Gasboy Blackmer GDP User Manual

MDE-4096C

Blackmer® Global Dispenser Pump Operation,

Maintenance and Kit Installation Manual

April 2008

Introduction

Purpose

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

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).

IMPORTANT INFORMATION

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.

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	Encore and Eclipse
	Manual
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

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

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

Introduction

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.

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 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 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)

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

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.

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

						Important Safety Information
No Open Fire				In an Emergency
		Open flames from matches, lighters, welding		Inform Emergency Personnel
				Compile the following information and inform emergency
torches or other sources can ignite fuels and their vapors.				personnel:
					• Location of accident (for example, address, front/back of
No Sparks - No Smoking					building, and so on)
					• Nature of accident (for example, possible heart attack, run
Sparks from starting vehicles, starting or using power tools,					over by car, burns, and so on)
burning cigarettes, cigars or pipes can also ignite fuels and					• Age of victim (for example, baby, teenager, middle-age,
their vapors. Static electricity, including an electrostatic					elderly)
charge on your body, can cause a spark sufficient to ignite					• Whether or not victim has received first aid (for example,
fuel vapors. Every time you get out of a vehicle, touch the					stopped bleeding by pressure, and so on)
metal of your vehicle, to discharge any electrostatic charge					• Whether or not a victim has vomited (for example, if
before you approach the dispenser island.					swallowed or inhaled something, and so on)
Working Alone					!	WARNING
It is highly recommended that someone who is capable of
						Gasoline ingested may cause unconsciousness
rendering first aid be present during servicing. Familiarize
						and burns to internal organs.
yourself with Cardiopulmonary Resuscitation (CPR) methods,
						Do not induce vomiting.
if you work with or around high voltages. This information is
						Keep airway open.
available from the American Red Cross. Always advise the
						Oxygen may be needed at scene.
station personnel about where you will be working, and
						Seek medical advice immediately.
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					!	WARNING
information in the service manual and OSHA documentation.
						Gasoline inhaled may cause unconsciousness
Working With Electricity Safely						and burns to lips, mouth and lungs.
						Keep airway open.
Ensure that you use safe and established practices in
						Seek medical advice immediately.
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
						WARNING
sealing devices and compounds are in place. Ensure that you					!
do not pinch wires when replacing covers. Follow OSHA
						Gasoline spilled in eyes may cause burns to eye
Lockout/Tagout requirements. Station employees and service
						tissue.
contractors need to understand and comply with this program
						Irrigate eyes with water for approximately 15
completely to ensure safety while the equipment is down.
						minutes.
Hazardous Materials						Seek medical advice immediately.
Some materials present inside electronic enclosures may
					!	WARNING
present a health hazard if not handled correctly. Ensure that
you clean hands after handling equipment. Do not place any						Gasoline spilled on skin may cause burns.
equipment in the mouth.						Wash area thoroughly with clear water.
						Seek medical advice immediately.
	!	WARNING
				IMPORTANT: Oxygen may be needed at scene if gasoline
	The pump/dispenser contains a chemical known to the
	State of California to cause cancer.			has been ingested or inhaled. Seek medical advice
				immediately.
				Lockout/Tagout
	!	WARNING
				Lockout/Tagout covers servicing and maintenance of
	The pump/dispenser contains a chemical known to the
				machines and equipment in which the unexpected
	State of California to cause birth defects or other			energization or start-up of the machine(s) or equipment or
	reproductive harm.			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

11-1/2” NPT x 1-3/4” LG. SCH. 80 NIPPLE and 1-1/2” NPT 150# Union (Gilbarco part numbers R11493-50 and K12179)

21-1/2” NPT x 1-3/4” LG. SCH. 80 NIPPLE and 1-1/2” NPT 300# Union (Gilbarco part numbers R11493-50 and Q10846-08)

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

Installing the Fittings

To install the fittings, proceed as follows:

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.

2Hand-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 “Troubleshooting Table” on page 29).

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

Operation

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.

! 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 precautions. Failure to do so may result in personal injury or property damage.

Note: Numbers within parentheses in the procedural steps in the manual refer to the numbers mentioned in the referenced figures.

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

1To 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).

2To 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

IMPORTANT INFORMATION

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 materials are ready to contain any released fuel.

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

Draining Pump

Figure 1: Typical Plug Location

Plug, Left Side

Casing (11)

Plug, Lower Right Face (11)				Plug, Upper
				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.

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

2Remove 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 Figure 1).

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

Maintenance

3Remove 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.

4If sump drainage is desired, remove the plug (11) near the mounting hole on the left side of pump casing (1).

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

6Properly dispose of all fluid drained from pump.

7After 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.

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

1Lower pump fluid level by removing the plug (11) located at the right of the strainer cover and rotating the pump shaft counterclockwise (CCW) approximately 10 turns (see Figure 2 on page 10).

Note: Removing the plug allows air to enter.

2Remove the three strainer cover screws (21).

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

4Carefully 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.

5If equipped, remove the inlet check valve assembly (16). Inspect for cracked or otherwise damaged O-Rings. Replace if damaged.

6Lift 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:

1If 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)

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

3Lubricate O-Ring before installing check valve assembly.

4Insert 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.

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

6Clean 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.

7Install 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.

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

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

Maintenance

PCV Removal

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:

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

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

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

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

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

PCV Installation

To install the PCV, proceed as follows:

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

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

Figure 3: PCV

Valve Cover (13)

Snap Ring (15)	Valve (10)

Spring (12)

Cover O-Ring (14)

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

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