Gasboy 9820K User Manual

Introduction

Purpose

This manual provides instructions for the installation of 9820K Totalizer Kits - M07091K001
(Gallon) and M07091K002 (Liter). Ensure that you read and follow all warnings and
safeguards that are outlined in the

Table of Contents

Topic Page

Introduction 1
Purpose 1
Table of Contents 1
Required Tools 1
Parts List 2
Warranty 2
Important Safety Information 3
Installation of the 9820K Totalizer Kit 5

MDE-4617

9820K Totalizer Kit Installation Instructions

December 2006

“Important Safety Information” section on page 3.

Required Tools

The following tools are required for the installation of 9820K Totalizer Kits:

• Phillips® screwdriver

• Straight blade screwdriver

• 7 mm wrench

• 13 mm wrench

• Needle-nosed pliers

MDE-4617 9820K Totalizer Kit Installation Instructions • December 2006 Page 1

Introduction

Parts List

The following table lists the parts included in 9820K Totalizer Kits.

Item Description Part Number Quantity

Gallon Totalizer Kit

M07091K001

1 Totalizer Mounting Bracket 015113 1 0
2 Metric Flange Nut M0414B005 0 1
3 9-digit Counter-clockwise Gallon

Odometer

4 9-digit Counter-clockwise Liter

Odometer
5 Cable Assembly, Drive 9/Dig.Tot 017365 1 1
6
7 Screw MH PNH PHL 6-32X Q11270-36 0 1
8 Pin Cotter 3/64 X 1/2 STL K02137-29 1 1
9 Instr-Tot Kit 9820, FLD/FA 031903 1 1
10 Tie Cable Q10178-01 1 1
11 Assembly, Bracket AST Totalizer M06737A001 1 1
12 Screw, Metric M8 X 18 M00417B009 2 2
13 Tie Cable Q10178-02 2 2

Spirol® Pin .062 X .500

039824 1 0

038925 0 1

Q10038-29 1 0

Liter Totalizer Kit

M07091K002

Warranty

For information on warranty , refer to MDE-4255 Gasboy®’s Warranty Policy Statement
regarding spare parts. If you have any warranty-related questions, contact Gasboy’s Warranty
Department at its Greensboro location.

Page 2 MDE-4617 9820K Totalizer Kit Installation Instructions • December 2006

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 dange rous 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 equipme nt

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-4617 9820K Totalizer Kit Installation Instructions • December 2006 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 electrostatic
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

Be sure to use safe and established practices in working with
electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Be sure grounding connections
are properly made. Make sure that sealing devices and
compounds are in place. Be sure 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. Be sure 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 needed 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-4617 9820K Totalizer Kit Installation Instructions • December 2006

Installation of the 9820K Totalizer Kit

To install the 9820K Totalizer Kit, proceed as follows:

1 Turn off and lock out all power to the system.

2 Remove the sheet metal front door from the unit.

Figure 1: Front View

Cable Assembly,
Drive 9/Dig.Tot (5)

Installation of the 9820K Totalizer Kit

Totalizer Mounting
Bracket (1)

Cable End Fitting with
Smaller Mounting Hole

Cable End Fitting

3 Install the Drive Cable Assembly to the Totalizer/Odometer using the Spirol Pin.

Note: Cable end fitting with the smaller mounting hole goes to the Totalizer (see Figure 1).

MDE-4617 9820K Totalizer Kit Installation Instructions • December 2006 Page 5

Installation of the 9820K Totalizer Kit

Figure 2: Back View

9-digit Counterclockwise
Odometer (3), (4)

Spirol Pin .062 X .500 (6)

Totalizer Mounting Bracket (1)

Metric Flange Nut (2)

Screw MH PNH PHL 6-32X (7)

4 Install the assembled Drive Cable Assembly with the Odometer/Totalizer to the Totalizer

Bracket mount using the two 6-32 screws. Then, use the two 8-32 Hex KEPS
this completed assembly to the Totalizer Bracket (see

Figure 2).

®

nuts to attach

5 Install the T otalizer Bracket to the frame with two M8 X 18 thread-forming screws (see Figure

1 on page 5).

6 Route the Drive Cable Assembly under the meter and up to the flange of the frame. Use the

Cotter Pin to install the loose end of the Drive Cable Assembly to the Gear Train Assembly
under the pulser housing (see

Figure 1 on page 5).

Page 6 MDE-4617 9820K Totalizer Kit Installation Instructions • December 2006

Installation of the 9820K Totalizer Kit

7 Use tie cables to secure the drive cable to the hole located on the right side of the meter shaft.

8 Restore power to the unit and check for proper operation of the Totalizer.

MDE-4617 9820K Totalizer Kit Installation Instructions • December 2006 Page 7

Installation of the 9820K Totalizer Kit

Gasboy® is a registered trademark of Gilbarco Inc. KEPS® is a registered trademark of Illinois Tool Works Inc. Phillips® is a registered
trademark of The Phillips Screw Co. Spirol

®

is a registered trademark of Spirol International Holding Corporation.

© 2006 GASBOY
7300 West Friendly Avenue • Post Office Box 22087
Greensboro, North Carolina 27420
Phone [phone] • http://ww w.gasboy.com • Printed in the U.S.A.
MDE-4617 9820K Totalizer Kit Installation Instructions • December 2006