v v E-Clip (2x)
–8 NP v v Frame, Lower Forms Entry
– 73G2601 1 Sample Check (2x)

Assembly 10: Document Insert Station Gears and Motor
4
1
5 2
8
9
10
12
11
13

Asm– Part
10– 42H1053 1 v Kit, DI Gears
Includes Asm Index 10-1, 10-2, 10-3, 10-4, and 10-5
–1 NP v v Gear, Motor
–2 NP v v Gear, Idler
–3 NP v v Gear, Shaft
–4 NP v v E-Clip
(Also part of Hardware Kit, 42H1063, Miscellaneous Fasteners.)
–5 NP v v E-Clip (X2)
– 42H1058 1 v DI Backup Roll Shaft Asm
Includes Asm Index 10-6, 10-7, 10-8, and 10-9, and 10-10
–6 NP v v Right Shaft Bearing
–7 NP v v DI Back-up Roller
–8 NP v v E-Clip
–9 NP v v Bearing, Shaft Eccentric
–8 NP v v Left Shaft Bearing -->
–10 NP v v Spring
(Also part of Hardware Kit, 42H1144, Miscellaneous Springs.)
–11 42H1120 1 v Motor, DI Feed
Includes screws
–12 NP v v Screws (2X)
–13 NP Frame

Assembly 11: Customer Receipt Drive, Cutter, and Platen

Asm– Part
11– 42H1065 1 v Thermal Cutter Asm
Includes Asm Index 11-1, 11-2, 11-3, 11-4, 11-5, 11-6, 11-7, 11-8, and lubricant
–1 NP v v Guide, Thermal (also part of 42H1164)
–2 NP v v Spring, Leaf or Lever/Spring
–3 NP v v Stud
–4 NP v v Blade, Stationary or Blade Asm, Stationary
–5 NP v v Pin
–6 NP v v Stud, Cutter
–7 NP v v Blade Asm, Rotating
–8 NP v v Pin
– NP v v E-clip
– NP v v E-clip Stationary Blade
– NP v v Lubricant
– 30L6443 1 v Platen Asm, Thermal
–9 NP v v Bearings, Thermal, Right
–10 NP v v Platen, Thermal
–11 NP v v Bearings, Thermal, Left
–12 42H1164 1 v Stripper
– 42H1060 1 v Kit, CR Cutter Gears
Includes Asm Index 11-13, 11-14, 11-15, 11-16, 11-17, 11-18, 11-19, and 11-20.
–13 NP v v E-Clip
–14 NP v v Gear, Pin
–15 NP v v Pin, Lever Drive
–16 NP v v E-Clip
–17 NP v v Spring, Cutter Stop
–18 NP v v Gear, Cutter
–19 NP v v Gear, Thermal Feed
–20 NP v v Gear, Thermal Idler
–22 NP v v Spiral Pin
–21 30L6445 1 v Clutch Asm, Cutter
Includes Spiral Pin (Asm Index 11-22).
–23 30L6444 1 v Motor, CR
Includes Screws (2x)
–24 NP Frame

Assembly 12: Hardware Kits

Asm– Part
12–1 42H1063 1 v Kit, Miscellaneous Fasteners
– 1622302 NP v v Washer (2X)
– 38H7338 NP v v Nut, Hex, Transport, M3 (9X)
– 38H7366 NP v v Screw, M3X14
– 38H7367 NP v v Screw, Motor (3X)
– 38H7402 NP v v Screw, Shoulder (2X)
– 42H1028 NP v v Screw, Ribbon Shield (2X)
– 42H1033 NP v v Plug, Front Shock
– 42H1091 NP v v Stud, Front Shock
– 42H1154 NP v v Clip (4X)
– 42H1155 NP v v Clip
– 42H1161 NP v v Tie, Cable (2X)
– 42H1162 NP v v Clamp, Cable
– 42H1169 NP v v Screw (2X)
– 42H1179 NP v v Washer(1X)
– 42H1204 NP v v Screw (M3)
– 4483179 NP v v Nut, M3 (2X)
– 53F4942 NP v v Washer, Lock (3X)
– 6341458 NP v v Clip (3X)
– 6410857 NP v v Screw, Lock (2X)
– 6428680 NP v v Screw (4X)
– 69F3557 NP v v Washer, Lock (2X)
– 73G2620 NP v v Clip (4X)
– 92F8349 NP v v Washer
– 93F0233 NP v v Clip (6X)
–2 42H1144 1 v Kit, Miscellaneous Springs
– 38H7337 NP v v Spring, Tensioner
– 38H7358 NP v v Spring Toggle
– 38H7369 NP v v Spring, Sensor
– 38H7370 NP v v Actuator, Toggle
– 38H7395 NP v v Spring, Thermal Head
– 3XH7433 NP v v Spring, DI
– 38H7438 NP v v Spring, Platen
– 38H7446 NP v v Spring, Ribbon Drive
– 38H7463 NP v v Spring, Cutter Clutch
– 38H7473 NP v v Spring, Cutter Stop
– 38H7509 NP v v Spring, Gate
– 42H1043 NP v v Spring, Thermal Latch
– 42H1075 NP v v Spring, Latch Return

Assembly 13: Cable Assemblies, Filler Panel, Power Supply

Asm– Part
13–1 42H1143 1 Cables, Logic Card
Includes Signal Cable, Power Cable, and Cable Clamp.
–2 42H1056 1 Cables, Thermal Printhead
Includes Both Cables, Cable Tie, and Spiral Wrap.
–3 42H1111 1 Cable Asm, Impact Printhead
–4 42H1157 1 Filler Panel
–5 42H1176 1 Power Supply (80W)
–6 72H3802 1 Cash Drawer Cable, Short
–7 72H3803 1 Cash Drawer Cable, Long
–8 86H2192 1 Cable, RS-232 Interface, 2 m
–9 86H2195 1 Cable, RS-232 Interface, 4 m
–10 42H1176 1 Power Supply, RS-232 Attached Only
–11 08L2014 1 Standard USB cable, 5 m
–12 01L1647 1 Distributed USB cable, 3.8M
–13 01L1646 1 Integrated USB cable, 0.5 m

Assembly 13: (continued) updated March 18, 2002

Chapter 6. Operation
Operating Controls and Indicators . . . . . . . . . . . . . . . . . 135
Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Ribbon Loading . . . . . . . . . . . . . . . . . . . . . . . . 137
Paper Loading . . . . . . . . . . . . . . . . . . . . . . . . 139
Thermal Printhead Cleaning . . . . . . . . . . . . . . . . . . . 141
Note: All covers must be installed on the SureMark printer during operation.
Operating Controls and Indicators

See page Chapter 3, “Problem Determination” on page 33 for operating controls and
indicators.
Printing
Figure 75 and Figure 76 on page 136 show the printable area on an inserted
document for both portrait and landscape.
Figure 75. Printable Area of an Inserted Document (Portrait)

Figure 76. Printable Area of an Inserted Document (Landscape)

Ribbon Loading
1. Open the ribbon cover. As the cover is opened, the printhead moves to a
position where you can easily load a ribbon.
Figure 77. Opening the Ribbon Cover
2. If there is already a ribbon cartridge installed, remove it by lifting it straight up.
Note: You might need to grab the body of the cartridge rather then the top to
remove.
Figure 78. Ribbon Cartridge Loading
Chapter 6. Operation – Models TI5 and TG5 137

3. Maintain ribbon tension by turning the ribbon cartridge knob as shown in

Figure 78 on page 137. Lower the cartridge into position until notches on its
sides snap into place on the printer guides. After the cartridge is in place, turn
the knob until the ribbon slides into place between the printhead and the ribbon
shield. See Figure 79 for correct ribbon positioning.
Ribbon Shield
Print Head
Correct Not Correct

Figure 79. Ribbon Path around the Printhead
4. Close the ribbon cover.

Paper Loading
1. Open the paper cover.
2. If there is any unused paper or if there is an empty paper roll core in the paper
roll bucket inside the printer, remove it before inserting a new paper roll. You
can throw the core in the trash can.
Figure 80. Paper Cover
Note: Refer to the label on the inside of the paper cover for a diagram of how
to load paper.
3. Place the paper roll into the paper roll bucket as shown in Figure 81 on
page 140. The leading edge of the paper should come from the direction of the
front of the printer and go across the top of the roll as shown in the diagram. If
it feeds from the bottom of the roll, you will have print problems.
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 15 to 20 cm (6 to 8 in.) of
paper with glue on it before loading it. Or, you can advance the paper
after loading to get rid of the glued paper.

Not Correct Correct
Thermal Paper Roll

Platen
Paper
Roll Core
Figure 81. Paper Loading Path
4. Place the leading edge of the paper over the metal guide. (See Figure 81.)
5. Close the paper cover.
6. 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.

Thermal Printhead Cleaning

The thermal printhead can be cleaned whenever print quality deteriorates.
1. Open the paper cover.
2. Using a cotton swab soaked in isopropyl alcohol, gently wipe the printhead
several times on its print line and on the surrounding area. See Figure 82.
3. Wipe off any residual alcohol with a dry swab.
If print quality does not improve after cleaning the thermal printhead, call for
service.
|
Figure 82. Printhead and Print Line Area


|
| Part 3. Models TF7 and TM7
| This part contains repair/replacement, adjustment, and daily operational procedures
| for models TF7 and TM7. It also contains the parts catalog for these models.


|
| Chapter 7. Problem Determination
| Offline Diagnostics . . . . . . . . . . . . . . . . . . . . . . . 145
| Customer Receipt Test . . . . . . . . . . . . . . . . . . . . 145
| Listing the MCT Settings . . . . . . . . . . . . . . . . . . . . 146
| RS-232 Hex Dump . . . . . . . . . . . . . . . . . . . . . . 147
| Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . 148
| Customer Receipt Paper Movement and Cutter Problems. . . . . . . . . 150
| Installing the 58–mm Paper Roll Feature RPQ . . . . . . . . . . . . . 152
| FRU Removal and Replacement . . . . . . . . . . . . . . . . . . 153
| Removing and Replacing the Top Cover and Inner Cover Assembly . . . . 153
| Removing and Replacing the Bottom Cover . . . . . . . . . . . . . 155
| Removing and Replacing the Interface and Main Logic Cards . . . . . . 156
| Removing and Replacing the Thermal Print Mechanism . . . . . . . . 158
Offline Diagnostics
The single-station SureMark printers provide the following diagnostic functions that
can be performed while the printer is in offline mode:
v Customer receipt test
v Listing of MCT settings
v RS-232 hex dump
Customer Receipt Test

To perform the customer receipt test:
1. Open the top cover. The LED will flash quickly.
2. Press and hold the paper feed button for 5 seconds. The LED indicator will
make one quick flash, accompanied by a beep, followed by a pause.
3. Close the top cover. The test starts.
v RS-232, RS-485 or USB serial interface
v Double-byte enabled
v Applicable parameters for RS-232 communications:
– 9600 or 19 200 baud rate
– DTR/DSR or XON/XOFF control

T
The Printers S/N is 12345678 1
Microcode EC level is 30 2
Serial Interface: RS232 3
Serial Interface : 19.2K Baud, XON / XOFF 4 ,5
Double Byte Character Sets 6
|"#$%&'()*+,-./0123456789:;<->?ABCDEFGHIKJK
LMNOPQRSTUVWXYZ[\]^_ abcdefghijklmnopqrstuvw
xyz{|}~.CüéâäàåcêëèïîìÄÅÉæÆôöòûùÿÖÜø£ØSsáíóú 7
ÁÑGg¿ · · · · ¡ · · ÁÂÀ I · ¢ · · · · · · · · ãÃ ·
H I III · · · · · · · · · · · · · õ Ð ÊËÈÍÎÏÌÓßOO ^ ` õÕµþÞUUUyY±÷ ` ^` ` ` ·
Cuts: 12363
CR Characters Printed: 77626
CR Motor Steps: 88974 8
CR Cover Openings: 17
CR Cut Fails: 7
9
|
| Figure 83. Offline Printer Test Pattern (Models TF7 and TM7)
Test Pattern Notes:

1. The serial number that prints will be the actual serial number of your printer. (If
the logic card has been replaced, this number must be reset to the original
serial number.)
2. The microcode level will be the actual level of your printer’s microcode.
| 3. The serial interface will be specified as RS232, RS485, or USB, depending on
| which interface is used to attach the printer to the system unit.
| 4. The line speed information appears only when the RS-232 interface is used.
| The value can be either 9.6K baud or 19.2K baud, depending on the RS-232
| switch settings. (See “Communication Mode Selections” on page 5.)
| 5. The RS-232 control mode information appears only when the RS-232 interface
| is used. The value can be either DTR/DSR or XON/XOFF, depending on the
| RS-232 switch settings. (See “Communication Mode Selections” on page 5.)
| 6. The feature enabled lines will appear only when the feature is installed.
| 7. This section contains the test pattern.
| 8. This section contains printer usage statistics that you can use for problem
| determination.
| 9. The line across the bottom should be solid with no blank spaces.
| Listing the MCT Settings

| To list the MCT settings:
| 1. Open the top cover. The LED will flash quickly.
| 2. Press and hold the paper feed button for 5 seconds. The LED indicator will
| make one quick flash, accompanied by a beep, followed by a pause.
| 3. Press and release the paper feed button again. The LED indicator will make two
| quick flashes, accompanied by a beep, followed by a pause.
| 4. Close the top cover to start the listing.
| Note: Pressing and releasing the paper feed button a third time will cause the
| printer to return to normal mode.

| RS-232 Hex Dump

| To enable hex dump mode for the Model TF7 or TM7 printer, press and hold the
| paper feed button while the printer is powered on. If the top cover is open, this also
| puts the printer in power-up offline mode.
Chapter 7. Problem Determination – Models TF7 and TM7 147

|
| Symptoms
| Review the following symptoms or messages and take the suggested actions.
| Table 7. Printer Symptoms or Messages – Models TF7 and TM7
| Symptom Repair Actions Listed in Most Likely Order of Failure
|| Printer does not power ON (LED 1. Check for a good connection and that the printer is plugged in.
| is off).
| 2. Check that the printer power switch, which is located under the top cover, is
| set ON.
| 3. Replace the power supply or system unit.
| 4. Exchange the printer interface card. Go to “Removing and Replacing the
| Interface and Main Logic Cards” on page 156.
| 5. Exchange the main logic card. Go to “Removing and Replacing the Interface
| and Main Logic Cards” on page 156.
|| Printer Ready LED is blinking. 1. Press the customer receipt feed button.
| 2. Check the paper supply to ensure that the receipt paper is loaded correctly.
| 3. Ensure that the cover is closed.
| 4. Press the paper out switch. If the LED stays on and stops blinking, then
| adjust the thermal paper switch (go to “Thermal Paper Switch Adjustment” on
| page 162). If the LED continues blinking, replace the thermal paper switch
| and the cutter lever.
| 5. Replace the main logic card.
| 6. Replace the inner cover assembly.
|| Customer receipt does not 1. Check to see if the thermal paper is jammed or loaded incorrectly.
| advance paper.
| 2. Go to “Customer Receipt Paper Movement and Cutter Problems” on
| page 150 to isolate the problem.
|| Customer receipt is missing 1. Check to see if the thermal paper is correctly installed.
| character dots.
| 2. Check and clean the printhead area, if contaminated.
| 3. Exchange the thermal printhead.
| 4. Exchange the printhead cable.
| 5. Exchange the main logic card.
|| Print on customer receipt is too 1. Check that the paper is new and in good condition.
| light.
| 2. Check that the thermal paper is installed correctly.
| 3. Check the printhead area, and clean it if it is contaminated.
| 4. Exchange the frame assembly.
| 5. Exchange the thermal printhead.
| 6. Exchange the inner cover assembly.
| Customer receipt (thermal) Problem is caused by operator pulling the receipt out of the printer. Instruct
| randomly missing rows of print, operators to use the CR feed button to advance the paper, instead of pulling the
| accompanied by one thin line on paper.
| receipt.
|| Cutter does not work correctly. 1. Check that the paper is loaded correctly.
| 2. If paper is folded or partially cut, go to “Customer Receipt Paper Movement
| and Cutter Problems” on page 150.
|| T7151 Printer card or cable is 1. Check or exchange the printer interface cable.
| failing.

| Table 7. Printer Symptoms or Messages – Models TF7 and TM7 (continued)

| Symptom Repair Actions Listed in Most Likely Order of Failure
| T7159 EEPROM error. Exchange the main logic card. Go to “Removing and Replacing the Interface and
| Main Logic Cards” on page 156.
| T7161 Command reject. An invalid command was sent to the printer.
|| T7165 CR paper is empty or cover 1. Ensure that paper is in the printer and the cover is closed.
| is open.
| 2. Press the customer receipt feed button to advance about 76 mm (3 in.) of
| paper.
| 3. Check to see if the paper is installed correctly in the customer receipt station.
| 4. Open the top cover and manually press the switch.
| 5. Adjust the switch. Go to “Thermal Paper Switch Adjustment” on page 162.
| 6. Exchange the thermal paper switch and the cutter sensor lever.
|| T7166 Firmware error. 1. Update the 4610 firmware by downloading a new image from the utility
| diskette. Go to Chapter 2, “SureMark Installation, Service, and Utility
| Software” on page 13.
|
|

|
| Customer Receipt Paper Movement and Cutter Problems
| This procedure helps isolate customer receipt paper movement or paper cutting
| problems.
| 1. Open the top cover.
| 2. Apply light pressure to the platen and turn the thermal drive gear in the direction
| of the arrow shown in Figure 84. The platen should move in the same direction
| as the gear moves. If the platen did not move, exchange the inner cover
| assembly.
| Apply light pressure to the platen and turn the thermal drive gear in the opposite
| direction. The cutter blade should move forward and then return to the fully
| open position. The platen should not move. If the blade does not move or the
| platen does move, replace the inner cover assembly.
| 3. If all of the above hardware worked correctly:
| a. Temporarily restore power to the printer. Press the paper out switch (see
| Figure 85 on page 151. The idler gear should briefly rotate. Remove power
| from the printer by either unplugging it from the wall outlet or turning off the
| system unit.
| b. If the gear does not rotate, exchange the idler gear and the customer receipt
| motor. See “Removing and Replacing the Thermal Print Mechanism” on
| page 158. Ensure that the thermal paper is loaded and the top cover is
| latched.
| c. If the gear still does not rotate, exchange the main logic card. See
| “Removing and Replacing the Interface and Main Logic Cards” on page 156.
| 4. If the cutter moves, but either does not cut the paper or only partially cuts the
| paper, exchange the inner cover assembly and the frame assembly.
|
|
Cutter blade Arrow on gear

Thermal drive gear
Platen
|
| Figure 84. Thermal Drive Gear
|

Paper out switch
Idler gear
|
| Figure 85. Paper Out Switch and Idler Gear
|
|

|
| Installing the 58–mm Paper Roll Feature RPQ
| To install the 58-mm Paper Roll Feature RPQ, you must replace the standard inner
| cover assembly.
| 1. Power off the printer by setting the printer power switch to off, powering off the
| system, or unplugging the external power source from the wall outlet.
| 2. Remove the top cover and inner cover assembly. See “Removing and Replacing
| the Top Cover and Inner Cover Assembly” on page 153.
| 3. Replace the 80-mm inner cover assembly with the 58-mm inner cover assembly.
| 4. Reinstall the top cover and the 58-mm inner cover assembly.
| Note: To enable the 58-mm Paper Roll Feature, you must set mode switch 4 to on.
| See Figure 86 for the location of the switch.
|
|
OFF
4
1 2 3
RS-232 mode switches
|
| Figure 86. Mode Switches for Single-Station SureMark Printers
|

|
| FRU Removal and Replacement
| This section includes removal and replacement procedures for the 4610 printer field
| replaceable units (FRUs) for Models TF7 and TM7.
| Removing and Replacing the Top Cover and Inner Cover Assembly
|
| Important
| This procedure shows you how to remove the top cover and inner cover
| assembly (FRUs). Stop when you get to the failing FRU, exchange the FRU,
| and reassemble. The FRUs are highlighted.
|
|
| 1. Power OFF the printer by turning the printer off, powering off the system or
| unplugging the external power source from the wall outlet.
| 3. Disengage the drag strip by pulling the drag strip away from the post.
| 4. While pressing up on the tab, slide the top cover and inner cover assembly
| toward the drag strip. See Figure 87 on page 154.
| 5. Remove the two screws at the back of the top cover.
| 6. Separate the inner cover assembly from the top cover. See Figure 87 on
| page 154.
| 7. Lift the top cover away from the inner cover assembly until the latch is freed.
| 8. Reassemble.
| Choose one of the following links to return to the procedure from which you came:
| v “Removing and Replacing the Interface and Main Logic Cards” on page 156
|

Top cover
Drag strip

Post
Metal Spring
Tab
Sphere
Top cover screws
Middle cover assembly
|
| Figure 87. Removing the Top Cover and Inner Cover Assembly
|
|

| Removing and Replacing the Bottom Cover

|
| Important
| This procedure shows you how to remove the bottom printer cover (FRU).
| Stop when you get to the failing FRU, exchange the FRU, and reassemble.
| The FRUs are highlighted.
|
|
| 1. Power OFF the printer by turning the printer off, powering off the system or
| unplugging the external power source from the wall outlet.
| 2. Invert the printer.
| 3. Press down on the tab at the back of the printer. A click sounds when the
| bottom cover is free. See Figure 88.
| 4. Lift the back of the bottom cover upward.
| 5. Lift the bottom cover away from the printer.
| 6. To reassemble, place the tabs on the front of the bottom cover into the slots at
| the bottom front of the inner cover assembly. Press down on the bottom cover
| until it almost touches the tab at the back of the printer, then press the bottom
| cover at each side of the tab to firmly seat the cover.
| Choose one of the following links to return to the procedure from which you came:
| v “Removing and Replacing the Interface and Main Logic Cards” on page 156
|
|
Bottom cover
Tab
Middle cover assembly
|
| Figure 88. Removing the Bottom Cover
|

| Removing and Replacing the Interface and Main Logic Cards

|
| Important
| This procedure shows you how to remove the interface and main logic FRUs.
| Stop when you get to the failing FRUs, exchange the FRUs, and reassemble.
| The FRUs are highlighted.
|
|
| 1. Invert the fully assembled printer.
| 2. Remove the bottom cover.
| 3. Remove all cables from the main logic card. See Figure 89.
| 4. Lift the main logic card and interface card straight up and out of the bottom
| cover.
| 5. Separate the connector that joins the main logic card and interface card. See
| Figure 90 on page 157.
| 6. Reassemble.
| 7. Whenever you exchange the main logic card, you must configure the printer
| model and then update the firmware. Make a note of the printer model and
| serial number, which are located on the label that is either on or under the front
| cover of the printer, then go to “Software Adjustments (Model TI5 and TG5
|
|
Main logic card
Cables
Interface card
|
| Figure 89. Removing the Interface and Main Logic Cards – Models TF7 and TM7
|

Main logic card
Connector
Interface card
|
| Figure 90. Separating the Interface and Main Logic Cards – Models TF7 and TM7
|
|

| Removing and Replacing the Thermal Print Mechanism

|
| Important
| This procedure shows you how to remove the thermal printhead assembly
| FRUs. Stop when you get to the failing FRUs, exchange the FRUs, and
| reassemble. The FRUs are highlighted.
|
|
| 2. Remove the bottom cover. Go to “Removing and Replacing the Bottom
| Cover” on page 155.
| 3. Remove the interface and main logic cards. Go to “Removing and Replacing
| the Interface and Main Logic Cards” on page 156.
| 4. Note how the printhead cables are routed, then disconnect the long printhead
| cable from the printhead.
| 5. Move the printhead cable out from under the plastic hook.
| 7. Push the tear bar toward the back of the printer, while pushing the metal frame
| toward the right. The assembly will drop out of the printer.
| 8. Remove the two screws that hold the customer receipt motor on.
| 9. Pull the customer receipt motor away from the frame assembly.
| 10. Remove the e-clip that holds the idler gear in place.
| 11. Remove the idler gear.
| 12. Remove the thermal printhead cables.
| 13. Remove two recessed screws to separate the printhead from the frame
| assembly.
|
|
Thermal printhead
Frame assembly
Long cable
Thermal printhead
cables
Recessed
screws Idler gear
Customer receipt E-clip

motor
Screws
|
| Figure 91. Thermal Print Mechanism
|
| 14. Reassemble.
| 15. Check the thermal paper switch operation and adjust if necessary. Go to
| “Thermal Paper Switch Adjustment” on page 162.

| 16. When you replace the thermal printhead or the customer receipt motor, run the
| service diskette and select Reset Statistics for the FRU. See “Software
| Adjustments (Model TI5 and TG5 Only)” on page 13.


|
| Chapter 8. Hardware Adjustment Procedures
| Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . 161
| Thermal Paper Switch Adjustment . . . . . . . . . . . . . . . . . 162
DANGER
CAUTION:

ESD Damage Prevention:
back-panel pins, or other ESD sensitive (ESDS) parts, the service person must be
strap and cord.
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.


Thermal Paper Switch Adjustment

1. Remove the paper from the printer.
2. Loosen the mounting screw for the thermal paper switch until the switch and the
bracket rotate smoothly. See Figure 92.
3. Rotate the thermal paper switch toward the printhead until the switch arm clicks.
4. Rotate the thermal paper switch away from the printhead until the switch arm
clicks again.
5. Rotate the thermal paper switch slightly further and secure the switch with a
screw.
6. Test the printer by installing about 150 mm (6 in.) of paper and closing the
cover. The blinking CR light should go to a steady state. If the light does not,
press the CR paper feed button to advance the receipt paper a few inches. The
printer ready LED should then go to a steady state.
7. With the paper cover still closed, feed the paper out of the printer. The printer
ready LED should start to blink, indicating an out-of-paper condition.
Switch mounting screw
Switch
Switch arm
Bracket
Figure 92. Thermal Paper Switch Adjustment

Chapter 9. Parts Listing

| Assembly 14: Covers . . . . . . . . . . . . . . . . . . . . . . 164
| Assembly 15: Interface and Logic Cards . . . . . . . . . . . . . . . 166
| Assembly 16: Thermal Printhead . . . . . . . . . . . . . . . . . . 168
| Assembly 17: Hardware Kits . . . . . . . . . . . . . . . . . . . 170
| Assembly 18: Miscellaneous Parts and Accessories . . . . . . . . . . . 172

Tear bar
Logic card
Light-emitting diode
Drive gear (LED)
On/off switch
Interface card

Assembly 14: Covers

Asm– Part
14–1 16K8622 1 Cover, Top (pearl white)
–1 16K8623 1 Cover, Top (iron gray)
| –2 16K8628 1 Inner Cover Assembly (80 mm)
| –2 16K8629 1 Inner Cover Assembly (58 mm)
| –3 NP Cover, Middle
| –4 16K8615 1 Cover, Bottom (litho gray)
| –4 16K8616 1 Cover, Bottom (storm gray)
| –4 16K8617 1 Cover, Bottom (iron gray)
| –
|
Chapter 9. Parts Listing – Models TF7 and TM7 165

|
| Assembly 15: Interface and Logic Cards
|

|| Asm– Part
| Index Number Units Description
| 15–1 16K8695 1 Card Asm, Main Logic (512K)
| –1 16K8602 1 Card Asm, Main Logic (2 MB)
| –1 16K8605 1 Card Asm, Main Logic (8 MB)
| –2 16K8603 1 Card Asm, Interface (RS-232 and RS-485), 38V
| –2 16K8607 1 Card Asm, Interface (RS-232 and RS-485), 24V
| –2 16K8604 1 Card Asm, Interface (USB)
|

|
| Assembly 16: Thermal Printhead
|
2
1

|| Asm– Part
| 16–1 16K8624 1 Thermal Printhead
| –2 16K8625 1 Cable, Thermal Printhead
| –3 16K8626 1 Motor/Idler Assembly
| –4 16K8618 1 Frame Assembly
| –5 16K8643 1 Sensor, Thermal Paper
| – 16K8674 NP v Screw, M2X12, pan head
| – 16K8532 NP v Sensor Plate
| – 16K8533 NP v Sensor Asm, paper
| – 16K8538 NP v Drag Strip
| – 16K8681 NP v Lever, Cutter Sensor
| – 16K8682 NP v Sprint, Cutter Sensor
|

|
| Assembly 17: Hardware Kits
|

|| Asm– Part
| 17–1 16K8627 1 Kit, Miscellaneous Parts
| – 16K8519 NP v Spring, extension – cutter
| – 16K8555 NP v Spring, right bushing
| – 16K8635 NP v Spring, left bushing
| – 16K8682 NP v Spring, cutter sensor
| – 42H1028 NP v Screw, M2X6 self-tapping
| – 42H1154 NP v E-clip, ETW-4
| – 42H1179 NP v Washer, RS-232 connector
| – 6341458 NP v E-clip, ETW-2.5
| – 6410857 NP v Screwlock, RS-232 connector
| – 6429529 NP v Screw, M3X4
| – 69F3557 NP v Lockwasher, RS-232 connector
| – 73G2620 NP v E-clip, ETW-3
| – 92F5403 NP v Screw, M3.5X7.1 thd cutting
| – 93F0233 NP v E-clip, ETW-2
| – 16K8508 NP v Spring, sphere retention
| – 16K8527 NP v Plunger, 58mm paper holder
| – 16K8633 NP v Sphere, paper holding
|

|
| Assembly 18: Miscellaneous Parts and Accessories
|

|| Asm– Part
| 18–1 42H1157 1 Filler Panel, used with Model 4694 slant top
| –2 30L6217 1 Filler Panel, used with SurePOS 700 Series slant top
| –3 30L6322 1 Filler Panel, used with SurePOS 700 Series flat top
| –4 16K8691 1 Filler Panel (litho gray)
| –5 16K8692 1 Filler Panel (storm gray)
| –6 42H1176 1 Power Supply, RS-232 or standard USB attached only
| –7 20P0365 1 Cable, RS-232 Interface, 0.75 m
| –8 86H2192 1 Cable, RS-232 Interface, 2 m
| –9 86H2195 1 Cable, RS-232 Interface, 4 m
| –10 08L2014 1 Standard USB cable, 5 m
| –11 01L1647 1 Distributed USB cable, 3.8M
| –12 01L1646 1 Integrated USB cable, 0.5 m
| –13 16K8702 1 Wall mounting bracket
| –14 72H3802 1 Cash Drawer Cable, Short
| –15 72H3803 1 Cash Drawer Cable, Long

Assembly 18: (continued) updated March 18, 2002

|
| Chapter 10. Operation
| Operating Controls and Indicators . . . . . . . . . . . . . . . . . 175
| Paper Loading . . . . . . . . . . . . . . . . . . . . . . . . 176
| Thermal Printhead Cleaning . . . . . . . . . . . . . . . . . . . 177
Note: All covers must be installed on the SureMark printer during operation.
Operating Controls and Indicators

See “Indicator, Control, and Printing Station – Single-Station SureMark Printers” on
page 4 for operating controls and indicators.

Paper Loading
1. Open the top cover.
2. If there is any unused paper or if there is an empty paper roll core on the paper
holder inside the printer, remove it before inserting a new paper roll. You can
throw the core in the trash can.
| 3. If the printer is configured for ″snap in″ paper loading (two white spheres are
| present behind the metal springs), then place the paper roll onto the paper roll
| holder as shown in Figure 93; otherwise, drop the roll into the bucket. The
| leading edge of the paper should come from the direction of the back of the
| printer and go across 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 15 to 20 cm (6 to 8 in.) of
| paper with glue on it before loading it. Or, you can advance the paper
| after loading to get rid of the glued paper.
|
Top cover
Paper roll Sphere
Metal
Spring
Bucket
Figure 93. Paper Loading Path
| 4. Close the top 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.
|

|
| Thermal Printhead Cleaning
| The thermal printhead can be cleaned whenever print quality deteriorates.
| 2. Using a cotton swab soaked in isopropyl alcohol, gently wipe the printhead
| several times on its print line and on the surrounding area. See Figure 94.
| 3. Wipe off any residual alcohol with a dry swab.
| If print quality does not improve after cleaning the thermal printhead, call for
| service.
|
|
|
| Figure 94. Printhead and Print Line Area
|
Chapter 10. Operation – Models TF7 and TM7 177


Part 4. Appendixes


Appendix A. Maintenance Inspection

Note: See Electrical Safety for IBM Customer Engineers, S229-8124.
An IBM maintenance inspection is to be performed as part of any alterations and

attachments review on any IBM product presently on lease rental, maintenance
agreement or per call service by IBM. If the inspection indicates that the level of
safeness of the IBM product is unacceptable, it must be brought up to an
acceptable level.
Maintenance Checklist
Note: All non-IBM devices and attachments must be removed from the system unit
before conducting the maintenance checklist. See the Hardware Service
Manual for Point-of-Sale Input/Output Devices.
1. Switch Ready mode OFF.
2. Disconnect the ac power cord from the wall receptacle.
3. Check the ac power cord for the following:
a. Use a meter to measure third-wire ground continuity for 0.1 ohms or less
between the external ground pin and the frame of the power supply.
Access the power supply frame at the rear near the fuse.
b. The ac power cord should not be frayed or damaged.
4. Check for non-IBM alterations. If any are present, has the R009 non-IBM
Alterations/Attachments Survey been completed?
5. Check for damaged or missing insulation on wires.
6. Check for exposed electrical connections or terminals.
7. Check for the presence and condition of the following safety labels:
a. The safety label on the outside surface of the video display (if present)
should read: “Hazardous voltage. Do not remove this cover. No serviceable
parts inside.”
b. Rechargeable battery labels should contain instructions for recycling.
8. Check the inside of the system base unit for obvious unsafe conditions such
as metal filings, contamination, water or other fluids, or marks of fire or smoke
damage.
9. Ensure that the voltage specified on the voltage label matches the voltage of
the ac power cord.
10. Ensure that the fasteners that hold the top cover of the power supply are not
missing and that they have not been changed.
11. For models with batteries, check the condition of the battery.
12. Ensure that Ready mode is OFF and reinstall the front panel.
13. Connect the ac power cord to a power receptacle and ensure that the machine
switches to Ready mode ON.


Appendix B. Preventive Maintenance Information
Preventive Maintenance Scheduling

Perform these preventive maintenance procedures during unscheduled service
calls.
Models TI5 and TG5

v Clean the dust and debris from the paper cover and ribbon cover areas.
| Models TF7 and TM7

| v Clean the dust and debris from the top cover area.


Appendix C. Tools and Supplies

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 185
Expendable Supplies . . . . . . . . . . . . . . . . . . . . . . 185
RS-232 Connector Pin Assignments . . . . . . . . . . . . . . . . 185
USB Connector Pin Assignments . . . . . . . . . . . . . . . . . . 185
Cash Drawer Connector Pin Assignments . . . . . . . . . . . . . . 186
Special Tools
To maintain the SureMark printers, you may need the following items that are not
supplied in the tool kit:
v 9-pin loop-back test connector (serial ports), P/N 38H6039
v Test check packet, P/N 73G2601
v Three E-clip tools, P/Ns 00453521, 9900612, and 9900059
v Printhead gap gauge, P/N 42H1190
Expendable Supplies
See “Resources on the Internet” on page 29 for information about OEM paper
certifications for the SureMark printers.
v Paper for the printer, order P/N locally
RS-232 Connector Pin Assignments

SureMark printers contain a 9-pin D-shell connector port for RS-232 communication.
This port is on the interface card, accessible under the printer without removing
printer covers. The connector has the following pin functions:
Pin Signal
1 Not Connected
2 Transmit
3 Receive
4 DTR (Not connected on 3-wire cable)
5 Signal Ground
6 DSR (Not connected on 3-wire cable)
7 Not Connected
8 Not Connected
9 Not Connected
USB Connector Pin Assignments

SureMark printers contain a USB port, if the USB feature is installed. This port is on
the interface card, accessible under the printer without removing printer covers.
Connection to the port can be with either the standard USB Type B connector,
which requires a 24-volt power brick, or with the powered USB connector, which
contains 24-volt power lines within the communications cable.
The standard USB Type B connector has the following pin functions:

Pin Signal
1 Vbus (+5 V dc)
2 Minus data
3 Plus data
4 Ground
The powered USB connector has the following pin functions:

Pin Signal
1 Ground (+24 V dc)
2 +24 V dc
3 Ground (Vbus)
4 Plus data
5 Minus data
6 Vbus +5 V dc
7 +24 V dc
8 Ground (+24 V dc)
Cash Drawer Connector Pin Assignments

SureMark printers have a single cash drawer connector. This connector can drive
either a single cash drawer or two cash drawers by using a special cable. The
connector also provides a status line which indicates if one of the cash drawers is
open.
Drive voltage for each cash drawer solenoid is 24 V dc at a current of 1 ampere.

Connector pins are assigned as follows:
Pin Signal
1 Not Connected
2 Solenoid 1 Driver
3 Cash Drawer Status
4 +24 V dc
5 Solenoid 2 Driver
6 Ground
The cash drawer solenoids should be connected between pins 4 and 2 for cash
drawer 1 and between pins 4 and 5 for cash drawer 2. A ″Y″ cable is required to
bring out all the appropriate lines to attach the two units.
The cash drawer status line has a 10k resistor pull-up connected to the +5 V dc.
Note: The drawer sensor should switch pin 6 to pin 3 when the drawer is open.

Appendix D. Translated Safety Notices

The following general safety considerations should be observed whenever you work
with electricity or with any electronic equipment.
DANGER
CAUTION:
For your safety, connect equipment requiring electrical power to a properly
CAUTION:
For safety when running the printer test, make sure personal articles such as
ties, necklaces, and bracelets do not get caught in the moving print head.
Nederlands - België
Algemene veiligheidsvoorschriften
U moet de volgende algemene veiligheidsvoorschriften in acht nemen telkens als u
met elektriciteit of met elektronische apparatuur werkt.
GEVARR!
Tijdens een onweer is het verboden met de apparatuur te werken of
signaalkabels aan te sluiten of los te koppelen.
LET OP !
Uit veiligheidsoverwegingen moet elektrische apparatuur op een correct

bedraad en geaard stopcontact aangesloten worden.
LET OP !
Uit veiligheidsoverwegingen moet u ervoor zorgen dat uw das, halssnoer of

armbanden niet tussen de bewegende printerkop geraken bij het testen van
de printer.
Français - Belgique
Consignes de sécurité générales

Vous devez tenir compte des consignes de sécurit;é générales suivantes lorsque
vous travaillez avec l’électricit;é ou avec du matériel électronique.
DANGER
Il est interdit de travailler avec le matériel et de connecter ou déconnecter
des câbles d’interface pendant un orage.

CAUTION:
Pour votre sécurité, branchez le matériel électrique sur une prise
correctement câblée et mise à la terre.
CAUTION:
Pour votre sécurité, branchez le matériel électrique sur une prise
correctement câblée et mise à la terre.
Português do Brasil
Considerações Gerais sobre Seguranç’a

As considerações gerais sobre segurança a seguir devem ser observadas sempre
que você trabalhar com eletricidade ou com qualquer equipamento eletrônico.
PERIGO
Nunca trabalhe em equipamento ou conecte ou desconecte cabos de
sinal durante períodos de choque.
CUIDADO
Para sua segurança, conecte o equipamento que necessita de força elétrica a

uma tomada aterrada adequadamente e com fiação correta.
CUIDADO
Por medida de segurança, ao executar o teste da impressora, certifique-se de

que artigos pessoais, tais como gravatas, colares ou pulseiras, não fiquem
presos na cabeça de impressão em movimento.
Dansk
Generelle sikkerhedsforskrifter
Vær altid opmäligrksom; på følgende generelle sikkerhedsforskrifter, når du arbejder
med elektricitet eller elektronisk udstyr.
Fare!
Arbejd aldrig med udstyr i tordenvejr. Det samme gäliglder for montering
og afmontering af signalkabler.
Pas på!
Af sikkerhedshensyn skal udstyrets netledning altid tilsluttes en stikkontakt

med korrekt forbindelse til jord.
Pas på!
Sørg for, at slips, halskäligder eller armbånd ikke kommer til at sidde fast i
skrivehovedet, når udskrivningstesten foretages.

Suomi
Yleiset turvaohjeet
Noudata seuraavia yleisiä turvaohjeita aina, kun teet sähkökytkentöjä tai käsittelet
sähkölaitteita;
VAARA
Ukonilman aikana ei saa kytkeä tai irrottaa kaapeleita eikä käsitellä
laitteita.
Varoitus
Kytke laitteiden verkkojohdot vain oikein kytkettyihin ja maadoitettuihin

pistorasioihin. Muutoin voit saada sähköiskun.
Varoitus
Kun testaat kirjoitinta, varo, ettei esimerkiksi solmiosi, kaulaketjusi tai

rannerenkaasi tartu liikkuvaan kirjoituspäähän.
Appendix D. Translated Safety Notices 189

Français
Généralités
Utilisez les informations générales ci-dessous pour chaque intervention sur du
matériel électrique ou électronique.
VAARA
N’effectuez ni intervention sur le matériel;, ni manipulation de câble
pendant un orage.
Attention: Par mesure de sécurité, le cordon d’alimentation doit être branché sur
un socle de prise de courant correctement câblé et mis à terre.
Attention: Par mesure de sécurité, éloignez; cravates, colliers et bracelets de la

tête d’impression pendant le test d’impression.
Deutsch
Allgemeine Sicherheitsüberlegungen
Bei Arbeiten mit Elektrizität oder an elektronischen Geräten müssen die folgenden
Sicherheitshinweise beachtet werden.
VORSICHT
Bei Gewitter keine Arbeiten am Gerät vornehmen und keine Kabel
anschließen oder lösen.
ACHTUNG
Gerät nur an eine Schutzkontaktsteckdose mit ordnungsgemäß geerdetem

Schutzkontakt anschließen.
ACHTUNG
Während des Druckertests darauf achten, daß Halstücher, Krawatten,

Ambänder oder Halsketten nicht am Schreibkopf hängen bleiben.

Italiano
Sicurezza - Considerazioni generali

Osservare le condizioni generali sulla sicurezza di seguito riportate quando si lavora
con l’elettricità o con apparecchiature elettroniche.
PERICOLO:
Non lavorare mai sulle apparecchiature nè collegare o scollegare cavi di
segnale durante temporali.
ATTENZIONE:
Per evitare scosse elettriche, collegare le apparecchiature alimentate elettricamente

a prese elettriche correttamente collegate alla terra di sicurezza.
ATTENZIONE:
Per sicurezza, mentre si eseguono le prove della stampante, prestare attenzione

che oggetti personali (quali cravatte, catenine e braccialetti) non rimangano
impigliati nella testina di stampa in movimento.
Norsk
Generelle sikkerhetsforskrifter
Du bør følge disse sikkerhetsforskriftene når du arbeider med elektrisitet eller
elektronisk utstyr.
FARE!
Arbeid aldri med utstyret i tordenväligr. I slike tilfeller må du verken
trekke ut signalkabler eller koble noen til.
ADVARSEL:
Av sikkerhetshensyn må du bare koble utstyret til en jordet stikkontakt.
ADVARSEL:
Av sikkerhetshensyn må du passe på at slips, halskjeder og andre løse

gjenstander ikke setter seg fast i skrivehodet når du kjører skrivertesten.
Português
Informaçõles de Segurança Gerais

As informações de segurança gerais que se seguem devem ser observadas
sempre que trabalhar com electricidade ou com equipamento electrónico

PERIGO
Nunca trabalhe com equipamento nem ligue ou desligue cabos de sinal
durante trovoadas.
CUIDADO
Para sua segurança, ligue os equipamentos alimentados por tensão eléctrica

a uma tomada devidamente ligada à terra.
CUIDADO
Para sua segurança, quando executar os testes da impressora, certifique-se

de que nenhum objecto pessoal como, por exemplo, uma gravata, colar ou
pulseira se prende à cabeça de impressão, quando em movimento.
Español
Consideraciones Generales de Seguridad

Las siguientes consideraciones de seguridad deben observarse siempre que se
trabaje con electricidad o con un equipo electrónico.
PELIGRO
No trabaje nunca con equipos ni conecte o desconecte cables de señal
durante períodos de tormenta eléctrica.
PRECAUCIÓN
Para su seguridad, conecte el equipo que requiera alimentación eléctrica a

una toma de alimentación debidamente cableada y conectada a tierra.
PRECAUCIÓN
Para su seguridad, cuando realice las pruebas de la impresora, asegúrese de

que objetos personales, como corbatas, collares o pulseras no quedan
atrapados en la cabeza de impresión móvil.

Svenska
Allmänna säkerhetsföreskrifter
När du arbetar med elektrisk utrustning:
Varning — livsfara:
Arbeta inte med utrusting eller in-/urkoppling av signalkablar vid
åskväder.
Varning — risk för personskada:
Anslut utrustningen till jordat eluttag.
Varning — risk för personskada:
Se till att personliga föremål såsom slips, halsband, armband eller liknande
inte fastnar i skrivhuvudet när du testar skrivaren.


Appendix E. Notices
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . 195
References in this publication to IBM products, programs, or services do not imply

that IBM intends to make these available in all countries in which IBM operates. Any
reference to an IBM product, program, or service is not intended to state or imply
that only IBM’s product, program, or service may be used. Any functionally
equivalent product, program, or service that does not infringe any of IBM’s
intellectual property rights may be used instead of the IBM product, program, or
service. Evaluation and verification of operation in conjunction with other products,
except those expressly designated by IBM, are the user’s responsibility.
IBM may have patents or pending patent applications covering 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.

ESD Damage Prevention
back-panel pins, or other ESD-sensitive (ESDS) parts, the service person must be
strap and cord.
wire ground, or the round ground prong on the ac power plug. Coaxial cable or
connector outside shells can also be used.
Handling Removed Cards
Logic cards removed from a product should be placed in ESD protective containers.
Trademarks
The following terms are trademarks of the IBM Corporation in the United States or
other countries or both:
v IBM
v SureMark

Other company, product, and service names may be trademarks or service marks
of others.

Part Number Index

Part Asm– Part Asm–
Number Index Page Number Index Page
01L1646 13–13 133 | 20P0365 18–7 173
| 01L1646 18–12 173 | 30L6217 18–2 173
01L1647 13–12 133 | 30L6322 18–3 173
| 01L1647 18–11 173 30L6406 3–8 113
02L0769 3– 113 30L6441 5–3 117
02L0821 3–7 113 30L6442 5–1 117
08L1843 5–11 117 30L6443 11– 129
08L2014 13–11 133 30L6444 11–23 129
| 08L2014 18–10 173 30L6445 11–21 129
10J0152 3–6 113 38H7337 12– 131
10J0153 1– 109 38H7338 12– 131
10J0153 3–7 113 38H7358 12– 131
1622302 12– 131 38H7366 12– 131
| 16K8508 17– 171 38H7367 12– 131
| 16K8519 17– 171 38H7369 12– 131
| 16K8527 17– 171 38H7370 12– 131
| 16K8532 16– 169 38H7395 12– 131
| 16K8533 16– 169 38H7402 12– 131
| 16K8538 16– 169 38H7438 12– 131
| 16K8555 17– 171 38H7446 12– 131
| 16K8602 15–1 167 38H7463 12– 131
| 16K8603 15–2 167 38H7473 12– 131
| 16K8604 15–2 167 38H7509 12– 131
| 16K8605 15–1 167 3XH7433 12– 131
| 16K8607 15–2 167 42H1028 12– 131
| 16K8615 14–4 165 | 42H1028 17– 171
| 16K8616 14–4 165 42H1033 12– 131
| 16K8617 14–4 165 42H1043 12– 131
| 16K8618 16–4 169 42H1044 6–3 119
| 16K8622 14–1 165 42H1045 6–11 119
| 16K8623 14–1 165 42H1046 7–3 121
| 16K8624 16–1 169 42H1047 7–1 121
| 16K8625 16–2 169 42H1048 7–8 121
| 16K8626 16–3 169 42H1051 8– 123
| 16K8627 17–1 171 42H1052 8– 123
| 16K8628 14–2 165 42H1053 10– 127
| 16K8629 14–2 165 42H1056 13–2 133
| 16K8633 17– 171 42H1058 10– 127
| 16K8635 17– 171 42H1059 5– 117
| 16K8643 16–5 169 42H1060 11– 129
| 16K8674 16– 169 42H1062 8– 123
| 16K8674 17– 171 42H1063 12–1 131
| 16K8675 17– 171 42H1065 11– 129
| 16K8681 16– 169 42H1075 12– 131
| 16K8682 16– 169 42H1091 12– 131
| 16K8682 17– 171 42H1106 6–2 119
| 16K8691 18–4 173 42H1107 6–1 119
| 16K8692 18–5 173 42H1108 6–7 119
| 16K8695 15–1 167 42H1109 6–6 119
| 16K8702 18–13 173 42H1110 6–5 119

Part Asm– Part Asm–

Number Index Page Number Index Page
42H1111 13–3 133 | 72H3802 18–14 173
42H1111 7–6 121 72H3803 13–7 133
42H1112 7–5 121 | 72H3803 18–15 173
42H1113 7–7 121 73G2601 9– 125
42H1114 6–10 119 73G2620 12– 131
42H1118 9–5 125 | 73G2620 17– 171
42H1119 9– 125 86H2192 13–8 133
42H1120 10–11 127 | 86H2192 18–8 173
42H1121 8–10 123 86H2195 13–9 133
42H1125 1–6 109 | 86H2195 18–9 173
42H1128 5–9 117 | 92F5403 17– 171
42H1129 5–8 117 92F8349 12– 131
42H1131 1–3 109 93F0233 12– 131
42H1132 1–2 109 | 93F0233 17– 171
42H1133 4–2 115
42H1134 9– 125
42H1135 2–2 111
42H1136 1–1 109
42H1137 5–2 117
42H1138 1–4 109
42H1139 2–1 111
42H1140 3– 113
42H1143 13–1 133
42H1144 12–2 131
42H1145 6–8 119
42H1154 12– 131
| 42H1154 17– 171
42H1155 12– 131
42H1157 13–4 133
| 42H1157 18–1 173
42H1161 12– 131
42H1162 12– 131
42H1164 11–12 129
42H1169 12– 131
42H1176 13–10 133
42H1176 13–5 133
| 42H1176 18–6 173
42H1179 12– 131
| 42H1179 17– 171
42H1180 5–7 117
42H1190 7– 121
42H1204 12– 131
4483179 12– 131
53F4942 12– 131
6341458 12– 131
| 6341458 17– 171
6410857 12– 131
| 6410857 17– 171
6428680 12– 131
| 6429529 17– 171
69F3557 12– 131
| 69F3557 17– 171
72H3802 13–6 133

Index
Numerics emulating Mod 3 or 4 printer (continued)
enabling with 4690 On-Line Terminal
4610 DBCS Installation Utility Diskette 17
Diagnostics 26
4610CVNT.EXE program 20
limitations 26
58-mm paper roll, installing 152
expendable supplies 185
A F
adjustments, mechanical
firmware update
cutter blade run-in 103
DI forms compensation adjustment 98
4690 OS utility program 24
DI open lever adjustment 102
limitation 25
printhead platen gap adjustment 100
POSS for Windows 23
thermal paper switch adjustment 106
via RS-232 attachment 24
thermal printhead adjustment 104
flash memory
AIP46MC5.HEX file 23
printing 27
AIPFNT46.EXE program 21
fonts
files for DBCS code pages 19
UDC files for DBCS code pages 22
C
cash drawer pin assignments 186
changing printer mode, DBCS to SBCS 28
cleaning
I
installing 58-mm paper roll 152
thermal printhead 141, 177
command modes
RS-232 5
RS-485 5
L
conversion utility, proportional fonts 29 legal notices 195
customer receipt paper problem 40 loading paper 139, 176
cutter problem 40 loading ribbon 137
D M
DBCS code page maintenance checklist 181
download 17 mechanical adjustment
font files 19 cutter blade run-in 103
UDC font files 22 DI forms compensation adjustment 98
DBCS code page download DI open lever adjustment 102
4610 DBCS Installation Utility Diskette 17 printhead platen gap adjustment 100
POSS for Windows 19 thermal paper switch adjustment 106, 162
DBCS user-defined character download 21 thermal printhead adjustment 104
download DBCS code page
POSS for Windows 19 N
notes
notices viii
E safety information viii
electrostatic discharge damage prevention 97 notices 195
emptying printer buffer 27
emulate Epson printer
enabling 28 O
limitations 28 offline testing 33
overview 27 offline tests, Model TI5
emulating Mod 3 or 4 printer customer receipt 33
enabling with 4610 DBCS Installation Utility document insert 34
Diskette 25 test pattern 35
offline tests, Models TF7 and TM7
customer receipt 145

offline tests, Models TF7 and TM7 (continued)

listing the MCT settings 146
R
related publications and diskettes viii
removal and replacement, Model TI5
bail 65
P clip springs 63
paper loading 139, 176 connector-attached interface card 76
parts listing, Model TI5 customer receipt motor 87
cable assemblies 132 customer receipt paper bucket 91
covers 108 customer receipt paper guide 90
customer receipt drive, cutter and platen 128 cutter clutch 89
document insert drive shaft assembly 124 cutter gear 89
document insert station 114 cutter gears 89
document insert station gears 126 cutter stud 83
document insert station platen and lever 122 DI feed roller 71
document insret station motor 126 document insert backup roller 68
filler panels 132 document insert feed motor 93
hardware kits 130 document insert platen assembly 63
impact printhead assembly 120 document insert sensor assembly 60
logic cards 112 front shock mount 49
operator switch and button assembly 110 front transport bearing 52
power supply 132 front transport shaft 52
printhead transport 118 hinge 83
ribbon drive assembly 118 home sensor 48
shock mounts 112 idler gear 89
thermal printhead assembly and cover 116 insert lever assembly 68
parts listing, Models TF7 and TM7 leaf spring 83
Models TF7 and TM7 163 lower forms entry frame 65
pin assignments main logic card 76
cash drawer connector 186 motor gear 93
RS-232 connector 185 operator buttons 46
USB connector 185 paper cover 42
power connections paper switch 77
connectors 10 pin gear 89
signals 10 platen spring 63
preventive maintenance 183 platen stripper 86
printer mechanism printhead 47
overview 12 printhead cable 59
printhead cleaning, thermal 141, 177 printhead carriage assembly 52
printing flash memory 27 printhead shaft 83
printing saved data 27 printhead spacer 75
problem determination, Model TI5 rear transport shaft 52
communication mode selection 5 ribbon cover 42
connections 10 ribbon drive assembly 49
customer receipt paper movement 40 ribbon guide 52
customer receipt test 33 rotating cutter blade 88
cutter problems 40 spiral pin 89
document insert test 34 stationary blade 83
messages 36 stop spring 89
RS-232 XON/XOFF 7 switch card 75
signals 10 tensioner 51
symptoms 36 tensioner spring 51
problem determination, models TF7 and TM7 thermal cables 77
customer receipt paper movement 150 thermal drag strip 81
customer receipt test 145 thermal drive gear 86
cutter problems 150 thermal guide 88
listing the MCT settings 146 thermal idler gear 86
messages 148 thermal latch 79
symptoms 148 thermal latch spring 79
proportional fonts thermal platen 86
conversion utility 29 thermal platen assembly 86
publications, related viii thermal printhead assembly 83

removal and replacement, Model TI5 (continued)

timing belt 52
top cover 42
transport motor 56
removal and replacement, models TF7 and TM7
bottom cover 155
cutter stud 158
inner cover assembly 153
interface card 156
main logic card 156
printhead shaft 158
stationary blade 158
thermal printhead assembly 158
top cover 153
Retail Store Solutions Web site 29
ribbon loading 137
RS-232 pin assignments 185
S
safety, translated notices 187
saved data, printing 27
software adjustment
updating firmware 22
using 4690 operating system 13
using POS Device Diagnostics 14
using reference/service diskette 14
special tools 185
T
testing, offline 33
tools and supplies 185
translated safety notices 187
TrueType fonts conversion utility 29
U
UDC font file names 22
USB pin assignments 185
Index 201

Readers’ Comments — We’d Like to Hear from You
SureMark Printers
DBCS Hardware Service Manual
Publication No. GY27-0397-00
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Applicable to your tasks h h h h h
Please tell us how we can improve this book:
Thank you for your responses. May we contact you? h Yes h No
When you send comments to IBM, you grant IBM a nonexclusive right to use or distribute your comments in any
way it believes appropriate without incurring any obligation to you.
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What are the main components of the SureMark printers described in the manual?

What are the main components of the SureMark printers described in the manual?

How is the manual organized and structured?

How is the manual organized and structured?

SureMark Printers

DBCS Hardware Service Manual

updated March 18, 2002 GY27-0397-00

Third Edition (September 2000)

Summary of Changes . . . . . . . . . . . . . . . . . . . . . xix

Part 1. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Chapter 2. SureMark Installation, Service, and Utility Software . . . . . . 13

© Copyright IBM Corp. 1999,2001 iii

| Enabling Epson Emulation. . . . . . . . . . . . . . . . . . . . 28

Part 2. Models TI5 and TG5. . . . . . . . . . . . . . . . . . . . . . . . . . 31

Chapter 3. Problem Determination . . . . . . . . . . . . . . . . . 33

Chapter 4. Hardware Adjustment Procedures. . . . . . . . . . . . . 97

iv SureMark DBCS Hardware Service

Chapter 5. Parts Listing . . . . . . . . . . . . . . . . . . . . 107

Chapter 6. Operation . . . . . . . . . . . . . . . . . . . . . . 135

| Part 3. Models TF7 and TM7 . . . . . . . . . . . . . . . . . . . . . . . . . 143

| Chapter 7. Problem Determination . . . . . . . . . . . . . . . . 145

| Chapter 8. Hardware Adjustment Procedures . . . . . . . . . . . . 161

| Chapter 9. Parts Listing . . . . . . . . . . . . . . . . . . . . 163

| Chapter 10. Operation . . . . . . . . . . . . . . . . . . . . . 175

Part 4. Appendixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Appendix A. Maintenance Inspection . . . . . . . . . . . . . . . 181

Appendix B. Preventive Maintenance Information . . . . . . . . . . 183

Appendix C. Tools and Supplies . . . . . . . . . . . . . . . . . 185

Appendix D. Translated Safety Notices. . . . . . . . . . . . . . . 187

Appendix E. Notices . . . . . . . . . . . . . . . . . . . . . . 195

Part Number Index . . . . . . . . . . . . . . . . . . . . . . 197

vi SureMark DBCS Hardware Service

Who Should Read This Manual

How This Manual Is Organized

The appendixes contain the following information:

© Copyright IBM Corp. 1999,2001 vii

Related Publications and Diskettes

Tell Us What You Think

From there, select Support at the left, then select Publications.

viii SureMark DBCS Hardware Service

x SureMark DBCS Hardware Service

xii SureMark DBCS Hardware Service

xiv SureMark DBCS Hardware Service

xvi SureMark DBCS Hardware Service

xviii SureMark DBCS Hardware Service

Web-only Update for GY27-0397-00 (March 2002)

Web-only Update for GY27-0397-00 (October 2001)

© Copyright IBM Corp. 1999,2001 xix

xx SureMark DBCS Hardware Service

© Copyright IBM Corp. 1999,2001 xxi

54. Removing the Spiral Wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

xxii SureMark DBCS Hardware Service

Part 1. General Information

© Copyright IBM Corp. 1999,2001 1

2 SureMark DBCS Hardware Service

Indicators, Controls, and Printing Stations – SureMark ModelS TI5 and

When the indicator blinks, one of the following conditions exists:

© Copyright IBM Corp. 1999,2001 3

Printer Ready LED