Gasboy Blackmer GDP User Manual

Page 1

Introduction

Purpose

This document provides information regarding the operation and maintenance of Blackmer® Global Dispenser Pumps (GDPs) as used in Gilbarco

This document also provides step-by-step instructions for kit installation. It is recommended that kits be installed by a Gilbarco Authorized Service Contractor (ASC).

Blackmer GDP pumps must only be installed in systems that have been designed by qualified engineering personnel. The system must conform to all applicable local and national regulations and safety standards. This manual must be kept with the pump.

Blackmer® Global Dispenser Pump Operation,

Maintenance and Kit Installation Manual

self-contained products.

IMPORTANT INFORMATION

MDE-4096C

April 2008

Intended Users

This document is intended for Gilbarco ASCs.

Topic Page

Introduction 1 Important Safety Information 4 Installation 6 Operation 7 Maintenance 8 Repair Kits 19 Pump Parts List 21 Troubleshooting 29

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 1

Page 2

Introduction

Required Tools

The following tools are required for the installation of the kit:

• 5 mm Allen® wrench

• 1/4-inch Allen wrench

• Heavy snap ring pliers

• Ratchet wrench

• 16 mm socket

• 13 mm or 1/2-inch socket

• Rubber mallet

• Torque wrench

Required Reading

Before servicing the pump, the technician must read, understand, and follow this document. Failure to do so may adversely effect the safe use and operation of the equipment.

Pump Model Identification

The pump model identification plate is located on the rear cover. The pump model number begins with M00955B. For example, M00955B207 is a complete model number.

Abbreviations and Acronyms

Term Description

ASC Authorized Service Contractor cmHg centimeter of mercury CW Clockwise CCW Counterclockwise GDP Global Dispenser Pump gpm gallons per minute inHg inch of mercury lbs pound-force lpm liters per minute mm millimeter N/A Not applicable Nm Newton-meter OIML International Organization of Legal Metrology* Opt. Optional

Page 2 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 3

Term Description

PCV Pressure Control Valve psi pounds per square inch RPM Revolutions Per Minute Std Standard UHF Ultra High Flow

* OIML Switch (optional) monitors air to fuel mix and is used primarily in

Europe.

Introduction

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 3

Page 4

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 th e pump/ 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 Gilbarco Authorized Service Contractor or call the Gilbarco Support Center at 1-800-800-7498. 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 Gilbarco replacement parts and retrofit kits on your pump/dispenser. Using parts other than genuine Gilbarco 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 Gilbarco 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.

Page 4 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 5

Important Safety Information

No Open Fire

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 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. 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/T agout requirements. S t ation 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 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.

In an Emergency

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.

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.

WARNING

Lockout/Tagout

Lockout/Tagout covers servicing and maintenance of

The pump/dispenser contains a chemical known to the State of California to cause birth defects or othe r reproductive harm.

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. Subpart S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR Part 1910.333 contains specific Lockout/ Tagout provision for electrical hazards.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 5

Page 6

Installation

Inlet Fittings

The Blackmer GDP is shipped without inlet fittings. Appropriate inlet fittings must be installed on site.

Configuration Table

The following table lists three possible inlet configurations.

Sl. No Inlet Configuration

1 1-1/2” NPT x 1-3/4” LG. SCH. 80 NIPPLE and 1-1/2” NPT 150# Union (Gilbarco part

2 1-1/2” NPT x 1-3/4” LG. SCH. 80 NIPPLE and 1-1/2” NPT 300# Union (Gilbarco part

3 3-Bolt Flange with flexible connector (order Gilbarco kit number K94194)

Installing the Fittings

To install the fittings, proceed as follows:

numbers R11493-50 and K12179)

numbers R11493-50 and Q10846-08)

1 Apply a pipe sealant (that is approved for use with petroleum products) to the threads.

CAUTION

Do not use Teflon® tape. Teflon tape may shred off and get caught within components.

2 Hand-tighten, and then wrench-tighten approximately by another 3 turns. The pump body is

aluminum.

CAUTION

Do not overtighten inlet fittings. The pump body is made of aluminum. Overtightening may strip pump threads.

3 Check for leaks (refer to the section “Troubl esho oting Table” on page 29).

Page 6 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 7

Operation

PCV Adjustment

Pressure Control Valves (PCVs) must be set to the desired single hose operation pressure. A retaining ring must be in place at all times during PCV adjustment.

Note: Numbers within parentheses in the procedural steps in the manual refer to the numbers

WARNING

Not using a retaining ring can release hazardous pressure that can cause personal injury or property damage.

Always ensure that the retaining ring is in place before making the PCV adjustment.

Take appropriate safety precaution s. Failure to do so may result in personal injury or property damage.

mentioned in the referenced figures.

Operation

To set the proper PCV operation pressure, proceed as follows:

1 To increase the pressure setting, turn the PCV cover (13) inward or clockwise (CW) using a

16 mm socket wrench (see Figure 3 on page 11).

2 T o decrease the pressure setting, turn the PCV cover (13) outward or counterclockwise (CCW)

using a 16 mm socket wrench (see

Figure 3 on page 11).

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 7

Page 8

Maintenance

Maintenance shall be performed by qualified technicians only. Follow procedures and warnings as presented in this manual.

Notes:1) Before removing plugs or covers, ensure that approved container and absorbent

Draining Pump

Figure 1: Typical Plug Location

IMPORTANT INFORMATION

materials are ready to contain any released fuel.

2) Follow all safety procedures for working around fuel and fuel vapors.

Plug, Left Side Casing (11)

Plug, Lower Right Face (11)

Front Head Cap Screw

To drain the bulk of the fluid from the pump, proceed as follows:

Note: Residual fluid may remain in the pump.

1 Put the approved tray in place to collect the fuel.

Plug, Upper Face (11)

2 Remove the plug (11) on the upper face of the head, directly to the right of the strainer cover

(19). This port may be used to monitor vacuum (see

Page 8 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Figure 1).

Page 9

3 Remove the plug (11) on the lower right face of the head (9). Fluid will be emptied by

removing this plug. Fluid must be properly contained during draining procedure.

Note: Pump contains up to 0.5 liters of fluid. Do not use this port to monitor system pressure.

4 If sump drainage is desired, remove the plug (11) near the mounting hole on the left side of

pump casing (1).

5 Manually turn the pump pulley counterclockwise (CCW) to aid in fluid removal.

6 Properly dispose of all fluid drained from pump.

7 After pump is drained, replace all plugs (11) using a non-hardening pipe sealant.

Note: Do not use Teflon tape.

Strainer/Check Valve Removal

Check valves (if equipped) should be replaced only if pump is experiencing frequent prime loss, indicating that the check valve is not functioning. Check valve should be installed when tank check valve is not available. Always use strainers with or without check valves. Strainer must be kept clean to ensure proper operation and pump life.

Maintenance

To remove the strainer/check valve, proceed as follows:

1 Lower pump fluid level by removing the plug (1 1) located at the right of the strainer cover an d

rotating the pump shaft counterclockwise (CCW) approximately 10 turns (see

Figure 2 on

page 10).

Note: Removing the plug allows air to enter.

2 Remove the three strainer cover screws (21).

3 Remove the strainer cover (19). Inspect cover O-Ring (18) for damage. If damaged, discard

O-Ring and replace with new O-Ring.

4 Carefully pull out strainer (17). Keep strainer in a horizontal position to avoid contaminating

pump with strainer debris. It may be necessary to use a small tool to gently hook the inside of the metal strainer end cap.

5 If equipped, remove the inlet check valve assembly (16). Inspect for cracked or otherwise

damaged O-Rings. Replace if damaged.

6 Lift dome strainer (25) out from the bore located behind the check valve assembly. Inspect

strainer for damage. Clean and/or replace, if necessary.

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Maintenance

Strainer/Check Valve Installation

To install the strainer/check valve, proceed as follows:

1 If equipped with the check valve option, insert the dome strainer (25) into the bore (see

Figure 2).

Figure 2: Strainer/Check Valve

Optional Dome Strainer (25)

Optional Check Valve (16)

Screws (21)

Strainer Cover (19)

Strainer (17)

Strainer Support

O-Ring (18)

2 Clean the debris from the check valve, especially at the O-Ring seats.

3 Lubricate O-Ring before installing check valve assembly.

4 Insert the check valve assembly (16) or check cap (30) into corresponding pump bore as

shown (see

Figure 2). Press the assembly squarely over receiving cylindrical surface until O-

Ring seats firmly over the surface and holds assembly in position.

5 Insert new or cleaned strainer (17) into bore, over check valve assembly.

6 Clean debris from strainer cover O-Ring groove and install O-Ring (18). If O-Ring does not

stay in place, use a small amount of all purpose grease to hold the O-Ring in groove.

7 Install strainer cover (19) with screws (21). Hand tighten, alternating between each screw to

keep the cover parallel to the casing face. Torque the screws to 150 in. lbs (17 Nm). Do not overtighten. Overtightening may cause damage to screw or casing.

8 Replace the plug (11) in the hole located to the right of the strainer cover (see Figure 1 on

page 8).

Page 10 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 11

PCV Removal

1 Drain the pump following the procedure provided in the section “Draining Pump” on page 8.

2 Remove the snap ring (15) (see Figure 3).

3 Using a 16 mm socket wrench, turn the valve cover (13) outward or counterclockwise (CCW)

4 Remove the spring (12) and valve (10).

5 If the valve does not come out with the spring, use needle nose pliers to remove it from the

Maintenance

CAUTION

Excessive wear on the PCV can cause improper pump performance, including flow loss or excessive or low discharge pressure.

To remove the PCV, proceed as follows:

until completely removed.

bore.

PCV Installation

To install the PCV, proceed as follows:

1 Inspect valve (10) for damage or excessive wear. Replace if necessary.

2 Install PCV in the reverse order of removal (see Figure 3).

Figure 3: PCV

Snap Ring (15)

Valve Cover (13)

Valve (10)

Spring (12)

Cover O-Ring (14)

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 11

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Maintenance

3 Apply a light application of grease on the cover of the O-Ring (14) to prevent the O-Ring from

being damaged during installation.

Modification of PCV or failure to correctly install all components of the PCV will void any regulating agency recognition applicable to this pump.

4 When the pump is operating at full speed, the discharge pressure must not exceed 50 psi (3.5

bar) with any discharge restriction (fully open to fully close discharge). If the pressure exceeds 50 psi (3.5 bar), refer to

Pump Cartridge Removal

CAUTION

Damage or excessive wear to pump cartridge can cause low suction, low flow, lock-up or excessive noise.

IMPORTANT INFORMATION

“PCV Adjustment” on page 7.

Note: Avoid introducing contamination into the unit during disassembly or installation of the

cartridge. Keep Parts clean.

To remove the pump cartridge, proceed as follows:

Note: Refer to the appropriate exploded view of pump and see Figure 7 on page 15.

1 Drain the pump following the procedure provided in the section “Draining Pump” on page 8.

2 Remove belt and pulley.

3 Remove strainer, check valve, and PCV. Refer to “Strainer/Check Valve Removal” on page 9

and “PCV Removal” on page 11 for disassembly instructions.

4 Remove the 10 head capscrews (5).

5 Slightly rotate the head (9) counterclockwise (CCW) around pump cartridge to provide

exposed edges to grasp.

6 Remove head (9) from pump casing.

7 If the pump cartridge (7) comes off with head, remove by rotating and pulling the cartridge

from the head bore (see

Figure 7 on page 15).

8 If the cartridge remains in the pump casing, grasp the shaft and/or liner and pull while slightly

turning back and forth. If necessary, gently tap around the circumference with a rubber mallet to loosen the cartridge assembly. Ensure that you keep it coaxial with the bore.

Page 12 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 13

CAUTION

Do not pry the cartridge out against the side walls, as this will damage the gasket seal surface.

Pump Cartridge Installation

Preliminary Steps

CAUTION

To prevent O-Ring damage, break corner on the pump body and cover at cartridge insertion point, as shown in Figures 4 through 6. Ensure that you remove any residual matter after you complete this procedure, as this may cause the pump to fail or wear prematurely.

Maintenance

Figure 4: Pump Cover

Using a file or sand paper , break corner as shown (See Figure 6 on page 14)

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 13

Page 14

Maintenance

Figure 5: Pump Body

Using a file or sand paper, break corner as shown (See Figure 6)

Figure 6: Breaking Corner

0.060” Max.

35°

Note: This figure represents a rough approximation.

To install the pump cartridge, proceed as follows:

1 Install the wave spring (6) in the cartridge bore with the dowel pin hole exposed by the gap in

the wave spring (see

Figure 7 on page 15).

Page 14 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 15

Figure 7: Pump Cartridge

Head Gasket (8)

Maintenance

Direction of Pump Cartridge Insertion

Pump Cartridge (7)

Wave Spring (6)

2 Lightly grease the O-Rings and the bore in which they fit using silicone grease.

3 Align the pump cartridge dowel pin with the dowel pin hole and slide in the pump cartridge

(7). If dowel pin is in the hole, you should be able to rotate the cartridge very lightly back and forth and feel the positive stops. The wave spring deflection will also be felt when the cartridge is pressed in axially.

4 Insert provided guides into screw holes. The guides will orient gasket as well as hold it in

position.

5 Install the head gasket (8). If needed, apply a thin film of motor oil onto the mating surface to

affix areas of the gasket that do not retain their position.

IMPORTANT INFORMATION

Ensure that you have completed the steps described in the “Preliminary Steps” section on page 13, before you proceed to step 6.

6 Carefully install the head (9) over the cartridge. Push head in until it comes approximately

1/4-inch from the casing face.

7 Carefully replace guides with head screws, threading each of them in a few turns.

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 15

Page 16

Maintenance

8 Alternating between the four screws closest to the shaft, draw in the head approximately one

turn on the screw at a time in order to keep the head parallel to the casing.

Notes:1) It is recommended that you t ighten a lternately opposing b olts on th e other side of the

cover instead of tightening the adjacent bolts.

2) Screws will become very tight if faces are not kept parallel. If necessary, return to

9 Once the head is fully drawn in, torque the four screws to 200 in. lbs (23 Nm).

10 Before tightening the remaining head screws, check that the pump shaft turns freely and

uniformly. If so, tighten the remaining screws to 200 in. lbs (23 Nm) and check that the pump shaft turns freely and uniformly.

11 Reinstall inlet check valve, strainer, and PCV as per previous instructions.

12 Reinstall belt and pulley (see step 1 on page 32).

13 Purge the unit of air and check for leaks.

Sump Float Removal

Pump will have poor suction or sump overflow if sump float mechanism is worn or damaged.

To remove the sump float, proceed as follows:

1 Drain the pump by following the procedure pertained in the section “Draining Pump” on

page 8.

step 3 and check to ensure that the cartridge pin is still aligned with the hole.

2 Remove the pump from the dispenser per dispenser installation instructions.

3 Remove the ten sump cover screws (5) (see Figure 8 on page 17).

4 Lift off the sump cover (4) and gasket (3). Inspect the gasket and replace, if worn or damaged.

5 The sump return float mechanism should operate freely. At full down position, the float valve

should center and seat against the rubber seal surface. If it does not seat, or parts are worn or damaged, remove the sump float assembly and replace.

Notes:1) The sump overflow float mechanism (if present) should operate freely. The float valve

should center and seat against the rubber seal surface when float is lifted straight up.

2) Either the sump float assembly (2) or the sump overflow float mechanism (23) can be removed by removing the two sump base mounting screws (24).

Page 16 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 17

Sump Float Installation

To install the sump float, proceed as follows:

1 Install the sump return float assembly (2) or sump overflow float assembly (23), holding the

mount to the casing with one finger and inserting the two screws (24) with the other hand. Ensure that the rubber washer has not fallen out and is properly seated in the recess of the float assembly mount (see

Figure 8: Sump Float Assembly

Maintenance

Figure 8).

Sump Overflow Float Assy. Option (23)

Sump Cover Screws (5)

Sump Cover (4)

Gasket (3)

Sump Return Float Assy. (2)

Mounting Screws (24)

2 Tighten the screws (24) to a torque of 18 in. lbs (2 Nm).

3 Check float mechanism. It should operate freely. At full down position, the sump return float

valve should center and seal against the rubber seal surface. The sump overflow float assembly should seat when the float is fully elevated.

4 Install the sump cover gasket (3). Correctly position the gasket onto all sealing surfaces.

5 Lower the sump cover (4) gently into place over the gasket with the pins aligned, while

ensuring that you do not move the gasket.

6 Install and tighten the center-most sum cover screw (5) to 200 in. lbs (23 Nm).

7 Install the remaining sump cover screws and tighten to 200 in. lbs (23 Nm), alternating in a

cross pattern.

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Page 18

Maintenance

OIML Switch Removal

To remove OIML switch, proceed as follows:

1 Cut and remove tamper resist wire.

2 Using a wrench, rotate the OIML Switch assembly (22) in a counterclockwise (CCW)

direction and remove it (see

CAUTION

Do not allow debris to fall into open port.

OIML Switch Installation

To install the OIML switch, proceed as follows:

1 Apply a very thin film of thread sealing compound onto the thread, beginning at about 3 mm

from the end.

Figure 9 on page 21).

CAUTION

Thread sealing tape is not advised as it may cause contamination.

2 Rotate the OIML switch assembly (22) threads in a clockwise (CW) direction into the sump

vent port by hand and tighten firmly with wrench (see

Figure 9 on page 21).

CAUTION

Do not allow debris to fall into open port.

3 Secure new tamper resist wire through appropriate holes in the switch body and pump casing

tab.

Page 18 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 19

Repair Kits

Table of Kits

Repair Kits

The following table lists fourteen repair kits.

Note: Kits listed specifically as Ultra High Flow (UHF) are for Ultra High Flow products

manufactured in Europe only.

Gilbarco Kit Number Kit Description

M00955K001 Inlet Strainer Kit-Std Pump (see note 1) 17 Strainer 1 X

M00955K002 Inlet Strainer Kit-UHF 17 Strainer, UHF 1 X

M00955K003 Check Valve Kit (see note 1) 16 Check Valve Assembly 1 X X

M00955K004 Inlet Strainer/Check Valve Kit-Std. Pump

M00955K005 Inlet Strainer/Check Valve Kit-UHF Pump 16 Check Valve Assembly 1 X

M00955K006 PCV Kit-Std Pump (see note 2) 10 (PCV) 1 X

M00955K007 PCV Kit (see note 3) 10 (PCV) 1 X

(see note

Reference No.

18 O-Ring, Strainer Cover 1

18 O-Ring, Strainer Cover 1 16 Check Valve Assembly 1 X

17 Strainer 1 25 Strainer, Dome 1 18 O-Ring, Strainer Cover 1

17 Strainer, UHF 1 25 Strainer, Dome 1 18 O-Ring, Strainer Cover 1

12 Spring, PCV 1 14 O-Ring, PCV Cover 1 15 Retaining Spring 1

Part Description Quantity Used On

Standard and

High Flow

UHF Only

Notes:

1. Not available for models M00955B102 and M00955B201.

2. Excludes model M00955B705 and UHF.

3. Includes only model M00955B705.

4. Available when sump vent location discharges from the standard vent location on top of the GDP unit. Not available when the alternate vent location on the rear cover is used.

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Page 20

Repair Kits

Gilbarco Kit Number Kit Description

M00955K008 PCV Kit-UHF Pump 10 PCV 1 X

M00955K009 Pump Cartridge Kit-std. Pump 6 Wave Spring 1 X

M00955K010 Pump Cartridge Kit- UHF Pump 6 Wave Spring 1 X

M00955K011 Inspection Kit 8 Gasket, Head 1 X X

M00955K012 Sump Overflow Check Valve Kit

(see note 4)

M00955K013 OIML Switch Kit 22 OIML Switch Assy 1 X X M00955K014 Sump Return Valve and Float Kit 2 Float, Sump Return Assy. 1 X X

Reference No. Part Description Quantity Used On

Standard and

High Flow

12 Spring, PCV 1 14 O-Ring, PCV Cover 1 15 Retaining Spring 1

7 Pump Cartridge 1 8 Gasket, Head 1 18 O-Ring, Strainer Cover 1 14 O-Ring, PCV Cover 1 20 Key, Shaft 1 15 Retainer Ring 1

- Pin-Gasket Guide 1

7 Pump Cartridge 1 8 Gasket, Head 1 18 O-Ring, Strainer Cover 1 14 O-Ring, PCV Cover 1 20 Key, Shaft 1 15 Retainer Ring 1

- Pin-gasket Guide 1

18 O-Ring, Strainer Cover 1 14 O-Ring, PCV Cover 1 3 Sump Gasket 1 23 Float, Sump Overflow

Assy 24 Capscrew 2 3 Sump Gasket 1

24 Capscrew 2 3 Sump Gasket 1

1 X X

UHF Only

Notes:

1. Not available for models M00955B102 and M00955B201.

2. Excludes model M00955B705 and UHF.

3. Includes only model M00955B705.

4. Available when sump vent location discharges from the standard vent location on top of the GDP unit. Not available when the alternate vent location on the rear cover is used.

Page 20 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 21

Pump Parts List

Figure 9: Pump Models 102 and 201

Optional 24

Pump Parts List

Optional

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 21

Page 22

Pump Parts List

Pump Models 102 and 201

The following is a list of parts for pump models M00955B102 and M00955B201 (see Figure 9 on page 21 for the exploded view of the pump assembly). This parts list is for reference only. Refer to “Repair Kits” on page 19 for replacement parts.

Item Description Part Number Quantity

1 Casing, Pump ** 1 2 Float, Sump Return Assembly (std)* 894876 1 3 Gasket, Sump 384861 1 4 Sump Cover Assembly ** 1 5 Screw, Taptite 924002 20 6 Wave Spring* 903408 1 7 Pump Cartridge* 894805 1 8 Gasket, Head* 384860 1

9 Head ** 1 10 PCV* 454800 1 11 Plug 908200 3 12 Spring, PCV* 474860 1 13 Cover, PCV 414800 1 14 O-Ring, PCV Cover* 702335 1 15 Retaining Ring* 903621 1 16 Check Valve Assembly ** 1 17 Strainer ** 1 18 O-Ring, Strainer Cover* 702332 1 19 Cover, Strainer ** 1 20 Key, Shaft* 909152 1 21 Capscrew 924021 3 22 OIML Switch Assy. (optional) 894830 1 23 Float, Sump Overflow Assy. (optional) 894850 1 24 Capscrew 924018 2-4

* Included in one or more repair parts kits. ** Not a saleable item.

Page 22 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 23

Figure 10: Pump Model 206

Pump Parts List

Optional

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 23

Page 24

Pump Parts List

Pump Model 206

The following is a list of parts for pump model M00955B206 (see Figure 10 on page 23 for the exploded view of the pump assembly). This parts list is for reference only. Refer to “Repair

Kits” on page 19 for replacement parts.

Item Description Part Number Quantity

1 Casing, Pump ** 1 2 Float, Sump Return Assembly

3 Gasket, Sump* 384861 1 4 Sump Cover Assembly ** 1 5 Screw, Taptite 924002 20 6 Wave Spring* 903408 1 7 Pump Cartridge* 894805 1 8 Gasket, Head* 384860 1 9 Head ** 1 10 PCV* 454800 1 11 Plug 908200 3 12 Spring, PCV* 474860 1 13 Cover, PCV 414800 1 14 O-Ring, PCV Cover* 702335 1 15 Retaining Ring* 903621 1 16 Check Valve Assembly* 894840 1 17 Strainer* 724890 1 18 O-Ring, Strainer Cover* 702332 1 19 Cover, Strainer 034863 1 20 Key, Shaft* 909152 1 21 Capscrew 924021 3 22 OIML Switch Assy. (optional) 894830 1 23 Float, Sump Overflow

24 Capscrew 924018 2-4 25 Strainer, Dome* 724893 1

* Included in one or more repair parts kits. ** Not a saleable item.

894876 1

(Std)*

894850 1

Assembly (Opt)

Page 24 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 25

Optional

Figure 11: Standard Flow Pump Model

Optional

Pump Parts List

Optional 11

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 25

Page 26

Pump Parts List

Standard Flow Pump Models

The following is a list of parts for the standard flow pump models M00955B107, M00955B207, M00955B705 and M00955B707 (see view of the pump assembly). This parts list is for reference only. Refer to “Repair Kits” on

page 19 for replacement parts.

Item Description Part Number Quantity

1 Casing, Pump ** 1 2 Float Assembly 894876 1 3 Gasket, Sump* 384862 1 4 Sump Cover

Assembly 5 Screw, Taptite 924002 21 6 Wave Spring* 903408 1 7 Pump Cartridge* 894805 1 8 Gasket, Head* 384860 1 9 Head ** 1 10 PCV* 454800 1 11 Plug 908200 3(4) 12 Spring, PCV* 474860 1

Spring, PCV* (705

only) 13 Cover, PCV 414800 1 14 O-Ring, PCV Cover* 702335 1 15 Retaining Ring* 903621 1 16 Check Valve

Assembly* 17 Strainer* 724890 1 18 O-Ring, Strainer

Cover* 19 Cover, Strainer 034863 1 20 Key, Shaft* 909152 1 21 Capscrew 924021 3 22 OIML Switch

Assembly 23 Float, Sump Overflow

Assembly 24 Capscrew 924018 4 25 Strainer, Dome* 724893 1 26 Sleeve, PCV ** 1 27 Seal Plug ** 1 28 Tube, Vortex ** 1 29 Plug 908202 1 30 Check Cap 724842 1

* Included in one or more repair parts kits. ** Not a saleable item.

Figure 11 on page 25 for the exploded

** 1

474865

894840 1

702332 1

894830 1

894850 1

Page 26 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 27

Figure 12: UHF Pump Models 602 and 605

Pump Parts List

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 27

Page 28

Pump Parts List

UHF Pump

The following is a list of parts for the UHF pump models M00955B602 and M00955B60 5 (see

Figure 12 on page 27). This parts list is for reference only. Refer to “Repair Kits” on page 19

for replacement parts.

Item Description Part Number Quantity

1 Casing, Pump ** 1 2 Float Assembly 894876 1 3 Gasket, Sump* 384861 1 4 Sump Cover

Assembly 5 Screw, Taptite 924002 21 6 Wave Spring* 903408 1 7 Pump Cartridge* 894806 1 8 Gasket, Head* 384860 1 9 Head ** 1 10 PCV* 454810 1 11 Plug 908200 4 12 Spring, PCV* 474870 1 13 Cover, PCV 414800 1 14 O-Ring, PCV Cover* 702335 1 15 Retaining Ring* 903621 1 16 Check Valve

Assembly* 17 Strainer* 724895 1 18 O-Ring, Strainer

Cover* 19 Cover, Strainer 034863 1 20 Key, Shaft* 909152 1 21 Capscrew 924021 3 22 OIML Switch

Assembly 23 Float, Sump Overflow

Assembly 24 Capscrew 924018 4 25 Strainer, Dome* 724893 1 26 Sleeve, PCV ** 1 27 Seal Plug ** 1 28 Tube, Vortex ** 1

* Included in one or more repair parts kits. ** Not a saleable item.

** 1

894840 1

702332 1

894830 1

894850 1

Page 28 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 29

Troubleshooting

This section provides troubleshooting and maintenance information for pumps.

Maintenance must be performed by qualified technicians only. Follow the appropriate procedures and warnings as presented in this manual.

Troubleshooting Table

The following table contains a list of troubleshooting symptoms and probable causes.

Symptom Probable Cause

Pump not priming or excessive time to prime

Reduced Capacity (Flow) • Pump speed too low

Noise • Inlet Restriction of:

Leakage 1 Port • Loose piping

2 Weep Hole • Damaged shaft seal O-Ring

3 Head or Sump Gasket • Damaged gasket

4 Sump Overflow • Excessively foamy fuel

Motor/Belt Overheating • Pump cartridge locked up

* This applies only to units equipped with the overflow check valve option.

Troubleshooting

IMPORTANT INFORMATION

• Suction line obstruction

• Air leak in suction line

• Clogged strainer (refer to “Strainer/Check Valve Removal” on

page 9 and “Strainer/Check Valve Installation” on page 10)

• Pump speed too low (check motor, pulleys and belt)

• Damaged or missing strainer cover O-Ring (refer to “Strainer/

Check Valve Removal” on page 9 and “Strainer/Check Valve Installation” on page 10)

• PCV open, worn or not seated properly (refer to “PCV

Removal” and “PCV Installation” on page 11)

• Air leak in suction lines

• Restriction in suction lines

• Excessive system pressure (flow loss to PCV)

• PCV open, worn or not seated properly

• Worn or damaged pump cartridge

a. Inlet piping b. Clogged strainer

• Excessive pump speed

• Pump inadequately fastened to the base plate

• Misaligned pulleys

• Improperly anchored piping

• PCV setting too high

• Excessive time with closed discharge line

• Damaged pump cartridge

• Excessive system pressure

• Improperly applied pipe thread sealant

• Damaged shaft seal

• Improperly torqued mounting screws

• Failure of sump float mechanism

• Failure of sump overflow check valve*

• PCV stuck closed

• Excessive speed

• Improper belt tightening or alignment

• Defective or damaged motor

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 29

Page 30

Troubleshooting

Checking Pump Vacuum

WARNING

You are working in a potentially dangerous environment of flammable fuels and vapors.

Fire or explosion could result in severe injury or death if you do not follow safe procedures.

Read and follow all safety precautions as outlined in the section “Important

Safety Information” on page 4.

CAUTION

Do not use Teflon tape. Teflon tape may shred off and get caught within components.

CAUTION

Ensure that fittings are properly tightened and check for leaks.

To check pump vacuum, proceed as follows:

1 Remove 1/4-inch NPT plug from the side of the strainer extrusion on pump face (see

Figure 13).

2 Install a long 1/4-inch pipe nipple by screwing into pump in order to extend beyond pump

pulley.

Figure 13: Pump Vacuum

Vacuum Port

Vacuum Gauge

Pipe Nipple

3 Attach the vacuum gauge into the pipe.

Page 30 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 31

Checking the Pump Pressure

To check the pump pressure, proceed as follows:

1 Remove the feedline filter from the manifold (see Figure 14).

2 Screw on filter cap (R18896-G1) modified with a 1/4-inch NPT tapped hole.

3 Attach the pressure gauge into the hole on the filter cap.

IMPORTANT INFORMATION

When testing is complete, replace the filter cap with the filter.

Figure 14: Pump Pressure Test Set-up

Troubleshooting

Fuel Filter

Manifold

Filter Cap

Pressure Gauge

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 31

Page 32

Troubleshooting

Pump Performance Test

1 Check the belt tension.

CAUTION

Tighter belt tensions can cause pump and motor bearing wear and premature failure. Loose belts may result in lower flow or excessive belt wear.

The recommended belt tension is 45-55 lbs. (200-244 Newtons).

Notes: 1) The proper belt tension is the lowest tension at which the belt will not slip.

2) Operate the unit with both pressure and vacuum gauges attached. Use an approved container to collect fuel. Clean spills promptly.

Belts and pulleys can pinch fingers and hands. Injuries may result. Avoid placing fingers or hands between belts and pulleys. Never turn power on to fit belt on pulley.

2 Run pump in by-pass with all nozzles closed and record pressure.

3 Run pump in full flow with all nozzles wide-open and record pressure and vacuum. Use a stop

watch to record flow rate in gpm or lpm.

4 If necessary, check the pump speed with a rpm photo-tachometer. Blackmer GDP nominal

speed should be approximately 1250 rpm.

Acceptable Pump Range Table

By-Pass-

Full Flow - All Nozzles Open

Pump Configuration Inlet Vacuum

inHg/cmHg

One Pumping Unit per Hose

Standard Flow 3-8 / 7.6-20.3 15-30 / 1.0-2.1 10-13 / 37-50 20-35 / 1.3-2.4 High Flow 3-8 / 7.6-20.3 25-40 / 1.7-2.8 18-24 / 68-90 28-45 / 1.9 -3.1

One Pumping Unit per Two Hoses

Standard Flow 3-8 / 7.6-20.3 20-35 / 1.3-2.4 17-20 / 64-76 22-38 / 1.5-2.6

Notes:

1. Pressures, vacuum and flow will vary depending upon installation factors, fuels and hardware configurations.

2. For UHF pump ranges, contact Gilbarco.

Discharge

Pressure

psi/bar

Flow Rate

gpm/lpm

Nozzles Closed

Discharge Pressure

psi/bar

Page 32 MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Page 33

This page is intentionally left blank.

Troubleshooting

MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 33

Page 34

Troubleshooting

The Advantage® Series, Encore®, Eclipse®, Gilbarco®, and Legacy® are registered trademarks of Gilbarco Inc. Allen® is a registered trademark of Industrial Fasteners, Inc. Blackmer

is a registered trademark of Dover Corporation. Teflon® is a registered trademark of E.I.

Du Pont de Nemours and Company.

© 2008 Gilbarco Inc. 7300 West Friendly Avenue · Post Office Box 22087 Greensboro, North Carolina 27420 Phone (336) 547-5000 · http://www.gilbarco.com· Printed in the U.S.A. MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008

Gasboy Blackmer GDP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Purpose

Intended Users

Table of Contents

Required Tools

Required Reading

Related Documents

Pump Model Identification

Abbreviations and Acronyms

Important Safety Information

Installation

Inlet Fittings

Configuration Table

Installing the Fittings

Operation

PCV Adjustment

Maintenance

Draining Pump

Strainer/Check Valve Removal

Strainer/Check Valve Installation

PCV Removal

PCV Installation

Pump Cartridge Removal

Pump Cartridge Installation

Sump Float Removal

Sump Float Installation

OIML Switch Removal

OIML Switch Installation

Repair Kits

Table of Kits

Pump Parts List

Pump Models 102 and 201

Pump Model 206

Standard Flow Pump Models

Troubleshooting

Troubleshooting Table

Checking Pump Vacuum

Checking the Pump Pressure

Pump Performance Test