Gasboy 61 Special Installation Instructions Manual

Model 61 Special

Installation Instructions

MDE-4445

(formerly 031232)

Company Programs and Documentation

All Gasboy computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall remain the property of, Gasboy. Such computer programs and documents may also
contain trade secret information. The duplication, disclosure, modification, or unauthorized use of computer programs or documentation is strictly prohibited, unless otherwise licensed by Gasboy.

FCC Warning

This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate this equipment.

Approvals

Gasboy, Greensboro, is an ISO 9001:2000 registered facility.

Underwriters Laboratories:

U.L. File# Products listed with U.L. NYFD of A # Product

MH4314 All dispensers and self-

MH6418 Power operated Transfer

MH7404 Hand operated Transfer

MH10581

Card reader terminals,

Site controller, Model 2000S

Data entry terminals, Model

Fuel Point Reader System

NCWM – Certificate of Compliance

Gasboy pumps and dispensers are evaluated by the National Conference of Weights and Measures (NCWM) under the National Type Evaluation Program (NTEP).
NCWM has issued the following Certificates of Compliance (COC):

contained pumping units

Pump Models 25, 25C, 26, 27,
28, 72, 72S, 72SP, 72X, 73
and 1820

Pump Models 1230 Series,
1243 Series, 1520 and 1720
Series

Key control unit, Model GKE-

B Series

Models 1000, 1000P

CFN Series

TPK-900 Series

COC# Product Model # COC # Product Model # COC # Product Model #

95-179A2 Dispenser

95-136A5 Dispenser 9800 Series

9100 Retail Series,
8700 Series, 9700 Series

Patents

Gasboy products are manufactured or sold under one or more of the following U.S. patents:

Dispensers

5,257,720

Point of Sale/Back Office Equipment

D335,673

Trademarks

Non-registered trademarks Registered trademarks

Atlas™
Consola™
Infinity™

New York
City:

4823 9100A, 9140A, 9152A,

4997

5046 9100Q, 9140Q, 9152Q,

91-019A2

91-0573A3

®

ASTRA

Fuel Point
Gasboy

®

Keytrol
Slimline

®

®

®

9153A,
9800A, 9840A, 9850A,
9852A,
9853A, 9140

9822A, 9823A

9153Q,
9800Q, 9840Q, 9852Q,
9853Q

Dispenser

Dispenser

California Air Resources Board (CARB):

Executive Order # Product

G-70-52-AM

G-70-150-AE

9100 Commercial Series

1000 Series FMS,
2000-CFN Series

Additional U.S. and foreign trademarks
pending.

Other brand or product names shown may
be trademarks or registered trademarks of
their respective holders.

Additional U.S. and foreign patents
pending.

Balance Vapor Recovery
VaporVac

This document is subject to change without notice. • For information regarding Gasboy Literature, call [phone]
E-mail: [e-mail] • Internet: http://www.gasboy.com
2005 GASBOY • All Rights Reserved

IMPORTANT WARNINGS AND SAFEGUARDS

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.

heck with Gasboy Technical Services for compatibility of liquids with pump materials. C

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

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

nstallation.

i
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 tha t
all employees be trained as to the location
and procedure for turning off power to the
entire system. Instructions regarding
proper operation of the equipment along
with the appropriate safety warnings
should be posted in plain view at the fuel

sland.

i
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 performing maintenance on the
dispenser.

DO NOT use Teflon tape for any pipe

hreads in the product.

t
DO NOT use consumer pumps for

umping fuel or additives into aircraft.

p
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

onsumption) or with water-based liquids.

c
DO NOT smoke near the pump or when

using the pump.
DO NOT use near open flame or electrical

quipment which may ignite fumes.

e
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
trucks. All containers must be filled on
the ground to prevent static discharge.
Always use Approved and Listed hoses
and nozzles with electric pumps and

ispensers.

d
DO NOT block open the nozzle in any

manner. Nozzles shall conform to UL and
NFPA code requirements for attended or

nattended service.

u
DO ensure that the pump is equipped with

proper filters based on the product being

ispensed and its intended use.

d
DO wear safety goggles and protective

clothes when dispensing any liquid which

ay be potentially harmful or hazardous.

m
DO keep all parts of body and loose

clothing clear of belts, pulleys, and other

xposed moving parts at all times.

e

A FUEL SPILL.

DO require washing and changing of

clothes if fuel is spilled on a person or
his/her clothing. Keep away from open

lames, sparks, or people smoking.

f
DO provide a receptacle for catching

roduct from pump/meter when servicing.

p
DO clean up product spills on the

driveway. Turn off and lock out all power

rior to cleanup.

p

DO ensure pump is properly grounded.
DO

ensure hose is compatible with fluid

eing dispensed. b

DO inspect hose, nozzle, and pump on a
regular basis for wear, damage, or other
conditions which may create a safety or

nvironmental hazard.

e
DO make sure all pipe threads are

properly cut and the inside reamed to
remove burrs. Use UL classified gasoline­resisting 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.
Properly plug all unused entries into the
junction box.

MDE-4445 Model 61 Special—Installation Instructions • March 2005 Page 1

Model 61 Special—Installation Instructions

Model 61 Special—Installation Instructions

NOTE: Apply a gasoline resistant pipe sealant to all male threads prior to assembly.

The 1” x 90” street elbow and the 1” x ¾” reducer are shipped loose. Follow the appropriate installation
diagram below.

Installation Without Filter

1 x 3/4 REDUCER BUSHING
017270
1 X 90 STREET ELL
024941

Installation With Filter

CUSTOMER-SUPPLIED

1 X 45 STREET ELL

CUSTOMER-SUPPLIED

REDUCER BUSHING

FILTER

1 X 3/4

017270

1" PIPE NIPPLE

CUSTOMER-SUPPLIED

1 X 90 STREET ELL
024941

Page 2 MDE-4445 Model 61Special—Installation Instructions • March 2005

Model 61 Special—Installation Instructions

Installation on a Tool Cabinet/Utility
Tank

This installation requires a socket adapter,

1 X 90 STREET ELL

024941

REDUCER BUSHING

1 X 3/4

017270

003835, and a lock nut, 039163 (not
provided). Thread the suction pipe
assembly into the socket adapter. Thread
the locknut into the socket adapter and
thread the completed unit into the 2” tank
flange. Thread the pumping unit into the
socket adapter. Lock pumping unit into
position by tightening lock nut against the
2” flange.

SUCTION PIPE ASSEMBLY

M03681A002

7300 West Friendly Avenue, P.O. Box 22087, Greensboro, NC 27420 • 1-800-444-5529

MDE-4445 Model 61 Special–Installation Instructions • March 2005 Page 3

GASBOY

GASBOY WARRANTY POLICY STATEMENT

(Limited Warranty)

New Product WARRANTY

GASBOY GUARANTEES NEW SERVICE STATION EQUIPMENT MANUFACTURED BY

GASBOY IN ACCORDANCE WITH THE PROVISIONS STATED BELOW:

Gasboy will repair or replace parts and equipment found to be defective in materials or workmanship during the warranty period, subject to the following:

• Labor and travel costs incurred by the Authorized Service Contractor (ASC) while servicing Gasboy equipment are included, unless excepted, and will be paid at previously contracted rates to the qualified
ASC.

• Warranty services must be performed by the nearest Authorized Service Contractor qualified to perform service on the defective equipment.

• Gasboy will supply new or rebuilt parts to replace parts which are found to be defective within the warranty period. Parts returned to Gasboy must be shipped with transportation charges paid and will be

replaced with parts with transportation charges prepaid by Gasboy.

• New Equipment installations must be registered with the Gasboy Call Center within 24 hours of installation to receive full warranty benefits; otherwise, the warranty period commences at the date of invoice.

• Warranty service response time is 24 hours from time service is requested, Monday through Friday (8:00 am until 5:00 pm), excluding weekends. Emergency warranty response time is on-site within 4 hours.

Hazardous warranty response time is on-site within one hour. Priority situations, emergency and hazardous, include imminent release of hazardous of dangerous materials, situations with imminent danger to
life or property, and a complete site-down situation or 50 percent or more of the fuel dispensing capacity for any one product is inoperative. Overtime will be paid for priority situations only occurring outside
routine warranty service hours.

• Warranty repair requiring rented equipment, overtime premium, lodging or charter travel must be approved in advance of service expenditure by the Gasboy Warranty Administration Department.

Commercial Pumps and Dispensers, Full -Cabinet Consumer Pumps

Commercial Pumps and Dispensers, Full-Cabinet Consumer Pumps are warranted against defects in material and workmanship for one year from date of installation or 24 months from date of original invoice,
whichever occurs first. Warranty coverage includes parts and labor.
Exclusions: This warranty excludes hose breakaways, nozzles, hoses and fittings, nozzle-end swivels, retriever cables, graphics materials specified by the customer, fuel filters, belts adjustments, meter calibration,
fluorescent lamps, vapor recovery testing and balance system piping, customer-specified items manufactured by others, and customer requested reprogramming of equipment. Some of these excluded items may be
warranted by their manufacturer, and warranty claims in connection with these items should be presented directly to the manufacturer.

Small Transfer Pumps, Meters, Pressure Regulators New Spare Parts

Small Transfer Pumps, Meters and Pressure Regulators are warranted against defects in material and
workmanship for 24 months from date of installation or 30 months from date of original invoice, whichever
occurs first. Non-registered equipment warranty will default to invoice date. The warranty covers parts only.
Excepting the Model 2020 Hand Pump, which has a 90-day part warranty from date of original invoice.

All new spare parts or warranted replacement parts are warranted against defects in material
and workmanship for one year from date of original invoice. The warranty covers parts
only.

Keytrol

The Keytrol is warranted against defects in material and workmanship for one year from date of installation or 24 months from date of original invoice, whichever occurs first. Warranty coverage includes parts and
labor

Fuel Management Systems Fuel Management Systems

CFN/Profit Point, Series 1000/FleetKey, TopKAT, and factory installed Fuel Point Reader are warranted
against defects in material and workmanship for one year from date of installation or 24 months from date of
original invoice, whichever occurs first. Warranty coverage includes parts and labor.
Standalone and Retrofit Fuel Point Readers, and Fuel Point-vehicle and dispenser components are warranted
against defects in material and workmanship for one year from date of installation or 24 months from date of
original invoice, whichever occurs first. The warranty covers parts only.
The warranty for field installed/retrofitted Fuel Point Readers is non-transferable. The removal and installation
of such components into another pump/dispenser will void the warranty.

Peripherals (Modems, CRT's, Flat Screen, Scanner, PIN Pad, Customer Display, ) are
warranted against defects in material and workmanship for one year from date of installation
or 24 months from date of original invoice, whichever occurs first The warranty covers parts
and labor.
Printers (Logger, Receipt, etc.) are warranted against defects in material and workmanship
for 90 days from date of installation or 180 days from date of original invoice. The warranty
coverage is parts and labor.
Peripherals (Encoders and Embossers) are warranted against defects in material and
workmanship for six months from date of original invoice. The warranty covers parts only.

General Exclusions

1. Problems caused by faulty installation are not covered by this warranty. This warranty applies only if equipment has been installed and used in accordance with Gasboy Installation, Operating and Service

Instructions. Problems caused by improper maintenance of equipment are not covered by this warranty.

2. Use of service personnel other than qualified Gasboy service providers without prior approval of the Warranty Administration Department will void payment of the warranty claim in question.

3. Damage suffered by Gasboy's equipment resulting from shipping, accident, power surges, neglect, misuse, act of Nature, or abuse is not covered by this warranty.

4. Use of non-Gasboy replacement parts, defects caused by the unauthorized addition of non-Gasboy items to Gasboy equipment or by the unauthorized alteration of Gasboy equipment voids this warranty.

5. THIS WARRANTY DOES NOT COVER ANY INDIRECT DAMAGES OR LOSS OF PRODUCT OR REVENUE. Repair or replacement of the defective part or component under the terms of this warranty

is the EXCLUSIVE REMEDY. Gasboy is not liable for incidental, consequential or indirect damages or loss, including without limitation personal injury, death, property damage, environmental damages,
product damages, loss of product, or loss of revenue or profits. Gasboy is not liable for any claims or lawsuits against the customer.

6. This warranty does not cover any pump or dispenser components in contact with fuels containing more than 5% methanol or 10% ethanol or 15% MTBE by Volume. This warranty does not cover any

component(s) exposed to M85/E85 fuel or other alcohol rich fuel.

THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND THERE ARE NO OTHER EXPRESSED, IMPLIED OR STATUTORY
WARRANTIES. WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY
EXCLUDED.

GASBOY • Warranty Department F-43 • 7300 W. Friendly Ave., P.O. Box 22087 • Greensboro, NC 27420 • Phone [phone] • Fax: [phone]

MDE-4255B 03/05 Printed in U.S.A