Gasboy Atlas Discharge User Manual

Introduction

This manual provides installation instructions for installing the Atlas Discharge and Valve Conduit Retrofit Kit.

Under certain service and installation conditions where the internal dispenser piping, conduit and mounting is distorted, some Gasboy Atlas units may develop a leak or inconsistent solenoid valve operation. This kit prevents these occurances.

MDE-4503

Atlas Discharge and Valve Conduit Retrofit

Kit

July 2005

Caution

Failure to follow the procedure outlined with in this kit may result in a compromised effectivity of this kit and could result in leaks or improper valve operation.

Required Reading

Before installing a kit, the installer must read, und erstand, and follow:

• This manual

• NFPA 30A, The Automotive and Marine Service Station Code

• NFPA 70, The National Electric Code

• Applicable federal, state and local codes and regulations

Failure to do so may adversely affect the safe use and operation of the equipment.

Note: This kit must be installed by a Gasboy Authorized Service Contractor (ASC) to ensure

Required Tools

The following tools are needed to install this kit:

• Standard Wrench Set (Metric and SAE) w/universal joint and 12 inch extension

• Set of combination wrenches (Metric and SAE)

• Flat tip screwdriver

• Cross tip screwdriver

• Punches (to help line up bolt holes)

warranty.

MDE-4503 Atlas Discharge and Valve Conduit Retrofit Kit • Jul y 2005 Page 1

Introduction

Parts Lists

M06228K001 - 1 - Hose Kit & M06228K002 - 2 - Hose Kit

Quantity Per Kit

Item Part Number Description M06228K001 M06228K002

1 Q12887_48 M8 X 18 CLINCH STUD 1 2 2 M06217B001 METER STABILIZER BRKT 1 2

3 M00414B003 M8 FLANGED NUT 1 2 4 M04681B001 COPPER DISCH TUBE 1 2 5 M06230B001 DISCHARGE FLANGE 1 2 6 Q10068_07 O-RING 2 4 7 M05230B009 M8 X 16 SEMS BOLT 6 12 8 N16289_20 1/2 “ EXPANSION UNION 1 2 9 R11976_52 1/2" X 3-1/4" NIPPLE 1 2 10 K42428 1/2" X 90 ELBOW 1 2 11 R11976_75 1/2" X 9-3/8" NIPPLE 1 2 12 R11976_39 1/2" X 1-1/8" NIPPLE N/A 1 13 K49306 1/2" X 45 ELBOW N/A 1 14 R11976_67 1/2" X 6-3/8" NIPPLE N/A 1

M06228K001, 002 Field Retrofit Kits - Atlas 2-Hose Dispenser Shown

Page 2 MDE-4503 Atlas Discharge and V alve Cond uit Retrofit Kit • July 2005

Important Safety Information

This section introduces the hazards and safety precautions associated with ins talling, i nspecting, ma intainin g or servicing this product. Before perform ing any tas k on this produ ct, 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 , v ap ors, an d high voltage or p res sures. Only trained or authorized ind ividuals kn owledgeable in th e 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 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.

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.”

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 breake r be fore ins pe cti ng , in stalling, maint aining, or servicing Gasboy equipment.

Evacuation, Barricading and Shut-Off

Any procedures requiring accessing the pump/dispenser or STPs requires the following three actions:

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 pro cedure, call a G asboy Authorized Service Contractor or call the Gasboy Service Center at 1800-444-5529. It is imp erative to yo ur safety a nd the safety o f others to understand the procedures before beginning work.

Follow the Regulations

There is applicable information in NFPA 30A; Automotive an d 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.

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 loc al regulations.

Safety Symbols and Warning Words

This section provides important information about war ning symbols and boxes. Alert Symbol

This safety alert symbol is used in this manual and on warning labels to alert you to a precauti on whi c h mu st 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 t o prev ent death, injury or damage to the equipment

DANGER - This signa l 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 dam age.

- 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-4503 Atlas Discharge and Valve Conduit Retrofit Kit • Jul y 2005 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

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.

WARNING

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 vapo rs. After gettin g out of a vehi cle, tou ch 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 n ot fami liar wit h this r equirem ent, re fer to information in the service manual and OSHA documentation.

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, possibl e 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 ingeste d may c ause unc onsciou sness and burns to internal organs. Do not induce vomiting. Keep airway open. Oxygen may be needed at scene. Seek medical advice immediately.

WARNING

Working With Electricity Safely

Be sure to use safe and est abli shed pr actic es in work ing with electrical devices. Poorly wired devices may cause a fire, explosion or electric al sh oc k. Be sure grounding co nne ct ion s

Gasoline inhaled may cause unconsciousness and burns to lips, mouth and lungs. Keep airway open.

Seek medical advice immediately. 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. Statio n emp loy ee s and ser vic e con trac t or s need to understan d and compl y with this program compl etely to ensure safety while the equipment is down.

WARNING

Gasoline spilled in ey es may cause bur ns to eye tissue. Irrigate eyes with water for approximately 15 minutes.

Hazardous Materials

Seek medical advice immediately Some materials present inside electronic enclosures may present a health hazard if not handled correctly. Be sure to

WARNING

clean hands after handling equipment. Do not place any equipment in mouth.

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 ene rgy, but does not cover electrical hazards. Referen ce Subpar t S of 29 CFR Part 1910

Page 4 MDE-4503 Atlas Discharge and V alve Cond uit Retrofit Kit • July 2005

- Electrical Hazards, 29 CF R Part 191 0.3 33 c ontains specific Lockout/Tagout provision for electrical hazards.

Installing the M06228K001 or M06228K002 Kit

The disassembly, replacement and reassembling process shown below is the same whether upgrading a Single Hose System or a dual Hose System.

Preparation

1 Request permission from the manager/owner to remove power from the unit and then remove

power using normal procedures. Observe the lockout/tagout safety proc edur es . Reference,“Important Safety Information” on page 3

2 Make sure you have the proper kit type (Single or Dual Kit).

3 Be prepared to follow all applicable safety rul es and pr ocedures. Reference,“Impor ta nt Sa fety

Information” on page 3

4 Using the proper tools, remove the back and front covers from the unit. Place covers in a safe

place to prevent damage or scratches. Save the mounting hardware for later reuse.

5 Follow all safety procedures and OSHA requirements as outlined in MDE-2531, Pump and

Dispenser Start-up/Service Manual. Follow Section 6, Meter Repair, under the heading “Before Beginning Work” to bleed fuel and shut-down the unit.

Hint: place a rag into the side pa nel s of the un it on both si des , this wi ll keep tools f rom falling into the well and getting lost. Figure 1

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