Gasboy 4860 User Manual

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SERIES 4860

METER-REGISTER

INSTALLATION/OPERATION/PARTS

MANUAL

035352

Rev. 03/07/03

INSTALLERS - IMPORTANT

In addition to installation information, this manual contains warnings, safeguards
and procedures on the use and care of the Series 4860 Meter-Register. Please
leave this manual with the meter owner after the installation is complete.

Copyright 2003 by Gasboy International LLC All rights reserved.
The information in this document is confidential and proprietary. No further disclosure shall be made without
permission from Gasboy International LLC Gasboy International LLC believes that the information in this document
is accurate and reliable. However, we assume no responsibility for its use, nor for any infringements of patents or
other rights of third parties resulting from its use. We reserve the right to make changes at any time without notice.

GASBOY INTERNATIONAL LLC LANSDALE, PA

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IMPORTANT WARNINGS AND SAFEGUARDS

Gasoline and petroleum products are flammable. To avoid injury or death to persons or damage to equipment or
property, follow these listed warnings and other warnings and precautions outlined in this manual when installing, using,
or working around this equipment. Check with GASBOY Technical Services for compatibility of liquids with pump
materials.

TURN OFF AND LOCK OUT ALL POWER TO PUMP BEFORE PERFORMING SERVICE, MAINTENANCE OR IN THE EVENT

OF A FUEL SPILL.

All products must be installed by a
qualified installer and used in
conformance with all building, fire, and
environmental codes and other safety
requirements applicable to its
installation and use, including, but not
limited to, NFPA 30, NFPA 30A, NFPA
395 & NFPA 70. A qualified installer is
familiar with fuel systems installations
under the above stated building, fire,
and environmental codes and other
safety requirements for the particular
type of installation.

This product is only part of a fuel
dispensing system and additional
equipment and accessories, such as,
but not limited to, breakaway
connectors, shear valves, pressure
regulators, flow limiters, and other
safety devices may be necessary to
meet the applicable codes.

For maximum safety, we recommend
that all employees be trained as to the
location and procedure for turning off
power to th e en tir e syste m. Instr ucti ons
regarding proper operation of the
equipment along with the appropriate
safety warnings should be posted in
plain view at the fuel island.

Before performing service or
maintenance (including changing of fuel
filters or strainers) or in the event of a
fuel spill, turn off and lock out all power
to the system. In battery-powered
pumps, disconnect power source. In
submersible pump applications, turn off
and lock out power at the master panel
and close any impact valves to the
submersible pump and any other
dispensers which use that submersible
pump. AC power can feed back into a
shut-off dispenser when dispensers
share a common submersible pump or
starter relay. Also block islands so no
vehicles can pull up to the dispenser
when the dispenser is being worked on.

DO NOT use Teflon tape for any pipe
threads in the product.

DO NOT use consumer pumps for
pumping fuel or additives into aircraft.

DO NOT use commercial pumps for
direct fueling of aircraft without filters
and separators necessary to ensure
product purity.

DO NOT use where sanitary design is
required (for food products for human
consumption) or with water-based
liquids.

DO NOT smoke near the pump or when
using the pump.

DO NOT use near open flame or
electrical equipment which may ignite
fumes.

DO NOT permit the dispensing of
gasoline or other petroleum products
into a vehicle with its motor running.

DO NOT permit the dispensing of
gasoline or other petroleum products
into unapproved containers or into
approved containers in or on vehicles
including tru cks. All co ntai ners must be
filled on the ground to prevent static
discharge. Always use Approved and
Listed hoses and nozzles with electric
pumps and dispensers.

DO NOT block open the nozzle in any
manner. Nozzles shall conform to UL
and NFPA code requirements for
attended or unattended service.

DO ensure that the pump is equipped
with proper filters based on the product
being dispensed and its intended use.

DO wear safety goggles and protective
clothes when dispensing any liquid
which may be potentially harmful or
hazardous.

DO keep all parts of body and loose
clothing clear of belts, pulleys, and
other exposed moving parts at all times.

DO require washing and changing of
clothes if fuel is spilled on a person or
his/her clothing. Keep away from open
flames, sparks, or people smoking.

DO provide a receptacle for catching
product from pump/meter when
servicing.

DO clean up product spills on the
driveway. Turn off and lock out all
power prior to cleanup.

DO insure pump is properly grounded.
DO insure hose is compatible with fluid

being dispensed.
DO inspect hose, nozzle, and pump on

a regular basis for wear, damage, or
other conditions which may create a
safety or environmental hazard.

DO make sure all pipe threads are
properly cut and the inside reamed to
remove burrs. Use UL classified
gasoline-resisting compound on all
joints of gasoline handling piping.
Sealing compound must also be
resistant to Gasohol (Ethanol and
Methanol). Use gasoline-resistant pipe
compound on male threads only; pipe
compound used on female threads can
be squeezed into the supply line where
it can enter the product stream and
become lodged in the pump or meter.

DO ensure that junction box covers are
in place and properly tightened. Mating
surfaces between the box and cover
must be free of dirt, nicks, and
scratches. All unused entries into the
junction box must be properly plugged.

035282 Rev. 1267

GASBOY INTERNATIONAL LLC

707 North Valley Forge Rd. Lansdale, PA, 19446 ● [phone] ● FAX: [phone]

INSTALLATION/OPERATION/PARTS

INSTALLATION

The 4860 meter can be installed either vertically or horizontally in a piping system. The inlet and
outlet are 90
strainer in the meter inlet to prevent jamming from foreign material. A 40 mesh or finer basket is
required.

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apart and can be rotated in relation to the register by 90o increments. Install a

OPERATING CHARACTERISTICS

The 4860 meter uses a nutating disc type measuring chamber and can be calibrated using an
adjusting screw. The pushbutton register records in gallons or liters up to 999 9/10. The totalizer
is a 7-wheel counter which records up to 999,999.9 gallons or liters. Pushing in the reset button
resets the four-wheel register to zero. Change gears permit the meter to be US gallons or liter
measure. The 4860 meter will accurately measure liquids with viscosities of less than 120 SSU

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(60

F) (16oC) at flow rates fr om 4 to 15 G PM or 15 to 57 LPM. Although designed specifically for
petroleum products, the 4860 meter can be used in applications where the materials are
compatible with recommendations of the manufacturer of the chemical or substance under
consideration.

CALIBRATION

NOTES: This meter was redesigned causing the calibration procedure to be different depending

on the age of your meter. Meters made after May 10,1995 are referred to as new style
meters; meters made before that date are referred to as old style.

This meter is for consumer use only and not for re-sale. It is not sealable by Weights
and Measures.

All GASBOY meters are adjusted for accurate measure for diesel within +
factory. However, since the conditions of the installation can affect pump accuracy, it is the
responsibility of the installer to check the pump for accuracy and make any needed adjustments.

Choose the flow rate at which the meter will be used most often for the zero calibration point. For
example, if the pump is being used with an automatic nozzle, calibrate with the nozzle set on the
middle or top notch position, whichever is used most frequently.

Use a certified five-gallon measure with a sight glass and scale showing cubic inches over or
under an exact five gallons. Fill and drain the test measure to completely wet the interior surfaces.
Reset the register to zer o and deliver an exact measured five gallons into the test measur e at the
selected flow. Read the level of the liquid in the sight glass on the scale in +

03/07/03 1

.05 gallons at the

cubic inches.

GASBOY Model 4860 Meter

For old style meters only, remove cap
screw, exposing the slotted head
calibration screw. Use a narrow blade
screw driver to turn the calibration screw
clockwise to correct for plus cubic inches
or counterclockwise for minus cubic inches
in the test measure.

Count the number of full turns and
fractional turns each time for reference in
judging the number and direction of any
additional turns required to calibrate the
meter to exact zero.

For new style meters, start with the screw turned all the way in clockwise. For gasoline
calibration, turn the screw approximately two full turns counter-clockwise. For diesel, turn the
screw approximately two additional full turns counter-clockwise.

Replace the cap screw (old style only) . Deliver about 1/2 gallon thr ough the meter before r esetting
to zero and retesting. Allow a ten second drain period each time the test measure is emptied to
assure accurate measure. Adjust and retest until register is zeroed at desired flow.

SERVICE

WARNING:

To reduce the risk of electrical shock when servicing, turn off and lock out all
power to the meter/pump.

NOTE: Numbers in parentheses correspond to the numbers shown on the parts illustration and

To service the pushbutton register, remove two (one on each side) screws (2) from bezel (1).
Remove bezel (1), gasket (3), and dial mask (4). Reset button (5) and spring (6) are released
when dial mask is removed. Remove screws (7), reset bearing (8 ) and screws (11) and lift out
register assembly. Drive shaft assembly (12) may be removed by taking out four bearing screws.

Replacing Bearing and Seal Assembly (Item 16, Old Style)

To replace the shaft seal or service the gear train on back of register housing (18), remove
housing from meter body by taking out four screws. NOTE: The meter housing will be full of liquid
so some means should be available to catch what drains from the case and lines. To remove
gears (22-25), remove three retaining rings (20) and dr ive key (21). Withdraw the drive shaft and
gear (14), spacer (15), meter stuffing box (16), and O-ring (17). Slide new O-ring over new
bearing seal like you would slide a ring on your finger. Insert shaft (14) through spacer (15) and
bearing (16) as shown in the exploded view. Press entire assembled shaft and seal through
housing and seat the square of the bearing firmly into the recess in the register housing (18).
Reassemble the balance of the register in reverse order of disassembly.

parts list on pages 4 and 5.

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