Gasboy 9120K User Manual
9120K and 9820K Series AST Pumps
Service and Parts Manual
MDE-4616B
Computer Programs and Documentation
Federal Communications Commission (FCC) Warning
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.
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 (UL):
UL File# Products listed with UL
MH4314
MH6418
MH7404
MH10581 Key con t r o l u n i t , M o d e l G K E - B S e r i e s
All dispensers and self-contained pumping
units
Power operated Transfer Pump Models 25,
25C, 26, 27, 28, 72, 72S, 72SP , 72X, 73 and
1820
Hand operated Transfer Pump Models 1230
Series, 1243 Series, 1520 and 1720 Series
Card reader terminals, Models 1000, 1000P
Site controller, Model 2000S CFN Series
Data entry terminals, Model TPK-900 Series
Fuel Point Reader System
New York City Fire Department (NYFD):
NYFD C of A # Product
4823 9100A, 9140A, 9152A, 9153A,
4997 9822A, 9823A
5046 9100Q, 9140Q, 9152Q, 9153Q,
5087 8753K, 8853K, 9153K, 9853K
5091 8752K, 9152K
5129 9122K, 9123K, 9822K, 9823K
9800A, 9840A, 9850A, 9852A,
9853A, 9140
9800Q, 9840Q, 9852Q, 9853Q
(restricted to diesel and nonretail gasoline sales)
National Conference of Weights and Measures (NCWM) - Certificate of Compliance (CoC):
Gasboy pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program (NTEP). NCWM has issued the following CoC:
CoC# Product Model # CoC# Product Model # CoC# Product Model #
95-179 Dispenser
95-136 Dispenser 9800 Series 91-057 Controller
9100 Retail Series, 8700
Series, 9700 Series
91-019 Dispenser
9100 Commercial
Series
1000 Series FMS,
2000S-CFN Series
California Air Resources Board (CARB):
Executive Order # Product
G-70-52-AM Balance Vapor Recovery
G-70-150-AE VaporVac
05-002 Atlas
8700K, 8800K,
9100K, 9200K, 9800K
Patents
Gasboy products are manufactured or sold under one or more of the following US patents:
Dispensers
5,257,720
Point of Sale/Back Office Equipment
D335,673
Trademarks
Non-registered trademarks
Atlas™
Consola™
Infinity™
Registered trademarks
ASTRA
Fuel Point
Gasboy
Keytrol
Slimline
Additional US and foreign patents pending.
®
®
®
®
®
Additional US and foreign trademarks pending.
Other brand or product names shown may be
trademarks or registered trademarks of their
respective holders.
This document is subject to change without notice. · For information regarding Gasboy Literature, call (336) 547-5661
E-mail: literature@gasboy.com · Internet: http://www.gasboy.com
© 2008 GASBOY · All Rights Reserved
Table of Contents
1 – Introduction 1
Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Model 9120K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Model 9820K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 – Important Safety Information 5
3 – Preventive Maintenance 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Hints for Better Pump Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Demand Competent Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Use Gasboy Authorized Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Operate with Reasonable Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Keep Water Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Clean the Dial Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Clean the Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Change the Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Power Reset External Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Adjust the Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Preserve the Finish of Your Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4 – Parts 13
Base and Motor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Meter Shelf, J-Box, and 9123 Register, Reset and Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Reset/Register Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Pulser Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Junction Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
9823 Pulser, Totalizer and Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Panels, Remote Register, Mounting Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
9123K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
9823K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Remote Register - Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Remote Register - Side View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Remote Register Chassis Assembly - Top View . . . . . . . . . . . . . . . . . . .32
Remote Register Chassis Assembly - Front View . . . . . . . . . . . . . . . . . .33
Remote Register Mounting Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Series Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008 Page i
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Page ii MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008
Purpose Introduction
1 – Introduction
Purpose
This manual is provided to assist the Gasboy Authorized Service Contractor (ASC) in
servicing the following units used with Aboveground Storage Tanks (ASTs):
• 9120K compact mechanical commercial pump
• 9820K electronic commercial pump
This manual also provides the parts list for the 9X20K units.
Note: Whenever information in this document applies to all the units listed above, the 9X20K
model reference is used.
General Description
Model 9120K
The Gasboy Series 9120K pump units are UL®-listed.
Note: NFPA regulations do not allow tank-mounted pumps to be used for the resale of fuel.
Model 9120K offers four-wheel mechanical-interlock registers. Mechanical pump registers
show the total volume for a delivery up to 999.9 gallons.
Standard features and specifications of the 9120K Series pumps are as follows:
• Discharge elbows
• A 12-foot length of hose
• A working voltage of 115/230VAC, 50/60 Hz
• Mechanical Volume Totalizer
• A switch detect and optional pulser outputs which allow monitoring of the register's
operation when it is connected to an automated fuel management system.
• Four-piston, positive-displacement meter
• Belt-driven, positive-displacement rotary-vane pump with an 80 mesh (300 micron)
strainer and integral air-separation
• Cabinet height of 25.4 inches. The other dimensions may be found on the bas e layout.
• The standard cabinet finish has the top, sides, and back painted black while the front panel
is painted white.
• Filters
MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008 Page 1
Introduction General Description
The available options and accessories for the Gasboy Series 9120K pumps are as follows:
• Interchangeable Automatic Nozzles
•Pulsers
• Special Lengths of Hose
• Vapor Recovery System
• 380 VAC 3-Phase Motor
Model 9820K
The Gasboy Series 9820K Aboveground Storage Tank Remote Access (ASTRA) pump units
are UL-listed.
Note: NFPA regulations do not allow tank-mounted pumps to be used for the resale of fuel.
The 9820K Series consists of two metal cabinet assemblies.
• One assembly is mounted on top of the tank and contains the pumping unit, meter,
electronic pulser, and all hydraulics. The hose and nozzle are connected to this assembly.
• The second assembly is mounted at a height to permit easy access by a user. It contains the
electronic register, controls, display and nozzle boot.
The Standard features and specifications of the 9820K Series pumps are as follows:
• One-inch high, 6-digit, backlighted Liquid Crystal Display (LCD)
• 1000:1 dual-phase, error-checking pulser (gallons); 250:1 dual-phase, error-checking
pulser (liters)
• AC authorization line for control of the unit
• Reset complete (Switch Detect) output that allows monitoring of the unit's operation when
it is connected to an automated fueling system
• Resettable electronic totalizer
• Discharge elbow
• Both models use a quiet and efficient pump which features an air eliminator, built into the
pump casting. The pump meter is a three piston, positive displacement meter which is
tested and calibrated for accuracy at any speed or pressure up to the maximum working
pressure of 50 psi.
• The standard pumping cabinet finish is white. The electronic register cabinet is black with
a blue graphics panel.
• Dual Stage Solenoid Valve
• Filter
Available options and accessories for the Gasboy 9820K Series pumps are as follows:
• Pulser output drive line (open collector), capable of driving 1, 10, 100, 250 and 500 pulses
per unit (gallons) or 1, 10, & 100 pulses per unit (liters)
• RS-485 communication for direct connect to Gasboy CFN or TopKATΤΜ equipment
• Battery backup for display of last transaction and capture of stored pulse count in the event
of a power failure.
• Mechanical totalizer
• A working voltage of 115 VAC (115/230 for motor) 60 Hz for domestic use, 230 VAC 50
Hz/60 Hz for international use.
• Other options include listed automatic nozzles, special lengths of listed hose assembly,
listed dual swivels, UL-recognized filters, Vapor Recovery, and Vapor Recovery Ready.
Page 2 MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008
Abbreviations and Acronym s Introduction
Abbreviations and Acronyms
Term Description
AC (or ac) Alternating Current
ASC Authorized Service Contractor
AST Aboveground Storage Tank
ASTRA Aboveground Storage Tank Random Access
CFR Code of Federal Regulations
CPR Cardiopulmonary Resuscitation
CPU Central Processing Unit
DC (or dc) Direct Current
LCD Liquid Crystal Display
NEC National Electrical Code
NFPA National Fire Protection Association
OSHA Occupational Safety and Health Association
PCB Printed Circuit Boards (preferred term: board)
STP Submerged Turbine Pump
UL Underwriters Laboratory
MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008 Page 3
Introduction Abbreviations and Acronyms
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Page 4 MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008
2 – Important Safety Information
This section introduces the hazards and safety precautions
associated with installing, inspecting, maintaining or servicing
this product. Before performing any task on this product, read
this safety information and the applicable sections in this
manual, where additional hazards and safety precautions for
your task will be found. Fire, explosion, electrical shock or
pressure release could occur and cause death or serious
injury, if these safe service procedures are not followed.
Preliminary Precautions
You are working in a potentially dangerous environment of
flammable fuels, vapors, and high voltage or pressures. Only
trained or authorized individuals knowledgeable in the related
procedures should install, inspect, maintain or service this
equipment.
Emergency Total Electrical Shut-Off
The first and most important information you must know is
how to stop all fuel flow to the pump/dispenser and island.
Locate the switch or circuit breakers that shut off all power to
all fueling equipment, dispensing devices, and Submerged
Turbine Pumps (STPs).
!
WARNING
!
The EMERGENCY STOP, ALL STOP, and
PUMP STOP buttons at the cashier’s station
WILL NOT shut off electrical po wer to the p ump/
dispenser. This means that even if you activate
these stops, fuel may continue to flow
uncontrolled.
Read the Manual
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 the Gasboy Service Center at 1800-444-5529. It is imperative to your safety and the safety of
others to understand the procedures before beginning work.
Follow the Regulations
Applicable information is available in National Fire Protection
Association (NFPA) 30A; Code for Motor Fuel Dispensing
Facilities and Repair Garages, NFPA 70; National Electrical
Code (NEC), Occupational Safety and Hazard Association
(OSHA) regulations and federal, state, and local codes. All
these regulations must be followed. Failure to install, inspect,
maintain or service this equipment in accordance with these
codes, regulations and standards may lead to legal citations
with penalties or affect the safe use and operation of the
equipment.
Replacement Parts
Use only genuine Gasboy replacement parts and retrofit kits
on your pump/dispenser. Using parts other than genuine
Gasboy replacement parts could create a safety hazard and
violate local regulations.
Safety Symbols and Warning Words
This section provides important information about warning
symbols and boxes.
Alert Symbol
You must use the TOTAL ELECTRICAL SHUTOFF in the case of an emergency and not the
console’s ALL STOP and PUMP STOP or
similar keys.
Total Electrical Shut-Off Before Access
Any procedure that requires access to electrical components
or the electronics of the dispenser requires total electrical
shut off of that unit. Understand the function and location of
this switch or circuit breaker before inspecting, installing,
maintaining, or servicing Gasboy equipment.
Evacuating, Barricading and Shutting Off
Any procedure that requires access to the pump/dispenser or
STPs requires the following actions:
• An evacuation of all unauthorized persons and vehicles
from the work area
• Use of safety tape, cones or barricades at the affected
unit (s)
• A total electrical shut-off of the affected unit (s)
This safety alert symbol is used in this manual and
on warning labels to alert you to a precaution which must be
followed to prevent potential personal safety hazards. Obey
safety directives that follow this symbol to avoid possible
injury or death.
Signal Words
These signal words used in this manual and on warning
labels tell you the seriousness of particular safety hazards.
The precautions below must be followed to prevent death,
injury or damage to the equipment:
DANGER: Alerts you to a hazard or unsafe practice
!
which will result in death or serious injury.
WARNING: Alerts you to a hazard or unsafe practice
!
that could result in death or serious injury.
CAUTION with Alert symbol: Designates a hazard or
!
unsafe practice which may result in minor injury.
CAUTION without Alert symbol: Designates a hazard
or unsafe practice which may result in property or
equipment damage
Working With Fuels and Electrical Energy
Prevent Explosions and Fires
Fuels and their vapors will explode or burn, if ignited. Spilled
or leaking fuels cause vapors. Even filling customer tanks will
cause potentially dangerous vapors in the vicinity of the
dispenser or island.
MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008 Page 5
No Open Fire
In an Emergency
Open flames from matches, lighters, welding torches
or other sources can ignite fuels and their vapors.
No Sparks - No Smoking
Sparks from starting vehicles, starting or using power tools,
burning cigarettes, cigars or pipes can also ignite fuels and
their vapors. Static electricity, including an electrostatic
charge on your body, can cause a spark sufficient to ignite
fuel vapors. Every time you get out of a vehicle, touch the
metal of your vehicle, to discharge any ele c tro static charge
before you approach the dispenser island.
Working Alone
It is highly recommended that someone who is capable of
rendering first aid be present during servicing. Familiarize
yourself with Cardiopulmonary Resuscitation (CPR) methods,
if you work with or around high voltages. This information is
available from the American Red Cross. Always advise the
station personnel about where you will be working, and
caution them not to activate power while you are working on
the equipment. Use the OSHA Lockout/ Tagout procedures. If
you are not familiar with this requirement, refer to this
information in the service manual and OSHA documentation.
Working With Electricity Safely
Ensure that you use safe and established practices in working
with electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Ensure that grounding
connections are properly made. Take care that sealing
devices and compounds are in place. Ensure that you do not
pinch wires when replacing covers. Follow OSHA Lockout/
Tagout requirements. Station employees and service
contractors need to understand and comply with this program
completely to ensure safety while the equipment is down.
Inform Emergency Personnel
Compile the following information and inform emergency
personnel:
• Location of accident (for example, address, front/back of
building, and so on)
• Nature of accident (for example, possible heart attack, run
over by car, burns, and so on)
• Age of victim (for example, baby, teenager, middle-age,
elderly)
• Whether or not victim has received first aid (for example,
stopped bleeding by pressure, and so on)
• Whether or not a victim has vomited (for example, if
swallowed or inhaled something, and so on)
WARNING
!
Gasoline ingested may cause unconsciousness
and burns to internal organs.
Do not induce vomiting.
Keep airway open.
Oxygen may be needed at scene.
Seek medical advice immediately.
WARNING
!
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
WARNING
!
Gasoline spilled in eyes may cause burns to eye
tissue.
Irrigate eyes with water for approximately 15
minutes.
Seek medical advice immediately.
Hazardous Materials
WARNING
Some materials present inside electronic enclosures may
present a health hazard if not handled correctly. Ensure that
you clean hands after handling equipment. Do not place any
equipment in the mouth.
!
WARNING
The pump/dispenser contains a chemical known to the
State of California to cause cancer.
!
Gasoline spilled on skin may cause burns.
Wash area thoroughly with clear water.
Seek medical advice immediately.
IMPORTANT: Oxygen may be needed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
Lockout/Tagout
WARNING
!
Lockout/Tagout covers servicing and maintenance of
machines and equipment in which the unexpected
The pump/dispenser contains a chemical known to the
State of California to cause birth defects or other
reproductive harm.
energization or start-up of the machine(s) or equipment or
release of stored energy could cause injury to employees or
personnel. Lockout/Tagout applies to all mechanical,
hydraulic, chemical or other energy, but does not cover
electrical hazards. Subpart S of 29 CFR Part 1910 - Electrical
Hazards, 29 CFR Part 1910.333 contains specific Lockout/
Tagout provision for electrical hazards.
Page 6 MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008
Hazards and Actions
!
WARNING
Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a
serious hazard.
Fire or explosion may result, causing serious injury or death.
Follow established emergency procedures.
The following actions are recommended regarding these hazards:
Collision of 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).
• Do not use console E-STOP, ALL STOP and PUMP STOP to shut off power. These keys do no t
remove AC power and do not always stop product flow.
• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow
open flames, smoking or power tools in the area.
• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.
MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008 Page 7
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MDE-4616B 9120K and 9820K Series AST Pumps Service and Parts Manual · September 2008 Page 8
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