Gasboy Blackmer GDP User Manual
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.
Table of Contents
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
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.
Related Documents
Document Number Title GOLD Library
MDE-3802 Encore® and Eclipse® Site Preparation
MDE-2833 Pumps and Dispensers Site Preparation Site Prep
MDE-2530 Pump and Dispenser Installation Manual Advantage® and Legacy® models
MDE-3985 Encore Installation Manual Encore and Eclipse
Manual
Encore and Eclipse
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
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
Important Safety Information
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
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
Installation
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
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
Maintenance
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).
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.
MDE-4096C Blackmer® Global Dispenser Pump Operation, Maintenance and Kit Installation Manual · April 2008 Page 9
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
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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