Gilbarco MDE-2360 Quick guide

tHlbarc0”
INSTALLATION
AND SERVICE
INSTRUCTIONS
MDE-2360
G-SITEm Form/Slip Printer
MDE-2360 989.2 Printed in U.S.A

FCC WARNING
This equipment generates, uses, and can radiate radio frequency energy. Equipment not installed according
to manufacturer’s instructions may interfere with radio communications. This equipment has been tested and
complies with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules. These
rules provide reasonable protection against such interference in a commercial environment. However, the
operation of this equipment in a residential area is likely to cause radio interference. The user is required to
correct this interference at his/her own expense.
COMPUTER PROGRAMS
All Gilbarco computer programs (including software on diskettes and within memory chips) are copyrighted by,
and shall remain the property of, Gilbarco Inc. Such computer programs may also contain trade secret infor-
mation. The duplication, disclosure, modification, or unauthorized use of computer programs is strictly prohib-
ited, unless otherwise licensed by Gilbarco.
This document is subject to change without notice.
0 1989 Gilbarco Inc.
All Rights Resewed
Some text and illustrations have been reproduced with the wriiten permission of DH Print.

SAFETY SUMMARY. ....................................................................................................................... ii
INTRODUCTION
Overview ........................................................................................................................................... 1
Purpose ............................................................................................................................................. 1
Related Documents ...................... ..................................................................................................... 1
Abbreviations.. .................................................................................................................................. .I
Hardware .......................................................................................................................................... .I
INSTALLATION
Site Criteria ....................................................................................................................................... 2
Getting Started .................................................................................................................................. 2
Physical Placement ........................................................................................................................... 2
SERVICE
Exploded View ................................................................................................................................. .3
Getting Started .................................................................................................................................. .
Form/Slip Printer Communication .................................................................................................... .7
Setting Up The Form/Slip Printer ..................................................................................................... .8
Preventive Maintenance.. ................................................................................................................. .9
Troubleshooting ............................................................................................................................... .12
Adjustments.. ..................................................................................................................................... 16
Replacements ................................................................................................................................... 20
Recommended Spare Parts ............................................................................................................. .31
Giilbarco MDE-2360 GSITEm Fcmn/SZipPrinter 0 1989 Gilbarm Inc. 09/21/89

Signal Words and Safety Symbols
This is a standard alert symbol. When you see this symbol,
along with the following signal words in Gilbarco manuals,
be alert to the potential for personal injury.
The hazard or unsafe practice willresult in
WARNING
The hazard or unsafe practice could result in
severe injury or death.
n ! DANGER
The hazard or unsafe practice could result in
minor Injury.
You are working in a dangerous environment. Fuels are highly flammable and explosive. Ob-
serve all safety precautions. Failure to do so will result in Injury or DEATH.
Wear eye protection. Use emergency power cutoff. No people In area. Clean up spills. No smoking.
No open flames. Collect fuel In approved No power tools. No vehicles in area. Use safety barricades.
containers.
Explosive Electricity Flammable
Read instructions for this and all related equipment. Do not allow untrained or unauthorized
persons to service equipment. Call a Gilbarco Authorized Service Contractor if you need help.
MDE-2360 GSITP Form/Slip Printer 0 1989 Gilbarw, Inc. 09/21/89

Overview
The Form/Slip Printer is an optional G-SITETMsystem peripheral. It validates credit card charge forms,
vouchers or cashier checks. The printer communicates directly with the TCRTM-15 console via a serial
RS232C interface.
Purpose
This manual provides information to install and maintain the Form/Slip Printer. It also provides
instructions to replace and adjust printer components.
Related Documents
MDE-2398 G-SITE Installation Manual
MDE-2399 G-SITE Service Manual
MDE-(Customer Specific) G-SITE Cashier/Operator Manual
Abbreviations
BPS - Bits Per Second
VAC - Volts Alternating Current
VDC - Volts Direct Current
VOM - Volt-ohm Meter
Hz - Hertz
Hardware
Form/Slip Printer DHPrint Model 4110 JournalNalidator Printer
Model Number T16886
Physical Dimensions
Weight 15 Ibs. (6.8 kg)
Height 7.5 inches (19.1 cm)
Width 8.25 inches (21.Ocm)
Depth 16.0 inches (40.6 cm)
Mechanical Characteristics
Duty cycle 120 characters per second, medium stroke printhead
Printhead gap .023” credit card form/slips
Printhead DHPrint 7 wire, in-line ballistic
Mechanism DHPrint 411 stepper motor driven dot matrix serial impact type
Power Requirements
Voltages 115VAC +l 0%, 60 Hz Single Phase
Power 200 Watts maximum
Fuse 2.0 AMP slow blow 230 VAC fuse
Environment
Temperature 32” to 122” Fahrenheit (O”to 50” Centigrade)
Storage -40” to 149’ Fahrenheit (-40” to 65” Centigrade)
Humidity 95% non-condensing
C5ilbmco MDE-2360 G.SITEm Form /Slip Printer 0 1989 Gilbarw Inc. 09/21/89

Site Criteria
installation of the Form/Slip Printer must be in accordance with the National Electrical Code NFPA 70, and
the Automotive and Marine Service Station Code NFPA 30A.
The site must be equipped with electrical service which will allow compliance with all installation require-
ments of a complete Fueling System. No other equipment wiring should share the conduit with this unit.
Install the Form/Slip Printer in an enclosed weather-protected structure. Make sure the installation site
meets environment specifications on previous page.
Getting Started
1. Check parts against parts list to make sure all parts were shipped.
2. Check installation site to be sure it meets site criteria.
3. Have all necessary materials on hand.
4. Check G-SITETMForm/Slip Printer for any possible shipment damage. Shipment damage is not
covered under Gilbarco’s warranty policy. Report any shipment damage to the carrier.
5. Check bottom panel of printer for model identification number.
6. Place unit in shipping carton to prevent exposure to elements and store indoors until ready for
installation.
Failure to turn printer power off
may cause serious injury or death.
I
Physical Placement
1. Be sure to turn off power.
1
2. Place the printer where it is not subjected to extreme temperature, direct sunlight, or liquid
spills.
3. install printer at least eighteen inches above the floor.
4. Install printer at least four inches from the wall to connect cables and open J-Cover (See
Figure 7).
The receptacle providing power to the unit must be a properly installed isolated ground receptacle
(Hubbell #iG 5261 or equivalent). This type receptacle is easily identified by its bright orange
color and triangle embossed into the face of the outlet. The green grounding screw must be
attached to the grounding conductor.
5. Plug in the printer’s power cord. Do not share a conduit with wiring for any device which draws
high amperage (compressor, freezer, etc.) or a device which is a source of RFI (TV, microwave,
intercom, two-way radio, etc.). Do not turn power on at the printer.
MDE-2360 G-SITE? Form /Slip Printer 0 1989 Gilbarw Inc. 09/21/89 @Wcmm

Getting Started
Before you install, adjust or replace components of the G-SITFX Form/Slip Printer, you need to be
familiar with inserting form/slip, performing self-test and installing the ribbon cartridge.
Ribbon Cartridge Installation
Failure to unplug power cord
may cause serious injury or
death.
1. Turn off printer power.
2. Remove slide cover by sliding cover approximately l-1/4” toward front of printer. Carefully, lift
cover off printer case (See figure 7).
Figure 1
On/Off Power
Cover
Form/Slip insertion
Slot \
4110 Panel
Giilkmm MDE-2360 G-SILT? Form ISlip Printer Q 1989 Gii’barwInc. 09/21/89

Exploded View
Figure 2
@h.
n__..-- 8 ‘\
Ribbon Advance
mature
Document
El)dcnLi?!?Ar h RightHand1
Pressure Rollem’
\ ,
Ribbon Guide
Printhead/ Y/c%
MDE-2360 GSITEm Fown /Slip Printer 0 1989 Gilbarw Inc. 09/21/89

Ribbon Cartridge installation (continued)
3. Center printhead by turning large gear towardback of printer (See Figure 2).
5. Insert ribbon over center tab of ribbon guide (See Figure 2). Slide ribbon in front of printhead
and behind both outside tabs on ribbon guide.
6. Snap cartridge into position by pressing both ends.
7. Turn ribbon advance on ribbon cartridge to take up slack.
8. Replace slide cover.
Form/Slip insertion
1. Slide form/slip into slot starting on left-hand side of unit. Slide form/slip with a 45 degree
downward and inward sweeping motion. Slide until form/slip touches the right-hand edge stop
(See figure 3).
2. The document clamp clamps the form/slip when the form/slip is against the bottom stop and
covers the sensor. The printer prints on the form/slip.
3. Slide form/slip out of slot when printing is complete.
Figure 3
~ilbam MDE-2360 G-SITEm Form /Slip Printer 0 1989 Gilburw Inc. 09/21/89

Self-Test
NOTICE!
Always insert form/slip before turning on printer
power. Failure to use form/slip while turning on
power can cause printhead damage.
insert a form/slip into the form/slip insertion slot and turn power switch to ON (See Figure 7).
Note: This is called the Self-Test.
The printer revision (version) number and DIP (Dual lnline Package) switch settings are printed on the
form/slip (See Figure 4). To set DIP switches, see Setting Up The Form/Slip Printer.
Figure 4: SAMPLE OF SELF-TEST
line 7 REV 2.5 MK 115 (varies for each version)
line2 MEMORY STATUS q OK
line 3 SW :
line 4 123 : BAUD RATE =’ 2400
line 5 45 : LiNES/iNCH = 8
line 6 6 : AUTO LF = ON
line 7 7: 40/46 COL q 40
line 8 6 : POLARITY
line 9 RTS = -12v
line 70 DIPSW 1 2 3 4 5 6 7 8
line 77 oc c cc 0 co
Line 1: Rev - software revision number, MK 115 - Gilbarco Use Only (varies for each version)
Line 2: Memory Status - indicates successful completion of the RAM (Random Access Memory)
and ROM (Read Only Memory) memory diagnostics
Lines 3 - 9: show the DIP switch settings and functions
Lines 10 - 11: DIPSW (Dual lnline Package Switches) - indicates which DIP switches are closed and
which are open .
closed - C open - 0
MDE-2360 GSITEW Form /Slip Printer 0 1989 Gilbarw Inc. 09121189 Giilbarco

Form/Slip Printer Communication
induced Noise Reduction
The communication port provides moderate induced noise protection.
For successful long distance communication:
1. Avoid bundling the FormSlip Printer cable with other wiring.
2. Run the cable away from devices which produce electrical noise (TV, microwave, intercom,
two-way radio, etc.).
interface With G-SiTETM
-0 - A -
\<l
7
Unplug AC power cord. Failure to
do so may cause serious injury or
death.
1. Turn off printer power and unplug power cord.
2. Connect communication cable (Q11542-31) to the port located on the back panel of printer
(See Figure 5).
3. Connect communication cable (Q11542-31) to P209 located on bottom panel of TCRRI’-15
console.
Figure 5
Communications
Gilbarn MD.&2360 GSITEm Form /Slip Printer 0 1989 Gilbarw Inc. 09/21/89

Setting Up The Form/Slip Printer
Change the Slip Printer setup by setting the DIP switches. The DIP Switches are located on the
bottom panel of the form/slip printer.
Note: Power must be turned off to properly set DIP switches.
1. Turn power OFF to set printers DIP switches.
2. The printer may already be set properly. Do not change the DIP switches if they are set correctly.
The following instructions guide you through setting the DIP switches. Failure to correctly set the DIP
switches may cause communication problems between the printer and the TCRTM-15console.
See figure 6 for Steps 3 - 7
3. Set the Baud Rate - 2400 BPS
Switch 1 - open
Switch 2 - closed
Switch 3 - closed
4. Set lines per inch - 8
Switch 4 - closed
Switch 5 - closed
5. Set automatic line feed
Switch 6 - open
6. Set characters per line - 40
Switch 7 - closed
7. Set busy signal polarity -1PVDC.
Switch 8 - open
8. Insert a form/slip into form/slip slot.
9. Turn power on to read DIP switches and perform a self-test.
10. Compare self-test results to Figure 4 to be sure DIP switch settings are correct.
MDE-2360 GSlTEm Form /Slip Printer 0 1989 Gilbarw Inc. 09/21/89 tiFdbarc0

Preventive Maintenance
introduction
This section instructs you on proper preventive maintenance procedures required for the printer.
Failure to routinely follow these procedures may result in unnecessary equipment damage. Form/Slip
Printer damage attributable to lack of, or improper use of, these procedures voids the device warranty.
Overview
Form/Slip Printer preventive maintenance should be performed daily, weekly and once every three
months. Station personnel are responsible for daily and weekly preventive maintenance. A Gilbarco
Authorized Service Contractor is responsible for three-month preventive maintenance.
Required Maintenance Supplies
-Isopropyl alcohol
aOil (Ql2055-23) or (Q11369-185)
*Grease (Q12055-22) or ((X1369-1 87 and Q11369-186)
*Lint-free cleaning cloth
-Cotton swabs
Required Maintenance Tools
*Thickness Gauges
*Vacuum cleaner with corner attachment, canned air (no more than 40 psi pressure) or air bulb.
Turn off printer power and unplug
power cord before performing any
maintenance on this device.
Failure to do so could result in
death or serious injury.
Do not use empty space in rear of printer as a
storage area. Failure to comply may cause
NOTICE
Do not use thinner or trichloroethyiene type
solvents to clean the printer casing. These
liquids can damage the casing.
GWmm MDE-2360 GSITEm Form /Slip Printer 0 1989 Gilbarw Inc. 09/27/89

Operator Dally Maintenance
Refer to Figures 1, 2,5, & 7 for location of parts.
1. Turn off printer power and unplug power cord. Disconnect communication cable.
2. Remove printer ribbon cartridge.
3. Use either canned air (use no more than 40 psi pressure), a vacuum cleaner, or an air bulb to
clear any paper particles from printer.
4. Turn large gear toward rear of unit to center prfnthead (See Figure 2).
5. Install ribbon cartridge (Q12055-24). Make sure the cartridge clicks into posftion. Carefully,
thread printer ribbon. Take up any slack by turning ribbon advance clockwise.
6. Insert form/slip for self-test.
7. Plug power cord into receptacle, connect communication cabie,and turn on printer power.
Figure 7
Pressure Roller
Operator Weekly Maintenance
Refer to Figures 1, 2,5, & 7 for location of parts.
1. Turn off printer power and unplug power cord. Disconnect communication cable.
2. Perform Daily Maintenance.
3. Remove printer ribbon cartridge.
4. Use alcohol, cotton swabs and a lint-free cloth to clean ink, dirt and grease from printer casing.
5. Turn large gear toward rear of printer to center printhead (See figure 2).
6. Clean pressure roller with an alcohol-soaked cotton swab (See Figure 2). Turn pressure roller
toward rear of printer until the document feed solenoid armature disengages (See Figure 2).
Clean entire pressure roller.
7. Dry roller with paper towel. Engage document feed solenoid armature by turning pressure
roller toward front of printer.
8. Clean document clamp with alcohol-soaked cotton swab. Dry rollers.
9. Center printhead.
10. install ribbon cartridge. Make sure cartridge clicks into position. Carefully, thread printer
ribbon. Take up any slack by turning ribbon advance clockwise.
11. Insert form/slip for self-test.
12. Plug power cord into receptacle, connect communication cable, and turn on printer power.
MDE-2360 GSIF Form /Slip Printer Q 1989 Gilbarw inc. 09121189 @F&arc0

Three Month Maintenance For Service Contractor
This section must be performed only by an Authorized Service Contractor (ASC).
Clean, lubricate and inspect the Form/Slip Printer once every three months. Service the printer more
frequently if it is subjected to heavy use, dirty environment, extreme temperature, extended shock or
vibration.
Notes: Lubricate printer after every repair. Use oil (Q1205523) or grease (Q12055-22).
Refer to Figures 1, 2,5, & 7 for location of parts.
1. Turn off printer power and unplug power cord. Disconnect communication cable.
2. Perform daily and weekly maintenance.
3. Remove document clamp and printer ribbon cartridge.
4. Clean all grease and dirt from unit.
5. Lightly, oil all pivot points. Use oil Q12055-23 or Q11369-185
6. Lightly, grease all shafts and gears. Use grease Q12055-22 or Q11369-186.
7. Insert a form/slip into the Form/Slip Printer slot. Make sure document stop is not loose
(See Figures 1& 3). Adjust document stop if it moves (See Adjusting Form/S/@ Stop in
ADJUSTMENTS).
8. Make sure right-hand edge guide is squarely and securely installed (See figure 2).
9. Make sure there are no missing or loose screws.
10. Rotate large gear to make sure printhead moves easily.
11. Make sure print drive cam bearings are in good condition (See Figure 2).
12. Insert thickness gauges to make sure gap between print bar and printhead is between .022”
and .024”. Check on both ends of print bar.
13. Make sure printhead, at the square shaft and print drive cam, moves less than l/16” in and out
and up and down.
14. Make sure ribbon is not snagged and ribbon track is not blocked.
15. Center printhead. Install ribbon cartridge. Make sure cartridge clicks into position. Turn large
gear to make sure ribbon advances. The ribbon advances when printhead moves to far right
and begins to move back to the left.
16. Replace document clamp.
17. Connect communication cable. Make sure power cord and communication cable are secure
and in good condition.
18. Make sure there is no communication interference.
19. Insert form/slip into form/slip slot for self-test.
20. Plug power cord into receptacle and turn on printer power. Verify correct DIP Switch settings
from self-test.
~ilbarco MDE-2360 GSITETM Form /Slip Printer Q 1989 Gilbarw Inc. 09/21/89

Troubleshooting
Print
Symptom: Faded print
Cause: Ribbon cartridge worn out
Cure: Replace ribbon cartridge (Q12055-24)
Symptom: Random dots missing or faded
Cause: Printhead/print bar gap incorrect
Cure: Adjust printhead gap
Symptom: Print smeared
Cause: Printhead dirty
Cure: Clean printhead
Cause: Printhead/print bar gap incorrect
Cure: Adjust printhead gap
Cause: Ribbon guide/printhead gap incorrect
Cure: Adjust ribbon guide gap
Printer Will Not Print Transmitted Data
Symptom: Printer self-tests correctly but does not print
Cause: Clamp command not given
Cure: Enter 14, #on TCRW-15 console to clear printer
~;N$: Communication connector loose, disconnected or connected incorrectly
: Connect communication connection correctly
Cause: DIP switch settings incorrect
Cure: Check DIP switch settings
Cause: Connectors from Controller Logic board to mechanism PCB incorrectly connected
Cure: Check connection
Cause: Ribbon cable from communication port to Controller Logic board or cable from printer to
console is defective
Cure: Check continuity of each cable. Replace if necessary.
Cause: Controller Logic board defective
Cure: Replace Controller Logic board (Q12055-09)
MDE-2360 GSITP Form /Slip Printer 0 1989 Gilbarw Inc. 09/21/89 C5ilbarco

Unit Does Not Power Up Correctly
Symptom: Printhead sweeps continuously
Cause: 8-pin connector improperly connected on either Controller Logic board or mechanism
PCB
Cure: Check 8-pin connector
Cause: Controller Logic board or printer mechanism defective
Cure: Run Test #l to determine defective component
Symptom: Printhead sweeps abnormally fast and then stops
Cause: Runaway D.C. motor
Cure: Power cycle unit
cure: Replace Controller Logic board (Q12055-09)
Cause: 8-pin connector improperly connected on Controller Logic board or mechanism PCB
Cure: Check 8-pin connector
Symptom: Printhead does not sweep
Cause: A.C. power connections loose or disconnected
Cure: Check power connections at source and printer
Cause: Fuse bad
Cure: Replace fuse (Ql2055-03)
Cause: Power switch or transformer improperly installed or connected
Cure: Check component connections
Cause: Power switch defective
cure: Remove power switch and check continuity
Cause: Fuse holder defective
Cure: Replace fuse holder (Ql2055-07)
Cause: Printhead jammed by improperly installed or defective ribbon cartridge
Cure: Remove ribbon cartridge. Turn large gray gear to check for free movement of printhead.
Reassemble and run self-test
Cause: Printhead jammed by paper in mechanism or drive gear teeth
Cure: Remove cause of jam, reassemble printer and run seff-test
Cause: Improper printhead/print bar gap
Cure: Adjust printhead/print bar gap
Symptom: Prints backward and upside down.
Cause: Cable connecting printhead wire housing to Controller Logic board installed incorrectly.
Cure: Disconnect cable at Controller Logic board. Turn connector 180” and reconnect.
CRibam MDE-2360 GSlTl?’ Form /Slip Printer Q 1989 Gilbarw Inc. 09/21/89

Printer Does Not Self-Test Properly
Symptom: Printhead sweeps on power up, printhead stops in center of print field and does not run
self-test
Cause: Bottom stop sensor not covered
Cure: Make sure sensor is covered and rerun self-test
Cause: Bottom stop sensor improperly connected
Cure: Inspect sensor
Cause: Controller Logic or printer mechanism connector improperly connected
Cure: Remove covers and check for correct connections
Symptom: Horizontal row(s) of dots missing on printout
Cause: llpin connector on Controller Logic board improperly connected
Cure: Check 14-pin connector
Cause: Printhead is damaged
Cure: Replace Printhead Assembly (Q12055-16)
Symptom: Self-test printout is mirror image of correct printout
Cause: 14-pin connector on Controller Logic board improperly connected
Cure: Check 14-pin connector
Document Does Not Advance Properly
Symptom: Document feed solenoid moves but document does not advance properly
Cause: Document feed solenoid or the clamp solenoid is improperly adjusted
Cure: If document advances when you push very hard on the center of the clamp, clamp
solenoid requires adjustment. Otherwise, document feed solenoid requires adjustment.
Symptom: Document does not advance
Cause: Document feed solenoid defective
Cure: Check document feed solenoid for continuity
Cause: Clamp solenoid defective
Cure: Check clamp solenoid for continuity
Cause: 7-pin connector from printer mechanism improperly connected on Controller Logic board
Cure: Check connection
Cause: 8-pin connector from printer mechanism improperly connected on Controller Logic board
Cure: Check connection
Cause: Controller Logic board defective
Cure: Replace Controller Logic board (Q12055-09)
MDE-2360 GSITEW Form /Slip Printer Q 1989 Gilbarw Inc. 09/21/89 C5ilbam

Test #l
Use a volt-ohm meter (20K ohms/volt minimum)
Controller Logic board 8-pin Connector
Use a V.O.M. (+lO VDC Scale):
1. Place a (+) probe to Pin 1
2. Place a (-) probe to Pin 6
3. Turn on printer power
If V.O.M. needle fluctuates upscale, the Controller Logic board is defective. Replace Controller Logic
board.
If V.O.M. needle fluctuates downscale, the printer mechanism is defective. Replace printer mechanism
(01205539).
Tests #2 And #3
Use a volt-ohm meter (20K ohms/volt minimum)
Remove fuse and printer mechanism (See Printer Mechanism in REPLACEMENTS).
On Controller Logic board:
1. Disconnect 3-pin connector.
Test #2
On Transformer:
2. Measure resistance between Pin 1 and Pin 2 with V.O.M. (R x 1 Scale).
3. Measure resistance between Pin 4 and Pin 5. The resistance should measure 10 ohms.
Test #3
On Transformer:
2. Measure resistance between Pin 6 and Pin 8. Resistance should measure less than 1 ohm.
3. Place a (+) probe to Pin 10. Resistance should measure less than 1 ohm. if resistance
measures more than 1 ohm, replace transformer.
C5ilbarco MDE-2360 GSlTEm Form /Slip Printer 0 1989 Gilbarw Inc. 09/21/89

Adjustments
Purpose
This section identifies the reasons for printer part adjustments and instructs you, by steps, how to adjust
the following components.
lprinthead and ribbon guide gap
*print drive cam bearings and printer frame gap
*form/slip stop
*clamp solenoid
*document feed solenoid
*flag position
Required Tools
*Thickness Gauge
lFlag adjusting tool (Ql2055-25)
l##2-8” Phillips Magnetic Screwdriver
Standard screw starter and driver
lGiyptol Sealant
Before You Start
Turn off printer power and unplug
power cord before adjusting any
components. Failure to do so
could result In death or serious
iniurv.
1. Turn off printer power and unplug power cord. Disconnect communication cable.
2. Open J-Cover. Remove slide cover by sliding cover approximately 1-l/4” toward front of printer.
Carefully, lift cover off printer case.
3. Remove document clamp, ribbon cartridge, and 4110 panel by lifting from two posts (See
Figures 1and 2).
MDE-2360 GSITEm Form /Slip Printer 0 1989 Gilbarw Inc. 09/21/89 GZilk3urco