Introduction
Purpose
This document provides instructions for installing the Weatherproofing Kit M07933K001 and
sealing the Electronics Cabinet on Atlas
Table of Contents
Topic Page
Introduction 1
Important Safety Information 3
Installation of the Weatherproofing Kit 5
MDE-4687
Weatherproofing Instructions for Atlas™ 9800 Units
August 2007
™
9800 dispensers and pumping units.
Required Tools
Figure 1: Tools
MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007 Page 1
Introduction
Parts List
The following tools are required for the installation of the kit:
• Phillips® screwdriver
• 3/16" Allen Wrench
• Ratchet and 1/ 2" Socket
• Roll Pin Punch
•Hammer
• Dry rags
• Cleaning solution or isopropyl alcohol
• Loctite (light or medium strength)
• Petroleum jelly or Silicone lubricant
The following table lists the parts included in the M07933K001 kit.
Item Description Part Number
1 New Bezels M05291A00X (Configured based on
2 Tube 3M™ 2084 Sealant END 1456 1
3 Gasket Strip 027078 5 feet
4 TopKAT™ Base Gaskets M07800B001 2
Related Documents
Document Number Title GOLD Library
MDE-4334 Atlas Start-up/Service Manual Gasboy Atlas Pumps/Dispensers
MDE-4363 Atlas Owner's Manual Gasboy Atlas Pumps/Dispensers
Warranty
For information on warranty, refer to MDE-4255 Gasboy®’s Warranty Policy Statement. If you
have any warranty-related questions, contact Gasboy’s Warranty Department at its Greensboro
location.
Quantity
2
Unit Serial Number)
Page 2 MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007
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.
Important Safety Information
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
There is applicable information in NFPA 30A; Automotive and
Marine Service Code, NFPA 70; National Electrical Code (NEC),
OSHA regulations and federal, state, and local codes which
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.
Emergency Total Electrical Shut-Off
The first and most important information you must know is
how to stop all fuel flow to the pump 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 power to the
pump/dispenser.
Total Electrical Shut-Off Before Access
Any procedure requiring access to electrical components or
the electronics of the dispenser requires total electrical shutoff of that unit. Know the function and location of this switch
or circuit breaker before inspecting, installing, maintaining, or
servicing Gasboy equipment.
Evacuation, Barricading and Shut-Off
Any procedures requiring accessing the pump/dispenser or
STPs requires the following three actions:
This means that even if you activate these
stops, fuel may continue to flow uncontrolled.
You must use the TOTAL ELECTRICAL SHUTOFF in the case of an emergency and not only
these cashier station “stops.”
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
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 that follow must be followed to prevent death,
injury or damage to the equipment
DANGER - This signal word is used to alert you to a
!
hazard to unsafe practice which will result in death or
serious injury
WARNING - This alerts you to a hazard or unsafe
!
practice that could result in death or serious injury.
CAUTION with Alert symbol - This signal word
!
designates a hazard or unsafe practice which may
result in minor injury.
CAUTION without Alert symbol - When used by itself,
CAUTION designates a hazard or unsafe practice
which may result in property or equipment damage.
- An evacuation of all unauthorized persons and vehicles
using safety tape, cones or barricades to the effected units
- A total electrical shut-off of that unit
MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007 Page 3
Working With Fuels and Electrical Energy
Prevent Explosions and Fires
Fuels and their vapors will become explosive if ignited. Spilled
or leaking fuels cause vapors. Even filling customer tanks will
cause explosive vapors in the vicinity of dispenser or island.
Important Safety Information
No Open Flames
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 electrost atic
charge on your body, can cause a spark sufficient to ignite
fuels and their vapors. After getting out of a vehicle, touch the
metal of your vehicle to discharge any electrostatic 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. Be familiar
with Cardiopulmonary Resuscitation (CPR) methods if you
are working 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 tag out and lock out
procedures. If you are not familiar with this requirement, refer
to information in the service manual and OSHA
documentation.
Working With Electricity Safely
Ensure to use safe and established practices in working with
electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Ensure grounding connections
are properly made. Ensure that sealing devices and
compounds are in place. Ensure not to pinch wires when
replacing covers. Follow OSHA Lock-Out and Tag-Out
requirements. Station employees and service contractors
need to understand and comply with this program completely
to ensure safety while the equipment is down.
Hazardous Materials
Some materials present inside electronic enclosures may
present a health hazard if not handled correctly. Ensure to
clean hands after handling equipment. Do not place any
equipment in mouth.
!
WARNING
This area contains a chemical known to the State of
California to cause cancer.
WARNING
!
This area contains a chemical known to the State of
California to cause birth defects or other reproductive
harm.
IMPORTANT: Oxygen may be needed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
Emergency First Aid
Informing Emergency Personnel
• Compile the following information for 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
WARNING
!
Gasoline spilled on skin may cause burns.
Wash area thoroughly with clear/water.
Seek medical advice immediately.
IMPORTANT: Oxygen may be need ed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
Lockout/Tagout
Lockout/Tagout covers servicing and maintenance of
machines and equipment in which the unexpected
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. Reference Subpart S of 29 CFR Part 1910
- Electrical Hazards, 29 CFR Part 1910.333 contains specific
Lockout/Tagout provision for electrical hazards.
Page 4 MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007
Installation of the Weatherproofing Kit
To install the Weatherproofing kit for 9800K Series pumps, p roceed as follows:
1 Reinstall the grommet that seals the area around the reset shaft.
2 Apply the sealant to the corner locations inside the Electronics Cabinet.
3 Apply the Gasket Strip to the outside of the Rain Gutter.
4 Install the new bezels.
Note: If the unit has a TopKAT mounted on it, perform step 5.
5 Ins t all the gaskets between the TopKAT and its base and also between the TopKAT base and
the dispenser unit.
Removal and Reinstallation of the Reset Grommet
To remove and reinstall the Reset Grommet, proceed as follows:
Installation of the Weatherproofing Kit
1 Loc ate the round Reset Grommet at the Reset shaft. See Figure 2.
2 Remove the front bezel from both sides of the unit.
Figure 2: Round Reset Grommet
3 Remove the four screws holding the top sheathing in place. Do not remove the top sheathing.
4 Remove the Reset Handle by driving out the Roll Pin. See Figure 3 on page 6.
MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007 Page 5
Installation of the Weatherproofing Kit
Figure 3: Removal of the Reset Handle
5 Remove the Nozzle Boot, Reset Handle Stops, and small black plastic plug. See Figure 4.
Figure 4: Nozzle Boot, Reset Handle Stops, and Small Black Plastic Plug
Remove these
Parts
Remove
Sheathing
Screws
Remove
Sheathing Screws
6 Remove the side sheathing screws (located inside the frame).
Page 6 MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007
Installation of the Weatherproofing Kit
7 Remove the Hose Retriever or Blanking Plate by removing the two nuts inside the frame.
8 Remove the grommet (lubricate the Reset Shaft, if neces sary).
9 Raise the top sheathing up slightly and pull the side sheathing away from the frame.
Note: Ensure that you do not bend the side sheathing.
10 Hold the side sheathing away from the frame to reinstall the grommet between the side
sheathing and frame (apply a small amount of lubricant for easy installation of the grommet
over the shaft). Place the larger diameter of the grommet against the frame. See
Figure 5: Installation of the Grommet Over the Shaft
Figure 5.
11 Carefully relax the side sheathing and fit it over the Reset Shaft and grommet. See Figure 6.
Figure 6: Reset the Shaft and Grommet
MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007 Page 7
Installation of the Weatherproofing Kit
12 Reinstall the hardware that was removed in steps 5 to 7.
Note: On electronic units, when reinstalling the Reset Handle Stops, ensure that you adjust the
stop rotation such that the magnetic switches inside the head are properly aligned.
Proper alignment means the magnet switches should be positioned parallel to each
other with a gap of approximately 3/16" (see
6). Loctite should be applied to both the cap screws used to install the stops so they do
not vibrate later.
Figure 7: Adjustment of the Reset Handle
Figure 3 on page 6 and Figure 4 on page
Adjust Reset Handle Stop
such that the Magnet
Switches are positioned
parallel to one another, with
approximately 3/16" gap.
Apply Loctite to both the cap
screws to prevent them from
vibrating loose later.
13 If the unit is Dual Hose, repeat steps 1 to 12 for the other side.
Page 8 MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007
Application of the Sealant in the Electronics Cabinet
To apply the sealant in the Electronics Cabinet, proceed as follows:
1 Before applying the sealant provided in the kit (3M 2084 Metal Sealant), use rags and cleaner
(or alcohol) to clean and dry the surfaces to be sealed. Then, apply the sealant at all locations
identified in
2 Apply the sealant to fill gaps in all four bottom corners and all four top corners inside the
cabinet. See
Figure 8: Application of the Sealant - Top Corners
Apply sealant to the upper
inside corners of head
section, at four places.
Figure 8 and Figure 9 on page 10.
Figure 8.
Installation of the Weatherproofing Kit
Apply sealant to the gap
(where the Rain Gutter
and the sheathing join).
Repeat this in all four
corners.
MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007 Page 9
Installation of the Weatherproofing Kit
Figure 9: Application of the Sealant - Bottom Corners
Apply sealant
to lower
inside
corners of
head section,
at four
places.
Application of the Gasket Strip Across the Front Edge of the Rain Gutter
To apply the Gasket Strip across the front edge of the Rain Gutter, proceed as follows:
1 Measure and c ut the Gasket Strip from the Kit (027078) to the correct length to fit across the
front of the Rain Gutter.
2 Clean the front surface of the Rain Gutter.
3 Apply a thin bead of sealant across the front surface of the Rain Gutter. See Figure 10.
Figure 10: Application of the Sealant - Front Surface
Page 10 MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007
Installation of the Weatherproofing Kit
4 Carefully apply the Gasket Strip to the front surface of the Rain Gutter. See Figure 11.
Figure 11: Application of the Gasket Strip
5 Wipe away any excess sealant when finished.
6 Repeat ste ps 1 to 5 for the other side of the unit.
Installation of New Bezels
To install the new bezels, proceed as follows:
Note: If the unit has the TopKAT option, complete the steps in “Installation of TopKAT Base
Gaskets” on page 12 before installing new bezels.
The improved bezels have neoprene gaskets around all the lenses, and also between the dial
face and the bezel. The screws have been sealed. Additionally, a bulb gasket has been factory
installed along the top edge of the bezel.
Figure 12: Improved Bezels with Neoprene Gaskets
MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007 Page 11
Installation of the Weatherproofing Kit
1 Reinstall both the new bezels using the original fasteners. Ensure that the bezel sits snugly
down on the unit.
Figure 13: Installation of New Bezels
2 Dispose the old bezels properly.
Installation of TopKAT Base Gaskets
To install TopKAT base gaskets, proceed as follows:
1 Lowe r the dispenser display panel.
2 Disconnect all power and signal lines from inside the TopKAT . Carefully pull these wires back
down into the dispenser head. Ensure that you do not scrape wire insulation or damage
terminations.
3 Remove the bolts inside the TopKAT that hold it to the Mounting Base. Carefully lay the
TopKAT on its side, resting it on a cloth on top of the dispenser.
4 Remove both cross braces from inside the dispenser to expose the TopKAT mounting bolts.
5 Remove TopKAT mounting bolts to free the TopKAT Mounting Base from the dispenser.
6 Remove any old taped Gasket Strips from both sides of the Mounting Base and clean both the
surfaces.
7 Remove the adhesive backing from the TopKAT Mounting Base Gaskets (M07800B001) and
apply one to each side of the Mounting Base. Ensure that you line up the bolt holes on the
gaskets to the bolt holes on the Mounting Base.
8 Reinstall the Mounting Base to the top of the dispenser.
Page 12 MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007
9 Route the TopKAT wiring back up into the TopKAT.
10 Reinstall the TopKAT to the Mounting Base.
11 Reconnect all power and signal wires inside the TopKAT.
12 Reinstall the cross braces inside the dispenser.
13 Test all dispenser and TopKAT functionality.
14 Close the dispenser display panels and TopKAT doors.
15 Install the dispenser bezels.
The installation of the Weatherproofing kit is complete.
Installation of the Weatherproofing Kit
MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007 Page 13
Installation of the Weatherproofing Kit
Phillips® is a registered trademark of Phillips Screw Company. Gasboy® is a registered trademark of Gasboy International. Atlas™ and
TopKAT
™
are trademarks of Gasboy International. 3M™ and Scotch-Seal™ are trademarks of 3M.
© 2007 GASBOY
7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone 1-800-444-5529 · http://www.gasboy.com · Printed in the U.S.A.
MDE-4687 Weatherproofing Instructions for Atlas™ 9800 Units · August 2007
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