Gasboy Fuel Point User Manual

Fuel Point

Parts Manual

PT -1954

(formerly C35709)

Computer Programs and Documentation

Federal Communications Commission (FCC) Warning

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.

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 required to correct the interference at his own expense. Changes or modifications not expressly
approved by the manufacturer could void the user’s authority to operate this equipment.

Approvals

Gasboy, Greensboro, is an ISO 9001:2000 registered facility.
Underwriters Laboratories (UL):

UL File# Products listed with UL

MH4314

MH6418

MH7404
MH10581 Key con t r o l u n i t , M o d e l G K E - B S e r i e s

All dispensers and self-contained pumping
units

Power operated Transfer Pump Models 25,
25C, 26, 27, 28, 72, 72S, 72SP , 72X, 73 and
1820

Hand operated Transfer Pump Models 1230
Series, 1243 Series, 1520 and 1720 Series

Card reader terminals, Models 1000, 1000P
Site controller, Model 2000S CFN Series
Data entry terminals, Model TPK-900 Series
Fuel Point Reader System

New York City Fire Department (NYFD):

NYFD C of A # Product

4823 9100A, 9140A, 9152A, 9153A,

4997 9822A, 9823A
5046 9100Q, 9140Q, 9152Q, 9153Q,

9800A, 9840A, 9850A, 9852A,
9853A, 9140

9800Q, 9840Q, 9852Q, 9853Q

National Conference of Weights and Measures (NCWM) - Certificate of Compliance (CoC):

Gasboy pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program (NTEP). NCWM has issued the following CoC:

CoC# Product Model # CoC# Product Model # CoC# Product Model #

95-179A2 Dispenser

95-136A5 Dispenser 9800 Series 91-057A3 Controller

9100 Retail Series, 8700
Series, 9700 Series

91-019A2 Dispenser

9100 Commercial
Series

1000 Series FMS,
2000S-CFN Series

California Air Resources Board (CARB):

Executive Order # Product

G-70-52-AM Balance Vapor Recovery
G-70-150-AE VaporVac

Patents

Gasboy products are manufactured or sold under one or more of the following US patents:

Dispensers

5,257,720

Point of Sale/Back Office Equipment

D335,673

Trademarks

Non-registered trademarks

Atlas™
Consola™
Infinity™

Registered trademarks

ASTRA
Fuel Point
Gasboy
Keytrol
Slimline

Additional US and foreign patents pending.

®

®

®

®

®

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. · For information regarding Gasboy Literature, call [phone]
E-mail: [e-mail] · Internet: http://www.gasboy.com
© 2005 GASBOY · All Rights Reserved

Table of Contents

Table of Contents

1 – Important Safety Information 1-1

2 – Introduction 2-1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Intended Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Related Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

3 – Parts List 3-1

Fuel Point Reader, C06699 - Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Fuel Point Reader, C06699 - Side View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Fuel Point Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Vehicle Module Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Vehicle Kit, C06761 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Hose Assembly - Internal Wire Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Hose Assembly - External Wire Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Hose Wire Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Page i PT-1954 Fuel Point Parts Manual · August 2005

Table of Contents

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Page ii PT-1954 Fuel Point Parts Manual · August 2005

1 – 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 se cti o ns in th is
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 To tal 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 Gasboy Authorized
Service Contractor or call the Gasboy Service Center at
1-800-444-5529. 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 Gasboy replacement parts and retrofit kits
on your pump/dispenser. Using parts other than genuine
Gasboy replacement parts could create a safety hazard and
violate 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 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)

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

PT-1954 Fuel Point Parts Manual · August 2005 Page 1-1

Important Safety Information

cause potentially dangerous vapors in the vicinity of the
dispenser or island.

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.

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.

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 to pinch wires when replacing covers. Follow OSHA
Lockout/T agout requirement s. S tation 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.

WARNING

!

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

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.

Lockout/Tagout

Lockout/Tagout covers servicing and maintenance of
machines and equipment in which the unexpected
energization or start-up of the machine(s) or equipment or
release of stored energy could cause injury to employees or
personnel. Lockout/Tagout applies to all mechanical,
hydraulic, chemical or other 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.

Page 1-2 PT-1954 Fuel Point Parts Manual · August 2005

Important Safety Information

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.

The following actions are recommended regarding these hazards:

Collision of a Vehicle with Unit Fire at Island Fuel Spill

• Do not go near a fuel spill or allow anyone else in the area.

• Use station EMERGENCY CUTOFF immediately. T urn of f all system circuit brea kers 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.

Page 1-3 PT-1954 Fuel Point Parts Manual · August 2005

Important Safety Information

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Page 1-4 PT-1954 Fuel Point Parts Manual · August 2005

Purpose Introduction

2 – Introduction

Purpose

This manual lists parts information for the Fuel Point system. Using part numbers when
ordering will speed up your order and reduce the possibility of the wrong parts being shipped.
When ordering replacement parts, ensure that you give the complete name and part number as
shown in the relevant parts list. It would also help to provide the serial number of the
equipment.

Intended Users

The intended users of this manual are:

• Authorized Service Contractors (ASCs)

• Customer Specified Contractors (CSCs)

Related Reading

The following documents contain related information and may be helpful when ordering parts
for the Fuel Point:

Document Number Title GOLD® Library

C35628 Fuel Point Reader Installation and Retrofit

Warranty

For information on warranty, refer to Gasboy’s Warranty Policy Statement - MDE-4255. If
you have any warranty-related questions, contact Gasboy’s Warranty Department at its
Greensboro location.

Gasboy Fuel Management Products

Instructions Manual

PT-1954 Fuel Point Parts Manual · August 2005 Page 2-1

Introduction Abbreviations and Acronyms

Abbreviations and Acronyms

The following table contains a list of acronyms used in this guide.

Acronym Definition

ASC Authorized Service Contractor
CPU Central Processing Unit
CSC Customer Specified Contractor
PC Personal Computer
PCB Printed Circuit Board

Page 2-2 PT-1954 Fuel Point Parts Manual · August 2005

3 – Parts List

Procedures requiring disassembly of portions of the system must be performed by ASCs or
CSCs only. Gasboy has a distributor network which services fuel dispensing equipment and
management systems in every section of the country.

To reduce the risk of electrical shock when servicing, turn off and lock out all power to the
Fuel Point system.

Parts List

WARNING

PT-1954 Fuel Point Parts Manual · August 2005 Page 3-1

Parts List Fuel Point Reader, C06699 - Front View

Fuel Point Reader, C06699 - Front View

Page 3-2 PT-1954 Fuel Point Parts Manual · August 2005

Fuel Point Reader, C06699 - Front View Parts List

Item Part No. Description

1 C35611 Cover Assy.
2 C35627 Housing
3 C35599 Wiring Cover
4 C06698 Chassis Assy., 115VAC
5 *C06723 Cable Assy., AC Term Blk.
6 *C06697 PCB Assy., RS485 Comm.
7 **C02978 IC, RS-485 Line Driver
8 **C03391 IC, RS-485 Line Receiver
9 *C08886 PCB Assy., CPU
10 **C35422KFPR IC, Programmed
NOTE: When ordering a program, you must specify that it is to be used in the Fuel Point Reader.
11 *C03756 Bushing, 1"
12 *C35601 I/S Cage
13 *C35667 P/S Hold Down Brkt
14 *C35619 Base Weld Assy.
15 *C06724 Cable Assy., Fuseholder
16 **C04044 Fuse, 3AG, 1 Amp, Slo-blo
17 *C35604 P/S Cover
18 *C02704 Toggle Switch SPST
19 *C06763 Cable Assy., DC Power
20 *C06725 Cable Assy., AC Power
21 *C06728 Cable Assy., 14-Pos Ribbon
22 *C06727 Cable Assy., 10-Pos Ribbon

* Indicates that this part is a subpart of the preceding part without an asterisk.

** Indicates that this part is a subpart of the preceding part with an asterisk.

PT-1954 Fuel Point Parts Manual · August 2005 Page 3-3

Parts List Fuel Point Reader, C06699 - Side View

Fuel Point Reader, C06699 - Side View

Page 3-4 PT-1954 Fuel Point Parts Manual · August 2005

Fuel Point Reader, C06699 - Side View Parts List

Item Part No. Description

1 C06767 Door Assy.
2 *035009 Lock w/Key
3 *C34753 Lock Cam
4 C06790 Mounting Kit (Not Shown)
5 C35618 Mounting Brkt.
6 C06778 Cable Assy. 115VAC Power Input (Not

Shown)

7 C06779 Cable Assy. RS-485 Comm Input (Not

Shown)
8 C08875 Gasket (Not Shown)
9 C06783 PCB Assy., I/S Barrier
10 C02446 Line Filter
11 C35668 Bracket P/S Hold Down
12 C06726 Cable Assy., Heater 115VAC
13 C06797 Power Supply, 5VDC
NOTE: Items 9, 10, 11, 12, & 13 are subparts of item 4 C06698 from front view pages.

* Indicates that this part is a subpart of the preceding part without an asterisk.

** Indicates that this part is a subpart of the preceding part with an asterisk.

PT-1954 Fuel Point Parts Manual · August 2005 Page 3-5

Parts List Fuel Point Parts

Fuel Point Parts

Page 3-6 PT-1954 Fuel Point Parts Manual · August 2005

Fuel Point Parts Parts List

Item Part No. Description

1 C06737 Master Authorizer
2 C06736 Programmer w/Charger

*C06847 Programmer, Vehicle Module
**C35422KFPP IC, Programmed

NOTE: When ordering a replacement program, you must specify that it is to be used in the Fuel Point
Programmer and provide the site name of the end user. If requesting changes to the current configuration, a
new Configuration Form may be required.

3 **C09492 Battery Pack, Replacement (Subpart of

4 *C09488 Charger, VM Programmer (Subpart of

5 C06832 Junction Box, Pre-Amp, Single

C06833 Junction Box, Pre-Amp, Twin
C07112 Junction Box, Pre-Amp, Single, Special

C07116 Junction Box, Pre-Amp, Twin, Special
6 C35706 Mounting Bracket
7 C08888 Pre-Amp PCB

C06847)

C06736)

* Indicates that this part is a subpart of the preceding part without an asterisk.

** Indicates that this part is a subpart of the preceding part with an asterisk.

PT-1954 Fuel Point Parts Manual · August 2005 Page 3-7

Parts List Vehicle Module Components

Vehicle Module Components

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??????????
????????

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??????????

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????????
??????????

????? ?

????? ?

????? ?

????? ?

Page 3-8 PT-1954 Fuel Point Parts Manual · August 2005

Vehicle Kit, C06761 Parts List

Vehicle Kit, C06761

PT-1954 Fuel Point Parts Manual · August 2005 Page 3-9

Parts List Hose Assembly - Internal Wire Components

Hose Assembly - Internal Wire Components

Page 3-10 PT-1954 Fuel Point Parts Manual · August 2005

Hose Assembly - External Wire Components Parts List

Hose Assembly - External Wire Components

PT-1954 Fuel Point Parts Manual · August 2005 Page 3-11

Parts List Hose Wire Repair Parts

Hose Wire Repair Parts

Page 3-12 PT-1954 Fuel Point Parts Manual · August 2005

© 2005 GASBOY
7300 West Friendly Avenue • Post Office Box 22087
Greensboro, North Carolina 27420
Phone [phone] • http://ww w.gasboy.com • Printed in the U.S.A.