All Gasboy computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall remain the property of, Gasboy. Such
computer programs and documents may also contain trade secret information. The duplication, disclosure, modification, or unauthorized use of computer programs or
documentation is strictly prohibited, unless otherwise licensed by Gasboy.
Federal Communications Commission (FCC) Warning
This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be re quired to correct the inte rference at his own exp ense. Changes or modifications not expressly approved by
the manufacturer could void the user’s authority to operate this equipment.
Approvals
Trademarks
Additional US and foreign trademarks pending.
Other brand or product names shown may be trademarks or registered trademarks of their respective holders.
This document is subject to change without notice.
E-mail: literature@gasboy.com · Internet: http://www.gasboy.com 2014 GASBOY. All Rights Reserved.
MDE-5044A Atlas® DEF Operation, Diagnostic, and Recommended Spare Parts Manual · April 2014 Page i
Table of Contents
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Page iiMDE-5044A Atlas® DEF Operation, Diagnostic, and Recommended Spare Parts Manual · April 2014
PurposeIntroduction
1 – Introduction
Purpose
This manual provides information on the operations, diagnostics, and recommended spare
parts for the Atlas
Intended Users
This manual is intended to assist the Authorized Service Representative (ASR) or technician
in troubleshooting, operating, and identifying the parts for the Atlas DEF dispenser.
Required Tools
®
Diesel Exhaust Fluid (DEF) dispensers.
Following tools are required for diagnosing and repairing the Atlas DEF dispenser:
• Digital Voltmeter
®
• Flat-blade and Phillips
Screwdrivers
• Set of Hydraulic Wrenches
• Rubber Mallet
• Magnetic Ring Tool (M10656B001) for units without M10257B002 Nozzle
Related Documents
Document
NumberTitleGOLD
FE-356Field Wiring Diagram Atlas Retail, Commercial, E-85, and
DEF Dispenser
MDE-4331 Atlas
MDE-4334 Commercial and Retail Series Atlas St
Fuel Systems Installation ManualGasboy Atlas Pumps/Dispensers
s with Electronic and Mechanical Displays
Abbreviations and Acronyms
TermDescription
ASRAuthorized Service Representative
CPUCentral Processing Unit
DEFDiesel Exhaust Fluid
E-CAL Electronic Calibration
Page 1-2 MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
2 – Important Safety Information
Notes: 1) Save this Important Safety Information section
in a readily accessible location.
2) Although DEF is non-flammable, diesel is
flammable. Therefore, for DEF cabine ts that are
attached to diesel dispensers, follow all the
notes in this section that pertain to flammable
fuels.
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 o r 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 in formation 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).
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
SHUT-OFF in th e cas e of an emerge nc y a nd not
the console’s ALL STOP and PUMP STOP or
similar keys.
!
WARNING
!
Total Electrical Shut-Off Before Access
Any procedure that requires access to electrical component s or
the electronics of the dispenser requires total elect rical shut off
of that unit. Understand the function and location of this switch
or circuit breaker before inspecting, installing, maintaining, or
servicing Gasboy 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 Gasboy Authorized Serv ice
Contractor or call the Gasboy Support Center at
1-800-444-5529. It is imperative to your safety and the safe ty of
oth
e
rs 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), Occupatio nal Safety and Health Administration
(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 lea d to leg al citation s
with penalties or affect the safe use and operation of the
equipment.
Replacement Parts
Use only genuine Gasboy replacement p art s and re trofit kits on
your pump/dispenser. Using parts other than genuine Gasboy
replacement parts could create a safety hazard and violate
local regulations.
Safety Symbols and Warning Words
This section provides important information about wa rn ing
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 prev
ent 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 followe d to prevent death, injury or
damage to the equipment:
DANGER: Al
erts yo
u 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
un
safe practice which may result in minor injury.
CAUTION w
i
thout 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.
DEF is non-flammable. Therefore, expl
osion and fire safety
warnings do not apply to DEF fluid lines.
!
!
!
Important Safety Information
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014Page 2-1
Important Safety Information
The pump/dispenser contains a chemical known to the
State of California to cause cancer.
WARNING
!
The pump/dispenser contains a chemical known to the
State of California to ca use birth defects or other
reproductive harm.
WARNING
!
Gasoline/DEF 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.
DEF generates ammonia gas at high er temperatures.
When opening enclosed panels, allow the unit to air out to
avoid breathing vapors.
If respiratory difficulties develop, move victim away from
source of exposure and into fresh air. If symptoms persist,
seek medical attention.
WARNING
!
WARNING
!
Gasoline inhaled may cause unconsciousness
and burns to lips, mouth and lungs.
Keep airway open.
Seek medical advice immediately.
WARNING
!
Gasoline/DEF spilled in eyes may cause burns to
eye tissue.
Irrigate eyes with water for approximately
15 minutes.
Seek medical advice immediately.
WARNING
!
Gasoline/DEF spilled on skin may cause burn s.
Wash area thoroughly with clear water.
Seek medical advice immediately.
WARNING
!
DEF is mildly corrosive. Avoid cont act with eyes , skin, and
clothing. Ensure that eyewash stations and safety
showers are close to the work location. Seek medical
advice/recommended treatment if DEF spills into eyes.
WARNING
!
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 ig nite 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 capab l e of
rendering first aid be present during servicing. Familiarize
yourself with Cardiopulmonary Resuscitation (CPR) methods, if
you work with or around high voltages. This informa tion 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.
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)
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/Tagout
requirements. Station employees and service contractors need
to understand and comply with this program complete ly 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.
Page 2-2MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014
IMPORTANT: Oxyg en may be needed at scene if gasoline has
been ingested or inhaled. Seek medical advice immediately.
Lockout/Tagout
Lockout/Tagout covers servicin g and maintenance of machines
and equipment in which the unexpecte d energization or sta rt-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 electric al haz ards.
Hazards and Actions
WARNING
Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a
serious hazard.
Fire or explosion may result, causing serious injury or death.
Follow established emergency procedures.
DEF is non-flammable. However it can create a slip hazard. Clean up spills promptly.
!
Collision of a Vehicle with UnitFire at IslandFuel Spill
The following actions are recommended regarding these hazards:
Important Safety Information
• Do not go near a fuel spill or allow anyone else in the area.
• Use station EMERGENCY CUTOFF immediately . Turn off all system circuit breakers to the island(s).
• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not
remove AC power and do not always stop product flow.
• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow
open flames, smoking or power tools in the area.
• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.
MDE-5044A Atlas® DEF Operation, Diagnostics, and Recommended Spare Parts Manual · April 2014Page 2-3
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