Introduction
Purpose
This document provides information on how to replace diaphragm and valve coil assemblies
on Atlas units.
Kit Ordering Information
Note: Refer to the t ag on the curr ent valve if you a r e un certain whether t o or d er a high voltage
or a low voltage valve coil assembly kit.
MDE-4448
Atlas™ Diaphragm and Valve Coil
Replacement Kits
April 2005
Use the following kit descriptions to order the correct kit for your unit.
Kit Number Kit Name
M04607K010 Diaphragm Kit
M04607K012 Valve Coil Assembly - Low Voltage (120/60, 110/50V)
M04607K013 Valve Coil Assembly - High Voltage (240/60, 220/50V)
Kit Component Parts
Diaphragm Kit
• O-Ring (Diaphragm)
• O-Ring (Body)
•Spring
• Diaphragm Assembly
Valve Coil Assembly - Low Voltage
• Coil Assembly
Valve Coil Assembly - High Voltage
• Coil Assembly
Recommended Tools
• Absorbent pad
• Approved fuel container
• Phillips
• Silicone grease
• Standard screwdriver
• Wrench set, US
®
head screwdriver
MDE-4448 Atlas™ Diaphragm and Valve Coil Replacement Kits • April 2005 Page 1
Introduction
Related Document
Document Number Document Title GOLD® Library
MDE-4434 Atlas Service Manual Gasboy Consumer & Commercial
Follow Codes
Before installing equipment, read, understand and follow the following codes:
• The Nation al Electric C ode (NFPA 70)
• The Automotive and Marine Service Code (NFPA 30)
• Any national, state and local codes that may apply
Failure to s ervice the equipment in accordance with these codes may adversely affect the safe
usage and operation of the system.
Before You Begin
1 Read all instructions before beginning work.
2 Follow all safety precautions.
3 Isolate unit at distribution box.
4 Turn off all power to unit. Turn off all associated submerged turbine pump (STP) power. Use
system circuit breakers. Multiple disconnects may be required.
5 Follow Occupational Safety and Hazard Association (OSHA) Lock-Out and Tag-Out
requirements. See MDE-4334 Atlas Service Manual for procedures.
6 Place nozzle(s) into an ap proved co ntainer t o drain and ble ed pressure . Some residual pressure
may remain.
7 Position an approved container for catching fuel under valve coil and/or diaphragm assembly
being serviced.
Page 2 MDE-4448 Atlas™ Diaphragm and Valve Coi l Repla ce ment Kits • Ap ril 200 5
Important Safety Information
Important Safety Information
This section introduces the hazards and safety precautions
associated with inst alling, ins pecting, main taining or s ervicing
this product. Before performi ng any ta sk on this pr oduct, 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, va pors , a nd high voltage or pres su res . Only
trained or authoriz ed indi viduals knowledg eable in the rela ted
procedures should ins tall, 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 breaker befor e in sp ec ting , i nstalling, maintai ni ng, or
servicing Gasboy equ ipm e n t.
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 mate rials suppli ed with this eq uipment. If y ou
do not understand a procedure, call a Gasboy Authorized
Service Contractor or call the Gasboy Service Center at 1800-444-5529. It is imp erative to y our safety and the sa fety of
others to understand the procedures before beginning work.
Follow the Regulations
There is applicable information in NFPA 30A; A uto m otive 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.
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 person s and vehic le s
using safety tape, cones or barricades to the effected units
- A total electrical shut-off of that unit
MDE-4448 Atlas™ Diaphragm and Valve Coil Replacement Kits • April 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, weldi ng 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 gettin g out of a vehicle, touc h 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 fami liar with th is requi rement , refer
to information in the service manual and OSHA
documentation.
Working With Electricity Safely
Be sure to use s afe a nd es t ablished practices i n w o rki ng w ith
electrical devices. Poorly wired devices may cause a fire,
explosion or electrical s hoc k. Be sure gro und ing con nec tio ns
are proper ly made. Make sure that sealing devices an d
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 underst and and comply with thi s p rogram completely
to ensure safety while the equipment is down.
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
!
Gasoline inhaled may cause unconsciou sness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
WARNING
!
Gasoline spilled in ey es may cause burns to ey e
tissue.
Irrigate eyes with water for approximately 15
minutes.
Seek medical advice immediately
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
!
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
IMPORTANT: Oxygen may be needed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
Page 4 MDE-4448 Atlas™ Diaphragm and Valve Coil Replac ement K its • April 200 5
electrical hazards . Refere nce Su bpa rt S of 29 C FR Part 1910
- Electrical Hazards, 29 CFR Part 1910.333 contains specific
Lockout/Tagout provision for electrical hazards.
Valve Coil Installation Instructions
Follow the directions below to replace the valve coil assembly.
Note: Valve coil assemblies have the volts and hertz stamped onto the valve coil body. This
information is located on the opposite side of the wiring assembly. Check to make sure
you have the correct replacement valve coil before replacing the existing coil.
Remove Old Valve Coil Assembly
1 Open the lower door.
2 Remove the junction box cover.
3 Locate the valve coil wiring conduit. See Figure 1: Valve Coil Assembly, Conduits and
Junction Box on page 5.
Caution:Replace one valve coil assembly at a time. Attempting to make two replacements
concurrently may cause problems with reconnecting valve coil wiring.
Valve Coil Installation Instructions
Figure 1: Valve Coil Assembly, Conduits and Junction Box
Valve Coil Wiring Conduits
Valve
Union connecting
Valve Coil Wiring
Conduit and
Junction Box
MDE-4448 Atlas™ Diaphragm and Valve Coil Replacement Kits • April 2005 Page 5
Valve Coil Installation Instructions
4 Loosen the union connecting the valve wiring conduit and the junction box. See Figure 1:
Valve Coil Assembly, Conduits and Junction Box on page 5.
5 Remove the red cap from the top of the valve coil assembly. See Figure 2: Valve Coil
Assembly and Diaphragm - Exploded View on page 6.
Figure 2: Valve Coil Assembly and Diaphragm - Exploded View
valve coil assembly
valve coil base
subassembly
valve coil base gasket
O-ring (diaphragm)
O-ring (body)
6
Push down on the valve assembly.
7 Insert the blade of a screwdriver between the nameplate and the valve assembly.
8 Use the screwdriver to pry off the nameplate. Put the red cap and the nameplate aside.
9 Loosen the union connecting the valve coil assembly and the conduit.
10 Rotate the valve coil and condui t. This will al low you to locate the red, black and yel low valve
Page 6 MDE-4448 Atlas™ Diaphragm and Valve Coil Replac ement K its • April 200 5
coil assembly wires in the junction box.
CAUTION
!
Do not cut the system wiring. Make certain you have
located the correct valve coil wiring before making any
cuts.
11 Cut the red, black and yello w valve coil assembly wires 2 inches from th e wire nut. Lea ve the
old wires connected to the wire nuts to map the new valve coil installation wiring.
12 Remove the existing valve coil assembly and wiring from the unit.
13 Unscrew the conduit from the coil and remove the wires.
Install New Valve Coil Assembly
1 Feed the new wiring through the conduit.
Valve Coil Installation Instructions
2 Screw the conduit into the valve coil wiring outlet and tighten so that the conduit will
reconnect to the junction box when installed.
3 Feed the wiring through the junction box union.
4 Place the new valve c oil as sembly i nto pos itio n on top o f th e base sub-as sembly. See Figure 2:
Valve Coil Assembly and Diaphragm - Exploded View on page 6.
5 Replace the nameplate and the red cap.
6 Pull the wiring tight ins ide the j unct i on box and tighten the union connecting the junction box
and the conduit.
Make Wiring Connections for New Valve Coil Assembly
1 Connect the red wire to the corresponding wire nut in the juction box. Discard the previous
wire section. Repeat for the yellow and black wires.
2 Replace the junction box cover, tightening all bolts, and close the lower door.
MDE-4448 Atlas™ Diaphragm and Valve Coil Replacement Kits • April 2005 Page 7
Diaphragm Installation Instructions
Diaphragm Installation Instructions
Follow the directions below to replace the diaphragm.
1 Open the lower door.
2 Unscrew the bonnet screws (4). See Figure 3: Valve Coil Assembly and Diaphragm -
Exploded View on page 8.
Figure 3: Valve Coil Assembly and Diaphragm - Exploded View
valve coil assembly
O-ring (diaphragm)
valve coil base
subassembly
valve coil base gasket
O-ring (body)
Remove valve bonnet, spring, diaphragm assembly, O-Ring (body) and O-Ring (diaphragm).
3
4 Put the valve bonnet and s crews aside f or later reasse mbly.
Page 8 MDE-4448 Atlas™ Diaphragm and Valve Coil Replac ement K its • April 200 5
Diaphragm Installation Instructions
5 Lubricate the new O-Ring (diaphragm) with silicone grease.
6 Install the new O-Ring (diaphragm).
7 Lubricate the new O-Ring (body) with silicone grease.
8 Install the new O-Ring (body).
9 Install the new diaphragm assembly and spring with the cup side facing the valve bonnet.
10 Replace the valve bonnet.
11 Thread valve bonnet screws into the valve body and tighten screws.
12 After reapplying power to the unit, run and check for leaks.
MDE-4448 Atlas™ Diaphragm and Valve Coil Replacement Kits • April 2005 Page 9
Causes of Improper Valve Operation
Causes of Improper Valve Operation
One or more of the following causes may contribute to improper valve operation.
• Faulty Control Circuits
• Burned-out Coil
• Low Volta ge
• Incorrect Pressure
• Excessive Leakage - In cases of excessive leakage, replace the complete valve assembly.
Use the following table to determine the correct valve assembly.
Valve Assembly Part Number Valve Assembly Description
M04607B001 Standard, Low Volt (120/60, 110/50V)
M04607B002 Standard, High V olt (240/60, 220/50V)
M04607B003 Standard, Low Vol t for Canada ATC (120/60, 110/50V)
M04607B005 Filter Manifold, No Valve
M04607B006 Filter Manifold, No Valve for Canada ATC
Solenoid Temperature
Valves are supplied with coils designed for continuous duty service. When the solenoid is
energized for a long period, the solenoid becomes hot and can be touched by hand only for an
instant. This is a safe operating temperature. Any excessive heating will be indicated by the
smoke and odor of burning coil insulation. See the following wiring schematic.
Figure 4: Wiring Schematic
Phillips® is a registered trademark of Philips Screw Company.
© 2005 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-4448 Atlas™ Diaphragm and Valve Coil Replacement Kits • April 2005
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