Gasboy atlas, Service Manual

Page 1: ...Commercial and Retail Series Atlas Start up Service Manual MDE 4334C...

Page 2: ...umping units MH6418 Power operated Transfer Pump Models 25 25C 26 27 28 72 72S 72SP 72X 73 and 1820 MH7404 Hand operated Transfer Pump Models 1230 Series 1243 Series 1520 and 1720 Series MH10581 Key c...

Page 3: ...3 1 Introduction 3 1 Purpose 3 1 Important Information about Releases 3 1 Topics in this Section 3 1 How to Use this Section 3 1 Certificate of Conformance CoC Numbers 3 1 Start up Checklists 3 2 Ins...

Page 4: ...2 Programming 5 20 Level 3 Programming 5 24 Option and Miscellaneous Programming Data Acquisition 5 26 Displaying Pump Totals 5 27 Error Codes and Descriptions 5 28 Programming 8700 Series Units 5 29...

Page 5: ...CA Atlas 8800 only 6 38 T17701 G1 LCD Display 6 inch Atlas 8800 only 6 38 Power Supplies 6 39 T19868 G1 Main Power Supply 6 41 T19428 G1 IS Barrier Assembly ATC 6 43 Q10131 03 Fuse 6 43 Electro mechan...

Page 6: ...s 7 30 Replacing O Rings Body and Cover Leaks 7 31 Calibrating Wheel Parts Repair 7 32 Replacing Piston Cups 7 32 Removing Replacing the Shaft Seal and Gasket Upper Seal Leaks 7 34 LC Meters 7 35 Remo...

Page 7: ...Retail Electronic Units 8 2 Sample Troubleshooting Form 8 3 Priority Codes 8 3 Table 1 Communications to the Console 8 4 Table 2 Fuel Delivery All Units 8 5 Table 3 Electronic Displays Electric Reset...

Page 8: ...Page vi MDE 4334C Atlas Start up and Service Manual April 2008 This page is intentionally left blank...

Page 9: ...sections in this manual cover the following topics Topics Page Read this First 1 1 Important Safety Information 2 1 Start up Procedures 3 1 Preventive Maintenance and Inspection 4 1 Pump Programming 5...

Page 10: ...the site 2 When placing the call ensure that the following are available Unit model and serial number Site name and telephone number Your technician number Problem description and history All require...

Page 11: ...Satellite Field Wiring Diagram Handbook 44 NIST Handbook 44 MDE 4255 Gasboy Warranty MDE 4319 TopKAT Installation Manual MDE 4331 Atlas Installation Manual MDE 4333 Atlas Site Preparation Manual MDE 4...

Page 12: ...rotection Association OSHA Occupational Safety and Health Association PIN Personal Identification Number POS Point of Sale Console or register that controls the pump dispenser for retail applications...

Page 13: ...s opposed to electronic digital type displays In units that are Commercial instead of Retail the external components are the same with the exception that they do not have a Monetary Sale amount a Pric...

Page 14: ...as opposed to mechanical displays In units that are Electronic Commercial instead of Retail the external components are the same with the exception that they do not have a Monetary Sale amount a PPU d...

Page 15: ...e A side at the bottom of the unit attached to the inside of the frame Refer to the following tables to determine the date code on a Gasboy pump or dispenser Month Codes A January E May J September B...

Page 16: ...STS Stainless Steel Top Sides TW1 Dual Hose Single Product TW2 Dual Hose Dual Product TW3 Satellite Combo Unit X Remote Dispenser X B Display Battery Backup 25 230VAC 50 Hz 35 380VAC 50 Hz 36 380VAC 6...

Page 17: ...rcial Mechanical Non Computing 1 Retail Electronic 8 Satellite 2 Type Commercial Electronic 8 Full Size Cabinet 5 Type Flow Rates Narrow 1 Ultra Hi Gallonage 40 to 50 gpm 0 Compact Cabinet 2 Not used...

Page 18: ...needed for a balanced system from the high hose retriever to the splitter all the way to the nozzle The Vapor Recovery kit is a retrofit kit used when providing your own vapor recovery system This ki...

Page 19: ...be available for all Pulse Output options RS 485 Interface When connecting a 9800 model to a Gasboy Cash Flow Network CFN or TopKAT system an RS 485 interface board must be installed in the unit The...

Page 20: ...Read this First Model Information Page 1 12 MDE 4334C Atlas Start up and Service Manual April 2008 This page is intentionally left blank...

Page 21: ...Read understand and follow this manual and any other labels or related materials supplied with this equipment If you do not understand a procedure call a Gasboy Authorized Service Contractor or call t...

Page 22: ...rd if not handled correctly Ensure that you clean hands after handling equipment Do not place any equipment in the mouth The pump dispenser contains a chemical known to the State of California to caus...

Page 23: ...a Vehicle with Unit Fire at Island Fuel Spill Do not go near a fuel spill or allow anyone else in the area Use station EMERGENCY CUTOFF immediately Turn off all system circuit breakers to the island s...

Page 24: ...Important Safety Information Page 2 4 MDE 4334C Atlas Start up and Service Manual April 2008 This page is intentionally left blank...

Page 25: ...other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of the document Refer to the Gilba...

Page 26: ...rep 4 Pumps require a check valve MDE 4333 Site Prep 5 Hose breakaways must be used and installed as per the manufacturer s recommendations For units with retrievers breakaways and whip hoses hose bre...

Page 27: ...ed NEC and local codes 8 All dispenser pump wiring should be properly spaced and isolated from wiring for electrically noisy devices such as variable speed STPs station equipment motors and other devi...

Page 28: ...ration or errors in calibration verification testing Improper purging can cause damage to meters and shorten their life Gasboy Atlas Gallon Unit of Measure Temporary pricing should have already been e...

Page 29: ...nd version for independently released sections will be included in the section title and footer of the document Refer to the Gilbarco Online document resource GOLD for the latest update This section w...

Page 30: ...avoid annoying pump shut downs a periodic preventive maintenance inspection plan must be established and followed Procedures requiring leak repair shear valve maintenance and disassembly of portions o...

Page 31: ...tlas equipment Performing Inspections This section provides instructions for scheduling two types of maintenance inspections General inspections Component inspections Safety Warnings You are performin...

Page 32: ...orized persons and vehicles and then use safety tape or cones as barricades Component Inspections Refer to Preventive Maintenance Table on page 4 7 to schedule component inspections The station owner...

Page 33: ...arts manual to ensure that you replace the strainer and filter required with the one designed for your model Always use a drip pan and absorbent material directly below the filter when removing the ca...

Page 34: ...lay Do not wax textured surfaces Waxing the textured surfaces can damage the units adversely affecting the appearance of units To retain the unmarked finish on stainless steel occasional cleaning is r...

Page 35: ...rough WARNING Leaking fuel can be ignited causing a fire or explosion Fire explosion or electrical shock could result in severe injury or death if you continue to use damaged pumps dispensers If you f...

Page 36: ...oltages Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death Do not attempt to service the Gasboy Atlas pump dispenser yourself and do not allow untrained personnel to serv...

Page 37: ...e breakaway whip hose should be attached to the nozzle 3 Consult the breakaway manufacturer for any additional required inspections 4 If repair is needed call an ASC to make the repairs WARNING Leakin...

Page 38: ...ck off the pump dispenser to prevent customers from operating the pump dispenser during inspection 3 Remove the lower panels slowly and carefully 4 Inspect all hydraulic connections and seals includin...

Page 39: ...to service Gasboy Atlas pumps dispensers Only Gasboy Atlas trained ASCs should service a Gasboy Atlas unit Filter change and strainer cleaning New Installations After 50 000 gallons 200 000 liters or...

Page 40: ...le in an approved container 5 Squeeze the nozzle operating lever If flow continues after several seconds the valve is defective 6 Place a few drops of SAE10 oil on the valve body shaft 7 Open and clos...

Page 41: ...ns pressurized flammable fuel and lethal voltages Servicing a Gasboy Atlas unit incorrectly could result in severe injury or death Do not attempt to service the Gasboy Atlas pump dispenser yourself an...

Page 42: ...appear hazy Do not wax the displays on the pump dispenser Owner Wash pump dispenser As needed Note Gasboy recommends more frequent cleaning for pumps dispensers located in salty or corrosive environme...

Page 43: ...sion for independently released sections will be included in the section title and footer of the document Refer to the Gilbarco Online document resource GOLD for the latest update This section was las...

Page 44: ...A calibrated container used by W M officials and calibrating technicians to accurately check or calibrate meters in a fuel dispenser Pump Refers to a dispensing unit that has a self contained suction...

Page 45: ...used to convert the two wire communication to a usable format for other POS manufacturers who cannot connect directly to the two wire system Programming of the Electronic Retail units is accomplished...

Page 46: ...ial can be configured for various operating conditions by setting the switch es and jump jacks if applicable located on the CPU Printed Circuit Assembly PCA General Configuration Details The 9800 seri...

Page 47: ...figuring the 9800 Series Pump Programming Figure 5 4 Access to CPU Board Loosen and remove screws Keep for reinstallation Note Display unit will swing forward and down after screws are removed Figure...

Page 48: ...e JP1 SW1 1 1200 Jumpered Closed 9600 Open Mode JP2 on M06333KXXXX CPU and SW1 2 on Previous CPU This jumper switch selects the mode in which the pump dispenser operates Set the mode to Online if the...

Page 49: ...this jumper switch is ignored This jumper switch is used to determine if hose pressurization is used If enabled the slow flow valve is opened before reset is complete to allow the hose to be pressuriz...

Page 50: ...nditions using the switch positions SW2 1 through SW2 10 The previous CPU only uses SW2 1 through SW2 4 Check these switches and change if necessary Switch settings must be changed with the power to t...

Page 51: ...equipment other than CFN System or TopKAT Electronic System that requires pulse output signals for example Pulse out I F configuration interfacing with Gasboy Series 1000 and non Gasboy systems the pu...

Page 52: ...1 XXX XXX XXXX XX Timeout Switch if JP2 on M06333KXXXX CPU is Jumpered or SW1 2 on Previous CPU is Closed When the pump dispenser is in the Standalone mode including Pulse out I F configurations it wi...

Page 53: ...compensated volume Probe Temperature 023 2 Probe temperature in Celsius only Flow Rate 189 2 Flow rate in LPM only Software Version 1 30 Software version number ATC Status 842 2 Automatic Temperature...

Page 54: ...ATC ON OFF for ATC OFF Error Codes When operating the pump dispenser the 9800 series unit shows a two digit error transaction code on the LCD display when transactions are terminated abnormally that i...

Page 55: ...ction Cash Display LSD in Volume Display F1 1 2222 0000 1 ENTER Repeats for Level 2 88888 Flashing 10 10 ENTER 2 1503 0000 2 ENTER Repeats for Level 3 88888 Flashing 17 17 ENTER 3 1309 0000 3 ENTER 88...

Page 56: ...Pump Programming Programming 8800 Series Units Figure 5 7 T20092 Pump Controller AT_PumpPCA_controller P206 P207 P208 P201 P204 P203 P202 P205 JP1 Manager Keypad Details Figure 5 8 Manager Keypad Layo...

Page 57: ...ENTER Value entry keys Sends the entered value to the pump CLEAR Clear key Used to clear the last keypad entry and exit the Money and Volume Totals mode Programming Errors The following table shows th...

Page 58: ...mode 1 displayed in the leftmost Total display indicates that this total is a non resettable money total The Vol Total key displays the volume for the grade selected Volume for both sides of the unit...

Page 59: ...e side with the junction box opening is Side 1 while the other side is Side 2 Power up and Command Code 8 will display the current software version For Level 1 programming proceed as follows 1 Press F...

Page 60: ...t the Hose Grade and then press Enter 4 Select the Allocation amount and then press Enter Note Repeat the steps above for the other Side Hose and Grade Command Code 4 Program Manual Blank Display Cash...

Page 61: ...Customer Programmable Preset Press Enter after making selections where 1 Program Button 1 Default 1 Money 2 Program Button 2 Default 5 Money 3 Program Button 3 Default 10 Money 4 Program Button 1 Def...

Page 62: ...llowing information gives specific programming steps for Level 2 commands All this information is entered on the Manager Keypad Ensure that you follow the steps shown The side with the junction box op...

Page 63: ...Sell configures the default value Normally select 4 for US If the displayed decimal point and calculated decimal point are different program FC 3 first 1 xxxx 2 xxx x 3 xx xx 4 x xxx Function Code 5 S...

Page 64: ...es the time for which the unit will be in a slowdown mode during a preset sale Setting it for too short a time will result in you missing the target sale Setting it for too long will increase the time...

Page 65: ...marily used for dispensers with mechanical STP leak detectors to allow the leak detector enough time to run its test 1 1 second 2 2 seconds 3 3 seconds 4 4 seconds 5 5 seconds 6 6 seconds 7 7 seconds...

Page 66: ...s Function Code 4 PPU Options 0 Level 1 price bar displays the level sent by console 1 Normal Level 3 Programming You must enter Level 1 and 2 before accessing Level 3 commands Level 1 Press Fl enter...

Page 67: ...Factor 0 No conversion factor 1 US Gallons 2 Imperial Gallons 3 Liters 4 1012 Pulses per gallon Function Code 2 Master Reset 0 No Master Reset 1 Master Reset Command Code 18 To Program Various Option...

Page 68: ...laying normal information Units with the option but not programmed for ATC will flash 100 To program the ATC option proceed as follows 1 Turn the programming switch on the ATC controller board to On N...

Page 69: ...re 301 Display Volume Correction Factor Meter Number Volume Correction Factor 302 Display Fuel Density Meter Number 730 Gas 840 Diesel 303 Display Temperature Meter Number Current Temperature 304 Disp...

Page 70: ...Not used 23 Grade Assignment Changed 24 Conversion Factor Changed Not Programmed 25 Two wire Standalone Mode Changed 26 No Conversion Factor Tape 27 Side A Two wire ID Changed 28 Side B Two Wire ID C...

Page 71: ...the installer to check the unit for accuracy and make the necessary adjustments Where required it is the owner s responsibility to report this device to the local Weights and Measures authority for in...

Page 72: ...s Position the lever to the desired setting and release Reinsert the cotter pin through the lever and plate Note If the lever will not move to the desired position rotate the right hand money wheel un...

Page 73: ...bly in this document Important Information about Releases Sections of this manual may be released independently of each other to supply the most current data Information about release date and version...

Page 74: ...mitting Diode PAM Pump Access Module PCA Printed Circuit Assembly may be used interchangeably with PCB PCB Printed Circuit Board may be used interchangeably with PCA POS Point of Sale PPU Price Per Un...

Page 75: ...T17328 G1 Pump Preset Display PCA P612 34 Cable R18944 G1from T17331 G1 Pump Preset PCA P413 34 to T17328 G1 Pump Preset Display PCA P612 34 Cable R19072 G1 from J921A to T18350 G3 Pulser Cable R19527...

Page 76: ...the Canadian market Fuse Q10131 03 Key Pad T17549 G1 Manager LCD T17701 G1 Main Display PCA 6 inch Power Supply T19868 G1 Main Pulser T18350 G3 Assembly Pump Controller T20092 G1 PCA Switch Q12514 10...

Page 77: ...63 01 Buzzer to Q12514 10 switch A1 PH B1 4 and B1 PH A1 4 to J921B and J921A to J1 3 to P1 Relays M04890A001 Ballast and 2 lamp assembly M04956A001 Relay Single A002 Dual M04956A005 Commercial ONLY R...

Page 78: ...from T20092 G1 Pump Controller PCA P205 16 to T18994 G1 Pump Interface PCA P305 16 R20128 G1 Cable from T20569 G1 OP ATC Control PCA P307 4 to Main Junction Box R20146 G1 Cable from T20092 G1 Pump Co...

Page 79: ...s a Pump Access Module PAM 1000 can be used to convert two wire communications to a usable format for other POS manufacturers who cannot connect directly to the two wire system Note To interface to th...

Page 80: ...mponents About Service Procedures About Service Procedures Figure 6 1 shows an example of a Front load and Side load Atlas 8800 Retail Unit The nozzle boot is located either on the front or side of th...

Page 81: ...age Fire explosion or electrical shock could result in severe injury or death if safety procedures are not strictly followed Do not smoke and prevent open flames in the pump area Promptly clean up spi...

Page 82: ...ontains a chemical known to the State of California to cause birth defects or other reproductive harm WARNING Replaceable Batteries Some PCBs contain replaceable batteries Insert all batteries correct...

Page 83: ...iption T18350 G3 Pulser Assembly T18994 G1 Hydraulic Interface PCA T19868 G1 Main Power Supply T20092 G1 Pump Controller PCA T17701 G1 Liquid Crystal Display LCD Main Display PCA While learning to ope...

Page 84: ...Figure 6 3 Atlas 9800 Series Block Diagram M07588A002 115 VAC without backup battery M07588A001 115 VAC with backup battery Atlas 9800 Power Supply Board P3 AC Input C06387 LCD Display Board P1 5 VDC...

Page 85: ...ry RAM connections for previous Atlas 9800K CPUs M05346A002 Dual 115 VAC and M05346A004 Dual 230 VAC Used on Models 9852K 9853K 9840K C06394 Dual 115 VAC and C06503 Dual 230 VAC Used on Models 9850K 9...

Page 86: ...Ultra High 9850K Liters C06426K9850L Ultra High 9850K Imperial Gallons C06426K9850M Figure 6 5 contains information regarding LEDs hose information switch locations and jump jack locations on the cur...

Page 87: ...9840K M06333K9840K CPU M06656K003 Standard 9800Q Models 9852A Q 9853A Q 9822A Q 9823A Q K M06333K9800AQ CPU M06656K004 Super High 9840Q Model 9840A Q M06333K9840AQ CPU M06656K005 Atlas 9800 Serial EE...

Page 88: ...ous Atlas 9800K CPUs TP1 P6 Totalizer P7 Relay Drive P8 RS 485 Pulser I F P10 Power Input P11 LCD Display Switch 1 Switch 2 TP2 P1 Hose 1 AC P2 Hose 2 AC P3 Pulser 1 P4 Handles P5 Pulser 2 P9 ISB PWR...

Page 89: ...4 Pulser 2 Pulser side B P4 4 M05105A001 Q12514 10 Pump Handle Switch A1 PH B1 4 Q12514 10 Pump Handle Switch B1 PH A1 4 P6 2 M05119A001 C01341 Sensor P7 3 Relay K1 3 and 4 Relay K2 3 and 4 P8 14 M05...

Page 90: ...9A002 Field Wiring Main Junction Box P2 14 Direct Connect M05346A002 115 VAC or M05346A004 230 VAC or M06333KXXXX 115 230 VAC P8 14 P802 2 M00455A002 Side A P803 2 M00455A002 Side B P804 3 M05108A001...

Page 91: ...ts Figure 6 12 M06587A001 Atlas 9800 Pulse out I F with EM Totalizer Board Notes 1 To be used with models 9850A Q K and models calling out for Dual Channel Dual Hose Pulse out I F not available on 985...

Page 92: ...Display Board has been shown to connect to the CPU Figure 6 14 C06387 Atlas 9800 LCD Display Boards Atlas 9800 Parts Atlas 9800 CPU Board M06333KXXXX The features of the Atlas 9800 Central Processing...

Page 93: ...9800K 9852K 9853K M06333K9850 9850 9850A 9850Q 9850K M06333K9840K 9840K 9840K M06333K9800AQ 9800Q 9852A Q 9853A Q 9822A Q 9823A Q K M06333K9840AQ 9840Q 9840A 9840Q Note The above software types can b...

Page 94: ...1 to 6 If the NOT OK LED illuminates after a second attempt call your service representative or contact Gasboy Technical Service 7 Disconnect AC power to the pump dispenser Remove the DC cable from th...

Page 95: ...ith the following 9800 CPU boards C06391 C06392 C06393 C06394 C06500 C06501 C06502 C06503 M05346A001 M05346A002 M05346A003 M05346A004 and M06333KXXXX Replaces previous 9800 power supplies as shown in...

Page 96: ...are on Atlas 9800 CPU board M06333KXXXX see Figure 6 15 on page 6 21 Serial EEPROM Board Software Type Pump Type M06656K001 9800K 9852K 9853K M06656K002 9850 9850A 9850Q 9850K M06656K003 9840K 9840K M...

Page 97: ...Figure 6 20 on page 6 31 Single Channel Dual Single Hose Pulse out I F see Figure 6 21 on page 6 31 Dual Channel Dual Hose Pulse out I F see Figure 6 22 on page 6 31 Compatible with models 9852K 9853K...

Page 98: ...llows RS 485 communications between the 9800 and a CFN System or TopKAT Electronic System Compatible with 9852K 9853K 9850K 9840K 9852A Q 9853A Q 9840A Q 9822A Q 9823A Q K Compatible with 9800 CPU Boa...

Page 99: ...Supply M07588A00X To install the Atlas 9800 Power Supply M07588A00X proceed as follows Always remove AC power from the pump dispenser before servicing the unit Failure to turn off the unit before serv...

Page 100: ...bly it must be replaced Refer to Installing the Atlas 9800 Power Supply M07588A00X on page 6 27 for details 2 Ensure that the AC power to the pump dispenser has been disconnected Remove the DC cable f...

Page 101: ...the screws 10 Re connect all the cables P1 to P9 and P11 if applicable Re connect the DC cable to P10 of the power supply 11 Apply power to the pump dispenser and take note of the display s The first...

Page 102: ...When configured for Dual Channel Single Hose Pulse out I F or Single Channel Dual Single Hose Pulse out I F the P3 connector is not connected When configured for Dual Channel Dual Hose Pulse out I F...

Page 103: ...le Hose Pulse out I F Pulse Side 1 Side 1B Output Side 1A Output Side 1A Return Side 1A Return Figure 6 21 Single Channel Dual Single Hose Pulse out I F Pulse Side 1 Pulse Side 2 Side 1 Output Side 2...

Page 104: ...e feed and 150 VDC for pulsers The interface receives 5 VDC from the Pump Controller PCA and supplies 120 VAC for the valve and STP signals Figure 6 23 shows the STP PCA layout that contains component...

Page 105: ...he technician must possess knowledge of the functions of components and how they relate to the system Figure 6 24 T20092 Pump Controller Atlas 8800 only AT_PumpPCA_controller P206 P207 P208 P201 P204...

Page 106: ...CD Display P801 34 Side A 2 places and Side B 2places P205 16 pin R19952 G1 T18994 G1 P305 16 P206 5 pin R19939 G1 T18994 G1 P306 5 P207 10 pin R19951 G1 T18994 G1 P307 10 P208 3 pin R20412 G3 J402 Fi...

Page 107: ...obes and meters used for temperature control are primarily for the Canadian market The ATC option measures the temperature of dispensed products and compensates for changes in the product volume due t...

Page 108: ...n the ATC is used T20569 ATC PCA Connections and Cables Connector via Cable to Assembly at Connector P204A T17768 G1 T17701 G1 P801 34 Side A 2 places and Side B 2 places P301 M02739A001 T20092 G1 P20...

Page 109: ...PTP5 16 P201 10 R20147 G1 T19428 G1 JIS 10 P203 16 R20148 G3 Probe 1 PTP5 16 T17549 G1 Manager Keypad Atlas 8800 only Figure 6 28 shows the Manager Keypad used in Atlas 8800 units to display pump tra...

Page 110: ...ight for the display of pump transaction information to the customer inside or at the pump Figure 6 29 T17622 G9 6 inch Display Backlight PCA Atlas 8800 only T17701 G1 LCD Display 6 inch Atlas 8800 on...

Page 111: ...n always use the correct replacement fuse CAUTION Figure 6 31 shows the ATC retail Atlas Cable M02739A001 from T20092 G1 Pump Controller PCA P205 16 and 207 10 to T20569 G1 OP ATC PCA P405 34 and P301...

Page 112: ...A1 4 PH A1 PH B1 J921A J405 J921B J921A Side B J921B PH B1 PH A1 Buzzer M04658A001 Cable Connector via Cable to Assembly at Connector T18994 G1 J405 20 M04658A001 R19072 G1 to T18350 G3 A side M04658...

Page 113: ...y uses a special voltage selector plug for establishing connections either to 115 VAC or 230 VAC systems Figure 6 33 T19868 G1 Main Power Supply 24 VAC To T18994 P308 2 Cable T9983 G1 To P302 6 LCD Ma...

Page 114: ...and dual pumps Figure 6 34 M04956A001 and 2 Relays Retail Commercial M04956A001_2 Relays For this Voltage Use this Plug 115 230 VAC P1 M04956A001 Single Retail Relay Assembly P1 3 115 230 VAC P1 M049...

Page 115: ...03 Fuse The size of the fuse used is 1 25 inches X 0 25 inches Electro mechanical Registers and Totalizers About Displays Depending on the configuration Atlas units may have electronic or mechanical r...

Page 116: ...f Atlas pumps there are two electronic totalizers one each on side A and side B The sides are connected by cable M04889A001 through 4 pin connectors J922A and J922B Figure 6 36 M00455A003 Electro mech...

Page 117: ...VAC single or dual layout containing the components related to the CPU T18994 G1 Pump Interface PCA Cable M04889A001 from T18994 G1 P405 20 to Q11763 01 Buzzer to Q12514 10 switch A1 PH B1 4 and B1 P...

Page 118: ...gure 6 39 shows the main V R Computer of the Mechanical PPU mechanism located in the side mounted Atlas unit Figure 6 39 Main V R Computer Atlas 8700 Electro mechanical Totalizer Assembly Read and fol...

Page 119: ...some time it is recommended that all backlight bulbs be replaced Others bulbs may be nearing the end of their service life Pulsers Read and follow all safety precautions in Read this First on page 1 1...

Page 120: ...y substitution or disconnect it and check the IS Barrier with an Ohmmeter 4 Measure 10 000 Ohms or 20 from gray to gray yellow to yellow brown to brown and orange to orange 5 Always read a low resista...

Page 121: ...moved during installation If the tie wrap is discovered on the pulser during a service it should be removed A tie wrap left in place can result in binding of the pulser shaft Event Logs can be used to...

Page 122: ...Page 6 50 MDE 4334C Atlas Start up and Service Manual April 2008 Electronic and Electrical Components Pulsers This page is intentionally left blank...

Page 123: ...other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of the document Refer to the Gilba...

Page 124: ...er GPU Global Pumping Unit GPM Gallons Per Minute LC Liquid Control PCV Pressure Control Valve PRV Pressure Relief Bypass Valve PSI Pounds of Pressure per Square Inch SAE Fasteners SAE Society of Auto...

Page 125: ...Retail Units A Center Flow Through CFT meter A new manifold and valve assembly A new pumping unit Figure 7 1 Dispenser and Pump Hydraulics Standard Models Solenoid Valve Filter Manifold Meter Air Gap...

Page 126: ...Meter Assembly Mechanical Computer Models Gallons Spare Parts item T20150 G6 See Note 1 CFT Meter Assembly Mechanical Computer Models Liters Spare Parts item T20150 G7 See Note 1 Meter Master Seal Ser...

Page 127: ...ef valve strainer sump system and control valve to prevent air metering Figure 7 3 Bennett Suction Pump Item Description Current Part Previous Part Quantity 1 Global Pumping Unit M04920B003 1 Per Grad...

Page 128: ...n result in severe injury or death if safety procedures are not strictly followed No cigarettes or open flames should be allowed near pumps or dispensers Ground the nozzle and prover can to prevent st...

Page 129: ...re at the station s STP and dispenser breakers 4 Open the nozzle into an approved container to bleed of the pressure Some residual pressure may remain Wear eye protection for hydraulic service where f...

Page 130: ...cannot be seen easily Pipes and Hydraulic Plumbing Follow these procedures when you work on piping Use Underwriters Laboratory UL approved pipe sealants suitable for the fuel involved for pipe threads...

Page 131: ...her grade of materials for load bearing devices For example structural and hydraulic device bolts The following tables provide general torque guidelines for plated steel screws and bolts pipe plugs an...

Page 132: ...ch 19 21 5 8 inch 26 29 3 4 inch 38 42 7 8 inch 49 54 Self contained Pumping Units Recommended Torque Unit in lbs Nm Pump head tightened in star pattern 200 23 Strainer cover 150 17 Rear cover 200 23...

Page 133: ...ly WARNING About the Purging System Purge air from the hydraulic system properly Failure to properly purge air from the system can damage components and result in inaccurate calibration and fuel deliv...

Page 134: ...and remove the line and petcock valve from the shear valve 8 Remove the hose from the test port Wear eye protection and exercise caution by removing the hose slowly with a cloth or by other means to...

Page 135: ...ing filters strainers and others 10 gallons 37 9 liters per hose To purge the pump dispenser proceed as follows 1 Lift the nozzle handle of the hose being purged 2 Place the nozzle in the approved con...

Page 136: ...e the hazard of fuel vapors that can be ignited from static discharge or other sources Maintain contact between the nozzle tip and prover can during all fueling procedures or use a grounding clip whil...

Page 137: ...e is too low Motors fail prematurely or stall pump only Units take a long time to prime pump only Units are noisy pump only The use of a combined vacuum and pressure gauge eliminates the need to carry...

Page 138: ...0 4 0 Test Point Location A Pressure Gauge in Shear Valve Dispenser only Location B Pressure Gauge in Filter Cap Port Special Discharge T fitting Location C Pressure Gauge in Discharge Fitting Measur...

Page 139: ...test to check the specific groups of parts meters shear valves filters and others An exceptionally high pressure drop for a specific flow rate indicates that a part is clogged or defective To measure...

Page 140: ...flow rate increases For dispensers Total System Pressure Drop Product Lift from bottom of STP to the dispenser base Pressure Drop through external piping Pressure Drop through dispenser including hos...

Page 141: ...ross nozzle and hose at full flow Use this table to evaluate the probable cause of dispenser low flow rate Low Flow Rate Symptom Probable Causes Observed pressure drop across the meter and valve is mo...

Page 142: ...m readings to determine if the pumping unit has the ability to move the product from the storage tank to the pump Inability to pull a vacuum may indicate that air is entering the system Use vacuum gau...

Page 143: ...ff power at the circuit breaker 8 Remove the gauge and install the plugs that may have been removed earlier using UL approved pipe sealant suitable for the fuel involved 9 Remove inlet plugs and recon...

Page 144: ...onfiguration Inlet Vacuum cmhg Discharge Pressure bar Flow Rate ipm Inlet Vacuum cmhg Discharge Pressure bar One Pumping Unit per Hose Standard Flow 10 2 25 4 1 0 2 1 37 50 10 2 17 8 1 3 2 4 High Flow...

Page 145: ...must be calibrated after installation and testing Use a five gallon prover for flow rates under 20 gpm 75 lpm If you use larger than five gallon prover cans the calibrating adjustment changes For del...

Page 146: ...the restraint seal wire from locking pin on the calibration wheel located on each meter Each adjacent pin hole represents 2 3 cubic inches 0 011 liter variance for a 5 gallon 18 9 liter measure Movin...

Page 147: ...adjust the measurement Moving the pin to one adjacent hole position changes the calibration by 2 3 cubic inch per five gallons dispensed To change by half this amount use the alternate locking pin hol...

Page 148: ...for Ultra Hi Models 9850K and 9850KX proceed as follows 1 Check the meter accuracy by delivering the product to a reliable and accurate 50 or 100 gallon or metric equivalent prover can Figure 7 12 98...

Page 149: ...nt M is the dispenser volume reading and A is the percent adjustment for the adjuster Meters Wear eye protection Residual pressure and entrapped fuel may still be present and may drain or spray while...

Page 150: ...e 7 13 CFT Meter Date and Model Code Location Assembled View of CFT Meter Service Tips Purge air from the system before performing a calibration Air in the system affects the accuracy of the calibrati...

Page 151: ...ng vapor recovery hoses can also result in calibration problems A top shaft seal kit to prevent leakage at extremely cold temperatures is available Repairing CFT Meters Before Beginning Work Before be...

Page 152: ...Air from the System on page 7 11 4 Calibrate the meter Replacing Cylinder Cover and Gasket Cylinder Cover Leaks Note Cork gaskets may show some staining Replace gaskets only when you note dampness or...

Page 153: ...g Housing O Ring To replace O Rings proceed as follows 1 Follow steps 1 to 3 in Before Beginning Work on page 7 29 2 Remove the body cover and lower bearing housing 3 Remove the O Ring s and install a...

Page 154: ...ou note an obvious leak Use new seals on reassembly Use steel screws for packing the retainer and do not overtighten Figure 7 16 Calibrating Wheel Parts Repair Packing Retainer Screw Adjust Cylinder C...

Page 155: ...il on the piston cup before closing 6 Reinstall the piston head Torque screws and apply Loctite 510 7 Install the cylinder cover with the new gasket Torque all meter bolts 8 Follow the steps in After...

Page 156: ...Cap Screws 3 Seal Cap Gasket Seal 1 Follow steps 1 to 3 in Before Beginning Work on page 7 29 2 Remove the pulser gears and connecting shafts if you cannot access the seal cap remove the meter 3 Ligh...

Page 157: ...icult to access A 13 mm universal socket makes installation and removal easier For calibration procedures refer to LC Meter Calibration Adjustment for Ultra Hi Models 9850K and 9850KX on page 7 26 Non...

Page 158: ...connect the pulser 3 Remove four bolts from the discharge casting 4 Remove four bolts on the inlet Note Support the meter while removing bolts 5 Remove the meter 6 Perform the necessary service on the...

Page 159: ...rator if water is in the tank For efficient operation and long life of pumps and dispensers replace fuel filters and clean strainers regularly After 50 000 gallons 189 000 liters or one month for new...

Page 160: ...uel filter options listed here are not sufficient for filtering aviation fuel Servicing Filters Before Removing Filters Before removing filters proceed as follows 1 Use OSHA Lock Out and Tag Out proce...

Page 161: ...and any involved STPs Remove parts slowly Collect fuel in approved containers Clean up all spills promptly Use an approved container to collect the residual fuel Use gasoline fuel approved absorbent m...

Page 162: ...ice Tips Only hand tighten the filter Do not use a filter wrench to tighten A light coating of oil on the gasket helps the seal to seat properly and allows for easier release at the time of removal Us...

Page 163: ...red alcohol Replace the strainer if it is damaged or partially clogged and not cleanable Always check clean the strainer when replacing a filter Ensure that you note the orientation of the tabs when r...

Page 164: ...spills Hose bulges are a sign of pressurized gasoline pushing against the cover A full rupture could occur at any time Use of teflon tape for NPT hose ends may result in damage to the dispenser outle...

Page 165: ...ist in the hose during disassembly and may cause fuel spray WARNING 6 Use a UL approved pipe sealant on hose coupling with NPT threads Follow all these recommendations Ensure that you follow the manuf...

Page 166: ...e The breakaway valve stops significant fuel drainage from the dispenser during drive offs if the nozzle or hose loop catches on the vehicle Always use UL listed breakaways For proper operation of the...

Page 167: ...on Be prepared for any residual pressure that may still exist in the hanging hardware 4 Check for damage to the nozzle especially the spout and threads 5 If the repair or replacement is the result of...

Page 168: ...er to the unit and open shear valves 9 Authorize the nozzle and check for leaks in the hose and plumbing especially the meter and filter 10 Purge the system of air See Purging Air from the System on p...

Page 169: ...not follow safety procedures Ensure that you correct any safety hazards and barricade the area Follow the manufacturer s instructions for the safe use operation and maintenance of the testing equipme...

Page 170: ...ct one probe to the nozzle spout and the other probe to the fuel outlet fitting at the outlet casting or other component grounded with the unit frame refer to Figure 7 23 For the probe to read properl...

Page 171: ...good contact Do not polish appearance parts such as sheet metal and so on If no problem exists isolate the defective part by performing continuity tests between and across the hose nozzle swivel brea...

Page 172: ...nut to secure Do not overtighten Always use appropriately sized padded or contoured plastic clamps for hoses Under sized clamps will damage the hose cover Figure 7 24 Replacing Retriever Reels Cables...

Page 173: ...ing on an inappropriate surface Figure 7 25 GPU Four Views Front View Side View Rear View General GPU Service Procedures This service manual contains basic service procedures for the GPU Note For addi...

Page 174: ...pumping unit To drain the GPU proceed as follows 1 Put an approved tray in place to collect the fuel 2 The pumping unit contains up to 0 5 liters 1 1 Pints or 0 53 Quarts of fluid 3 If sump drainage i...

Page 175: ...and may void warranty The strainer must be kept clean to ensure proper operation and to extend the life of the pumping unit Figure 7 27 Strainer Check Valve Side View Rear View Strainer Cover Pump Sh...

Page 176: ...inspect the gaskets 3 Insert the check valve assembly or strainer support into the corresponding pumping unit bore see Figure 7 27 on page 7 53 Press the assembly squarely over the receiving cylindri...

Page 177: ...l as fluid Excessive wear or a sticking PCV can cause improper pump performance including flow loss excessive or low discharge pressure or metering of air under a dry tank condition To remove a PCV pr...

Page 178: ...ice Tips PCVs normally fail from excessive wear or sticking Symptoms of failure may be reduced flow rate reduced pressure or metering of air with a dry tank The plug in the cap can be removed and a di...

Page 179: ...he Pump Bypass Preload It is not recommended to alter the bypass adjustment from the factory setting However if the flow rate is low and other means of increasing flow rate such as cleaning filters ha...

Page 180: ...ive wear Occasionally a seizure in the bore can result Wear seizure can result in either lower or very low flow or less commonly motor stalling and very occasionally noise If the pumping elements appe...

Page 181: ...ing unit Note For additional maintenance servicing and troubleshooting information of the XU2A refer to MDE 4320 Gasboy UHF Pump Blackmer XU2A Rebuild Kit Installation Manual General XU2A Service Proc...

Page 182: ...t a closed discharge valve for more than a minute Draining the Pump To drain the pump run the pump with the discharge valve open and intake valve closed Bleed air into the pump through the intake gaug...

Page 183: ...luded to indicate part identification 1 To increase the pressure setting remove the relief valve cap 1 and gasket 88 if equipped Turn the adjusting screw 2 inward or clockwise Inspect the PRV cap gask...

Page 184: ...on at other locations can cause flow or sump overflow problems Ask Gasboy for the valve type and follow the manufacturer s instructions completely for installation Sump Overflows Use the following tab...

Page 185: ...t activates and turns the motor back on Motors do not require a manual reset The 220 380 VAC motors do not have a thermal overload switch If overload shut off occurs frequently Check the voltage switc...

Page 186: ...nsion can cause premature belt failure noise or pulley failure as well as reduced flow rate Belts and pulleys can pinch fingers and hands Injuries may result Avoid placing fingers or hands between bel...

Page 187: ...cessive wear in grooves excessive pulley to shaft clearance or excessive bearing play Cracks and so on Adjusting the Belt To adjust the belt proceed as follows 1 Loosen the two shoulder bolts at the b...

Page 188: ...e due to thermal expansion which could damage parts or make nozzles difficult to open Solenoid Valves Solenoid valves use a solenoid coil to open or close a valve Valves of this type are either fully...

Page 189: ...for dispensers 2 Shut off power to the unit and for any involved STPs in the dispensers Use OSHA Lock out Tag out procedure 3 Open the nozzle into an approved container to bleed of any pressure Some...

Page 190: ...ARNING About Valve and Filter Manifolds The Valve and Filter manifold connects to the meter inlet and provides filtration upstream of a built in 1 2 stage solenoid valve Filters should be selected and...

Page 191: ...ream of the meter Figure 7 32 Valve and Filter Manifold RTD Probe Port Thermowell Port ATC Only Inlet from Feedline Filter and Strainer Adapter Discharge to Meter Diaphragm Replacement Coil Replacemen...

Page 192: ...a may determine your service philosophy High labor costs favor replacement Difficult removal from unit favors partial rebuild in the unit Gasboy recommends the following services for average or lower...

Page 193: ...ter Manifold Check Valve O Ring Meter Potential Problems Damage to hydraulic parts can occur from thermal expansion or driving over a hose if the valve is inoperative If a valve sticks open a sale may...

Page 194: ...ench to apply force to the fitting CAUTION UL requires all dispensers to use shear valves Follow these recommendations while installing or servicing shear valves Read and follow the shear valve manufa...

Page 195: ...e bottom of the valve to connect to the service system piping Note This configuration is for the Atlas Model 9850KXTW1 only All other Atlas models should use a standard inlet configuration All shear v...

Page 196: ...y hand several times Place the valve back in service T 52A Pressure Regulator Valve Option The Model T 52A PRV is a unique control valve developed for use with suction type island dispensers It can be...

Page 197: ...equire as do all mechanical parts occasional cleaning and lubrication when in service The intervals at which this should be done vary with conditions of operation Under normal conditions service of co...

Page 198: ...Page 7 76 MDE 4334C Atlas Start up and Service Manual April 2008 Hydraulic Mechanical Components Mechanical Computers This page is intentionally left blank...

Page 199: ...2007 Topics in this Section Topic Page Troubleshooting Tables Commercial Electronic and Retail Electronic Units 8 2 How to Use this Section Example A customer calls and says I don t have any displays...

Page 200: ...ections A 20 Display boards Table 3 Displays and Electronic Resets Bulb Backlight Cable Cable Connections Coll Solenoid Valve Displays 5 7 9 No display some boards A Troubleshooting Troubleshooting Fo...

Page 201: ...and so on first Letters toward the other end of the scale have been reported less frequently but can still be an issue Avoid repeating the same repair if the symptoms remain unchanged after attempting...

Page 202: ...ong for Application Firmware Pump Interface Board Master Reset Required Power Supply Main Power to Unit Missing Programming Console Programming Unit Retail Units Pump Interface Board Switch Power Pump...

Page 203: ...re Low Diesel Valve Solenoid Hydraulics Valve Meter Check Valve Shear Valve STP Dispenser Line Check Vapor Line Back Pressure Vibration Bad Mounting CPU Board CPU Switch Settings Delivery Product 2 7...

Page 204: ...Switch Settings Totalizer Bad Totalizer PCB RAM Mechanical Computer Bad Displays Electronic 7 9 10 13 14 20 41 50 52 55 66 68 77 83 85 86 96 98 46 Displays Don t Come On Immediately C D A Error Codes...

Page 205: ...Communication loss error A C D 12 No communication with dispenser A 20 Pulser fail single B C B A 21 Pulser fail all B A B C 23 Grade assignment changed B A 24 Conversion factor changed C B A 25 Two w...

Page 206: ...Inlet Pressure Regulating Vibration Bad Mounting CPU Board Reset Electronic Mechanical Handle Responses 2 7 10 14 16 19 28 29 39 50 51 52 55 58 61 62 66 68 75 77 79 84 89 90 97 101 106 108 113 No res...

Page 207: ...ervice Procedure Poor STP Switch power Pump Handle Temperature Low Diesel Valve STP Dispenser Line Check Vibration Bad Mounting Water Intrusion Possible Wiring Error CPU Board CPU Switches Repeated Pr...

Page 208: ...Troubleshooting Tables Troubleshooting Tables Commercial Electronic and Retail Electronic Units Page 8 10 MDE 4334C Atlas Start up and Service Manual April 2008 This page is intentionally left blank...

Page 209: ...ased independently of each other to supply the most current data Information about release date and version for independently released sections will be included in the section title and footer of the...

Page 210: ...1 Mechanical Single facing Junction Box Display both Sides Totalizer this Side Mechanical Single facing Junction Box Mechanical Single Opposite Junction Box Side Figure 9 2 Electronic Single Side load...

Page 211: ...3 Electronic Single Front load facing Junction Box Blank Bezel Totalizer this Side Display this Side Electronic Single Front load facing Junction Box Electronic Single Front load opposite Junction Bo...

Page 212: ...up and Service Manual April 2008 Figure 9 5 Electronic 1 Grade 2 Hose Side load facing Junction Box Totalizer this Side Hose 2 Display Hose 1 Display Air Gap Grille Figure 9 6 Electronic 1 Grade 2 Hos...

Page 213: ...rations Wiring and Configuration Figure 9 7 Mechanical 2 Grade 2 Hose facing Junction Box GR1 Totalizer this Side GR2 Opposite Side GR1 Display GR2 Display Figure 9 8 Electronic 2 Grade 2 Hose Side lo...

Page 214: ...Atlas Start up and Service Manual April 2008 Figure 9 9 Electronic 2 Grade 2 Hose Front load facing Junction Box Air Gap Grille GR2 Display GR1 Opposite Side GR2 Totalizer this Side GR1 Opposite Side...

Page 215: ...tronic Super Hi Side load facing Junction Box Display both Sides Air Gap Grille Totalizer this Side Figure 9 12 Electronic Super Hi Front load facing Junction Box Electronic Super Hi Front load facing...

Page 216: ...e 9 8 MDE 4334C Atlas Start up and Service Manual April 2008 Figure 9 13 Combo Unit facing Junction Box Combo Unit facing Junction Box Combo Unit opposite Junction Box Side Satellite Inlet Master Inle...

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Page 218: ...al April 2008 ExxonMobil is a registered trademark of Exxon Mobil Corporation Co Vent and Gilbarco are registered trademarks of Gilbarco Inc Loctite is a trademark of Henkel Loctite Corporation Optimu...