Gasboy M04230K00X User Manual

Introduction

This manual provides installation instructions for the Gasboy Pulser Kits M04230K001 through M04230K013. The kits and associated models covered in this manual are listed and described in the Kit Identification section.

Required Reading

Before installing a kit, the installer must read, understand, an d follow:

• This manual

• NFPA 30A, The Automotive and Marine Service Station Code

• NFPA 70, The National Electric Code

• Applicable federal, state and local codes and regulations

MDE-4282B

Gasboy Pulser Kits M04230K00X Installation

July 2005

Failure to do so may adversely affect the safe use and operation of the equipment.

Note: This kit must be installed by a Gasboy Authorized Service Contractor (ASC) to ensure

Required Tools

The following tools are needed to install the Pulser Kits:

warranty.

•Wrench Set

• Flat tip screwdriver

• Cross tip screwdriver

• Punches (to remove and install pins)

MDE-4282B Gasboy Pulser Kits M04230K00X Installation • July 2005 Page 1

Introduction

Kit Identification

Kit number Description

M04230K001 - KIT PLSR CX 9100QTW2, QXTW2 Pulser and Coupling Assembly; 10:1 M04230K002 - KIT PLSR CC 9100QTW2, QXTW2 Pulser and Coupling Assembly; 100:1 M04230K003 - KIT PLSR 1:1 9100QTW2, QXTW2 Pulser Assembly; 1:1; 91 LTR M04230K004 - KIT PLSR CX 9100Q, QX Pulser and Coupler Assembly; 10:1 M04230K005 - KIT PLSR CC 9100Q, QX Pulser and Coupler Assembly; 100:1 M04230K006 - KIT PLSR 1:1 9100Q, QX Pulser Assembly; 1:1; 91 LTR M04230K007 - KIT PLSR CX 9140Q, QX Pulser and Coupling Assembly; 10:1 M04230K008 - KIT PLSR CC 9140Q, QX Pulser and Coupler Assembly; 100:1 M04230K009 - KIT PLSR 1:1 9140Q, QX Pulser Assembly; 1:1; 91EK LTR M04230K010 - KIT PLSR CZ 87Q Pulser Assembly; 10:1 Money VR 10/4 M04230K011 - KIT PLSR CZ 87QTW Pulser Assembly; 10:1 Money VR 10/4 M04230K012 - KIT PLSR CM 87Q/QX Pulser Assembly; 100:1 Money VR 10 M04230K013 - KIT PLSR CM 87QTW/QXTW Pulser Assembly; 100:1 Money VR 10

Page 2 MDE-4282B Gasboy Pulser Kit s M042 30K 00X Inst allatio n • July 2005

Parts Lists

Introduction

M04230K001 - KIT-PLSR CX 9100QTW2, QXTW2 10:1

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 2

051806 SCR 1/4-28X5/8 HHC 6 068891 WASHER,LOCK EXT 1/4 1114 14 046970 PLATE-MOUNTING PULSER 100:1 2 056877 SPACER .944 NOM.LENGTH (F) 4 046973 PLSR & CPLG ASSY;10:1 2 025015 ELBOW-CONDUIT 1/2 X 45 M/F MCH 2 023944 CONDUIT-BENT PULSER1 TWIN 1 066400 1/2"UNY EXP PROOF COND UNION 3 064830 CONDUIT TEE, MACHINED 1 023946 CONDUIT-BENT PULSERS T TWIN 1 051805 SCR 1/4-20X5/8 HHC PL 6 043225 PIN SPIROL 5/64X7/16 CRS ZINC 2 031035 HUB-QUAN. SHAFT EXTENSION 2 027041 GEAR, QUANTITY 2 049406 RING RET 5133-25-ZF 2 027044 PLATE AND IDLER GEAR ASSY 2 053920 SCR 1/4-20X5/8 WSH HD TYP T 2 023945 CONDUIT-BENT PULSER2 TWIN 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 2 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

M04230K002 - KIT-PLSR CC 9100QTW2,QXTW2 100:1

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 2

051806 SCR 1/4-28X5/8 HHC 6 068891 WASHER,LOCK EXT 1/4 1114 14 046970 PLATE-MOUNTING PULSER 100:1 2 056877 SPACER .944 NOM.LENGTH (F) 4 046972 PLSR & CPLG ASSY;100:1 2 025015 ELBOW-CONDUIT 1/2 X 45 M/F MCH 2 023944 CONDUIT-BENT PULSER1 TWIN 1 066400 1/2"UNY EXP PROOF COND UNION 3 064830 CONDUIT TEE, MACHINED 1 023946 CONDUIT-BENT PULSERS T TWIN 1 051805 SCR 1/4-20X5/8 HHC PL 6

MDE-4282B Gasboy Pulser Kits M04230K00X Installation • July 2005 Page 3

Introduction

Part Number Description Quantity

043225 PIN SPIROL 5/64X7/16 CRS ZINC 2 031035 HUB-QUAN. SHAFT EXTENSION 2 027041 GEAR, QUANTITY 2 049406 RING RET 5133-25-ZF 2 027044 PLATE AND IDLER GEAR ASSY 2 053920 SCR 1/4-20X5/8 WSH HD TYP T 2 023945 CONDUIT-BENT PULSER2 TWIN 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 2 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Page 4 MDE-4282B Gasboy Pulser Kit s M042 30K 00X Inst allatio n • July 2005

M04230K003 - KIT PLS R 1:1 9100QTW2, QXTW2

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 2

051806 SCR 1/4-28X5/8 HHC 6 068891 WASHER,LOCK EXT 1/4 1114 14 046970 PLATE-MOUNTING PULSER 100:1 2 056877 SPACER .944 NOM.LENGTH (F) 4 046969 PLSR & CPLG ASSY;1:1EK LTR 2 025015 ELBOW-CONDUIT 1/2 X 45 M/F MCH 2 023944 CONDUIT-BENT PULSER1 TWIN 1 066400 1/2"UNY EXP PROOF COND UNION 3 064830 CONDUIT TEE, MACHINED 1 023946 CONDUIT-BENT PULSERS T TWIN 1 051805 SCR 1/4-20X5/8 HHC PL 6 043225 PIN SPIROL 5/64X7/16 CRS ZINC 2 031035 HUB-QUAN. SHAFT EXTENSION 2 027041 GEAR, QUANTITY 2 049406 RING RET 5133-25-ZF 2 027044 PLATE AND IDLER GEAR ASSY 2 053920 SCR 1/4-20X5/8 WSH HD TYP T 2 023945 CONDUIT-BENT PULSER2 TWIN 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 2 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Introduction

M04230K004 - KIT PLSR CX 9100Q, QX 10:1

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 1

MDE-4282B Gasboy Pulser Kits M04230K00X Installation • July 2005 Page 5

Introduction

Part Number Description Quantity

027044 PLATE AND IDLER GEAR ASSY 1 053920 SCR 1/4-20X5/8 WSH HD TYP T 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 1 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Page 6 MDE-4282B Gasboy Pulser Kit s M042 30K 00X Inst allatio n • July 2005

M04230K005 - KIT PLSR CC 9100Q, QX 100:1

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 1

051806 SCR 1/4-28X5/8 HHC 3 068891 WASHER,LOCK EXT 1/4 1114 7 046970 PLATE-MOUNTING PULSER 100:1 1 056877 SPACER .944 NOM.LENGTH (F) 2 046972 PLSR & CPLG ASSY;100:1 1 025015 ELBOW-CONDUIT 1/2 X 45 M/F MCH 1 066400 1/2"UNY EXP PROOF COND UNION 1 023939 CONDUIT-BENT PULSER1 SINGLE 1 051805 SCR 1/4-20X5/8 HHC PL 3 043225 PIN SPIROL 5/64X7/16 CRS ZINC 1 031035 HUB-QUAN. SHAFT EXTENSION 1 027041 GEAR, QUANTITY 1 049406 RING RET 5133-25-ZF 1 027044 PLATE AND IDLER GEAR ASSY 1 053920 SCR 1/4-20X5/8 WSH HD TYP T 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 1 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Introduction

M04230K006 - KIT PLS R 1:1 9100Q, QX

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 1

051806 SCR 1/4-28X5/8 HHC 3 068891 WASHER,LOCK EXT 1/4 1114 7 046970 PLATE-MOUNTING PULSER 100:1 1 056877 SPACER .944 NOM.LENGTH (F) 2 046969 PLSR ASSY;1:1 91EK LTR 1 025015 ELBOW-CONDUIT 1/2 X 45 M/F MCH 1 066400 1/2"UNY EXP PROOF COND UNION 1 023939 CONDUIT-BENT PULSER1 SINGLE 1 051805 SCR 1/4-20X5/8 HHC PL 3 043225 PIN SPIROL 5/64X7/16 CRS ZINC 1 031035 HUB-QUAN. SHAFT EXTENSION 1 027041 GEAR, QUANTITY 1 049406 RING RET 5133-25-ZF 1 027044 PLATE AND IDLER GEAR ASSY 1 053920 SCR 1/4-20X5/8 WSH HD TYP T 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1

MDE-4282B Gasboy Pulser Kits M04230K00X Installation • July 2005 Page 7

Introduction

Part Number Description Quantity

C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 1 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Page 8 MDE-4282B Gasboy Pulser Kit s M042 30K 00X Inst allatio n • July 2005

M04230K007 - KIT PLSR CX 9140Q, QX 10:1

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 1

051806 SCR 1/4-28X5/8 HHC 3 068891 WASHER,LOCK EXT 1/4 1114 7 046970 PLATE-MOUNTING PULSER 100:1 1 056877 SPACER .944 NOM.LENGTH (F) 2 046973 PLSR & CPLG ASSY;10:1 1 025015 ELBOW-CONDUIT 1/2 X 45 M/F MCH 1 066400 1/2"UNY EXP PROOF COND UNION 1 023952 CONDUIT-BENT PULSER 40 1 051805 SCR 1/4-20X5/8 HHC PL 3 043225 PIN SPIROL 5/64X7/16 CRS ZINC 1 031035 HUB-QUAN. SHAFT EXTENSION 1 027041 GEAR, QUANTITY 1 049406 RING RET 5133-25-ZF 1 027044 PLATE AND IDLER GEAR ASSY 1 053920 SCR 1/4-20X5/8 WSH HD TYP T 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 1 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Introduction

M04230K008 - KIT PLSR CC 9140Q, QX 100:1

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 1

051806 SCR 1/4-28X5/8 HHC 3 068891 WASHER,LOCK EXT 1/4 1114 7 046970 PLATE-MOUNTING PULSER 100:1 1 056877 SPACER .944 NOM.LENGTH (F) 2 046972 PLSR & CPLG ASSY;100:1 1 025015 ELBOW-CONDUIT 1/2 X 45 M/F MCH 1 066400 1/2"UNY EXP PROOF COND UNION 1 023952 CONDUIT-BENT PULSER 40 1 051805 SCR 1/4-20X5/8 HHC PL 3 043225 PIN SPIROL 5/64X7/16 CRS ZINC 1 031035 HUB-QUAN. SHAFT EXTENSION 1 027041 GEAR, QUANTITY 1 049406 RING RET 5133-25-ZF 1 027044 PLATE AND IDLER GEAR ASSY 1 053920 SCR 1/4-20X5/8 WSH HD TYP T 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1

MDE-4282B Gasboy Pulser Kits M04230K00X Installation • July 2005 Page 9

Introduction

Part Number Description Quantity

C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 1 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Page 10 MDE-4282B Gasb oy P ulser K its M042 30K0 0X I nstalla tion • J uly 2005

M04230K009 - KIT PLS R 1:1 9140Q, QX

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 1

051806 SCR 1/4-28X5/8 HHC 3 068891 WASHER,LOCK EXT 1/4 1114 7 046970 PLATE-MOUNTING PULSER 100:1 1 056877 SPACER .944 NOM.LENGTH (F) 2 046969 PLSR ASSY;1:1; 91EK LTR 1 025015 ELBOW-CONDUIT 1/2 X 45 M/F MCH 1 066400 1/2"UNY EXP PROOF COND UNION 1 023952 CONDUIT-BENT PULSER 40 1 051805 SCR 1/4-20X5/8 HHC PL 3 043225 PIN SPIROL 5/64X7/16 CRS ZINC 1 031035 HUB-QUAN. SHAFT EXTENSION 1 027041 GEAR, QUANTITY 1 049406 RING RET 5133-25-ZF 1 027044 PLATE AND IDLER GEAR ASSY 1 053920 SCR 1/4-20X5/8 WSH HD TYP T 1 025045 ELBOW-CONDUIT 1/2 X 90 M/F MCH 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 5/8D 1 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Introduction

M04230K010 - KIT PLSR CZ 87Q 10:1 MONEY

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 1

068891 WASHER,LOCK EXT 1/4 1114 3 056877 SPACER .944 NOM.LENGTH (F) 2 032940 KIT-PULSR VR 312020-767 1 K14830 SCREW, HEX HD CAP FINISHED 3 023959 CONDUIT-BENT PULSER -MONE 1 N16289 20 UNION EXP STD 1/2” M&F 1 025045 ELBOW-CONDUIT 1/2 X 90 M/ 1 C08682 TIE-WRAP, IDENTIF (1”X5/16) 1 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

M04230K011 - KIT PLSR CZ 87QTW 10:1 MONEY

Part Number Description Quantity 056895 SPACER TOP .835 NOM.LGTH 2

068891 WASHER,LOCK EXT 1/4 1114 6

MDE-4282B Gasboy Pulser Kits M04230K00X Instal lation • July 2005 P age 11

Introduction

Part Number Description Quantity

056877 SPACER .944 NOM.LENGTH (F) 4 056876 SPACER .944 NOM.LENGTH (S) 1 032940 KIT-PULSR VR 312020-767 2 023957 SCREW, HEX HD CAP FINISHED 1 023188 CONDUIT-BENT PULSER -MONE 1 N16289 20 UNION EXP STD 1/2” M&F 3 064830 CONDUIT TEE, MACHINED 1 000154 CASTING - CONDUIT TEE 1 023946 CONDUIT - BENT PULSERS T TW 1 038138 CONDUIT 1/2 X 19 1 K14830 SCREW HE X HD CAP FINISH 6 023958 CONDUIT _ BENT PULSER2 -MON 1 038132 CONDUIT 1/2 X 19-25/32 1 025045 ELBOW-CONDUIT 1/2 X 90 M/ 1 005045 ELBOW-CONDUIT 1/2 X 90 M/ 1 C08682 TIE-WRAP, IDENTIF (1”X5/16) 2 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Page 12 MDE-4282B Gasb oy P ulser K its M042 30K0 0X I nstalla tion • J uly 2005

M04230K012 - KIT PLSR 100:1 MONEY CM 87Q

Part Number Description Quantity

056895 SPACER TOP .835 NOM.LGTH 1 068891 WASHER,LOCK EXT 1/4 1114 3 056877 SPACER .944 NOM.LENGTH (F 2 032942 KIT-PLSR VR 312020-924 VR 1 K14830 SCREW HE X HD CAP FINISHE D 3 023959 CONDUIT-BENT PULSER -MONE 1 N1628920 UNION EXP STD 1/2" M&F 1 025045 ELBOW-CONDUIT 1/2 X 90 M/ 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 1 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

M04230K013 - KIT PLSR 100:1 MONEY CM 87QTW

Part Number Description Quantity

056895 SP ACER TOP .835 NOM.LGTH 2 068891 WASHER,LOCK EXT 1/4 1114 6 056877 SP ACER .944 NOM.LENGTH (F 4 032942 KIT-PLSR VR 312020-924 VR 2 023957 CONDUIT-BENT PULSER1 -MON 1 N16289 20 UNION EXP STD 1/2" M&F 3 064830 CONDUIT TEE, MACHINED 1 023946 CONDUIT-BENT PULSERS T TW 1 K14830 SCREW HEX HD CAP FINISHED 6 023958 CONDUIT-BENT PULSER2 -MON 1 025045 ELBOW-CONDUIT 1/2 X 90 M/ 1 C08682 TIE-WRAP,IDENTIF(1"X5/16) 2 MDE-4282 Pulser Kit Installation Manual 1 047401 POLY BAG 5 X 6 1 018656 CRTN 14.312 X 11.375 1

Introduction

MDE-4282B Gasboy Pulser Kits M04230K00X Instal lation • July 2005 P age 13

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 precau ti ons for your task will be found. Fir e, exp los ion, 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 worki ng i n a pot ent ia ll y dan ger ous 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

The first and most important information you must know is how to stop all fuel flow to the pump and island.

Emergency Total Electrical Shut-Off

Locate the switch or circuit breakers that shut-off all power to all fueling equipment, dispensing devices, and submerged turbine pumps (STPs). These you must operate in the event of an emergency.

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 SHUT-OFF in the case of an emergency and not only these cashier station “stops.”

Total Electrical Shut-Off Before Access

Any procedure requiring access to electrical components or the electronics of the dispenser requires total electrical shut-off of that unit.

NFPA 30A, Section 4-1.2, published by the National Fire Protection Association, requires the installation o f a n ea sily accessible switch or circuit bre aker to shut-off the power to al l f uel ing equipment, dispensing de vices and ST Ps in th e event of an emergency. Know the func tion a nd location of this switc h or circuit brea ker before inspe cting, instal ling, maintaini ng, or servic ing Gilbarco equipment.

Page 14 MDE-4282B Gasb oy P ulser K its M042 30K0 0X I nstalla tion • J uly 2005

Important Safety Information

Evacuation, Barricading and Shut-Off

Any procedures requiring accessing the pump/dispenser or STPs requires the following three actions:

• An evacuation of all unauthorized persons and vehicles

• Using safety tape or cones as barricades to the effected units

• A total electrical shut -off of that unit

Read this Manual

Read, understand and follow this manual and any other labels or related materials supplied with this equipment. I f y ou 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

There is ap plicable info rmation in: NFPA 30A: Automotive and Marine Service Code; NFPA 70:

National Electrical Code (NEC); OSHA regulations; and federal, state, and local codes

which must be followed. Failure to install, inspect, maintain or service this equipment in accordanc e with these codes, regul ations and sta ndards may lead to legal c itations with penalties or affect the safe use and operation of the equipment.

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 that follow must be followed to prevent death, injury or damage to the equipment

• DANGER - This signal word is used to aler t you to a haza rd to uns afe pra ctice which wil l

result in death or serious injury

• WARN ING - This alerts you to a hazard or unsafe practice that could result in death or

serious injury.

• CAUTION with Alert symbol - This signal word designates a hazard or unsafe practice

which may result in minor injury.

• CAUTION without Alert symbol - When used by itself, CAUTION designates a hazard

or unsafe practice which may result in property or equipment damage.

MDE-4282B Gasboy Pulser Kits M04230K00X Instal lation • July 2005 P age 15

Important Safety Information

Prevent Explosions and Fires

Fuels and their vapors will become explosive if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will cause explosive vapors in the vicinity of dispenser or island.

No Open Flames

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 fuels and their vapors. After getting out of a vehicle, touch the metal of your vehicle to discharge any electrostatic charge before you approach the dispenser island.

Informing Emergency Personnel

Compile the following information for emergency personnel:

• Location of accident (e.g. address, front/back of building, etc.)

• Nature of accident (e.g. possible heart attack, run over by car, burns, etc.)

• Age of victim (e.g. baby, teenager, middle-age, elderly)

• Whether or not victim has received first aid (e.g. stopped bleeding by pressure, etc.)

• Whether or not victim has vomited (e.g. if swallowed or inhaled something, etc.)

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.

Other Useful Safety Information

This subsection provides additional safety information.

OSHA Lock-Out and Tag-Out Requirements

OSHA Standard 29 CFR 1910-147 Control o f Hazardo us Ener gy Sourc es (Lock- Out/Tag-Out) covers ways to avoid personal injury because power was turned on or fuel pressure was applied

(1) Turning off equipment power and fuel under pressure.

(2) Use of a locking device (breaker, valve, etc.) or label device with a warning tag.

unexpectedly while servicing equipment. The rule requires:

Station employees and service contractors need to understand and comply with this program completely to ensure safety while th e equipment is down.

Page 16 MDE-4282B Gasb oy P ulser K its M042 30K0 0X I nstalla tion • J uly 2005

Use Electrostatic Discharge Precautions

Place yourself at a neutral static-free potential by doing the following:

1 Touch an unpainted metal surface.

2 Use a wrist strap connected to a grounded metal frame or chassis.

Important Safety Information

MDE-4282B Gasboy Pulser Kits M04230K00X Instal lation • July 2005 P age 17

Installing the Pulser Kit in Twin Unit

Preparation

1 Request permission from the manager/owner to remove power from the unit and then remove

power using normal procedures. Observe the lockout/tagout safety procedures.

2 Using the proper key for the unit, unlock and remove the doors from both sides of the unit.

Place doors in a safe place to prevent damage or scratches.

3 On both sides of the unit, remove the two screws securing the bezel and remove the bezel.

Store bezels and screws in a safe place for reuse.

4 Remove the screws securing the dial face in place and remove the dial faces from each of the

computers on both sides. Store dial faces and screws in a safe place to prevent damage or scratches.

5 Make sure you have the proper kit for the model dispenser to be retrofitted.

6 The computers will have to be temporarily moved to allow space between the units to install

the pulser parts.

Temporarily Moving the computers

To move the computers, proceed as follows:

1 Note that there are two drive shafts connected to the computer. Make a note of the exact

position of the shafts. Things to note are:

• Bottom (vertical) shaft i s se ttin g in a slot on the l ower end. The pins on th e sha ft are in the shallower of the slots.

• The side shaft is pinned to the drive shaft in the computer and the rotating wheel has a mark on it. The mark must be po int i ng up whe n re assembled to properly al ign the readout number register.

2 Remove the pin from the side (horizontal) shaft mounted to the computer. Save pin for

reassembly.

3 Loosen and remove the three mounting bolts securing the computer in place. Save for

remounting.

4 Move the computer sufficiently to allow space for mounting the pulser parts (out of dispenser

if necessary). Care must b e take n to e nsu re th e lar g e gear on the side of t he comput er i s kept in the same 'OFF" position.

5 Repeat the procedure for the second computer.

Page 18 MDE-4282B Gasb oy P ulser K its M042 30K0 0X I nstalla tion • J uly 2005

Installing Drive Gear on Meter Computer Shaft

In the kit, locate two 043225 pins, two 031035 hubs, two 027401 gears, and two 049406 retaining rings.

1 On one of the computers, press a pin into the hole in the computer quantity shaft until it is

flush on one side of the shaft.

Installing the Pulser Kit in Twin Unit

Retaining Ring

Hub

Computer Shaft

2 Place a hub on the shaft with the slotted portion of hub straddling the extending pin and align

hole in the hub with pin.

3 Push the pin through the hole in the hub until the pin is extending equally on both sides of the

hub.

4 Place a gear on the hub and align pin in the shaft with bearing slot in gear. 5 Secure gear in place by placing a retaining ring in the slot near the end of the shaft. 6 Repeat steps 1 through 5 on the shaft of the other computer.

Installing Plate and Idler Assembly

1 In the kit, locate two 053920 screws and two 027044 Plate and Idler Assemblies.

Note: The 053920 mounting screw for the Plate and Idler Assembly is a self-tapping screw.

Tu rning t he screw into the mounting hole in the computer si de fra me and then removing it without the assembly in place will make mounting the assembly easier.

2 At one of the computers, hold a Plate and Idler Gear Assembly in place and loosely secure

with the mounting screw. Boss and bracket holes in the computer align assembly for proper gear meshing.

Plate and Idler Gear Assembly

Mounting Screw

Note: This illustration is shown rotated 90 degrees from its installed position.

MDE-4282B Gasboy Pulser Kits M04230K00X Instal lation • July 2005 P age 19

Installing the Pulser Kit in Twin Unit

CAUTION

Excessive tightening of mounting screw will crack the plastic plate

3 Ensure proper gear position, alignment, and meshing and tighten mounting screw.

4 Repeat Steps 2 through 4 to mount second Plate and Idler Gear Assembly on other computer.

Assembling 046970 Pulser Mounting Plate and 0469XX Pulser and

Coupling Assembly

1 In the kit, locate t wo 046970 mounti ng plates , two 0469XX* Pul ser and Coupl ing Assembl ies,

six 051805 screws, and six 068891 lock washers. *The part number depends on which kit is being installed. See Parts List for part number.

2 Place a mounting plate on a Pulser and Coupling Assembly, align the three mounting holes,

and loosely secure with three screws and three lock w ashers.

3 Tighten all screws equally.

4 Repeat steps 2 and 3 for the other mounting plate and pulser and coupling assembly.

Completing Assembly and Mounting Pulser Units

1 In the kit, locate the foll owing parts:

• two 0469XX* Pulser and Coupling Assemblies

• two 056895 Spacers

• two 056877 Spacers

• four 051806 screws

• four 068891 washers

• two 025015 elbows

• one 023945 conduit - bent pulser twin

• one 023944 conduit - bent pulser twin

2 Feed the pulser and coupling assembly wires through the 025015 elbow and install the elbow

on the pulser and coupling assembly.

023945 conduit

025015 elbows

023944 conduit

Front pulser

Page 20 MDE-4282B Gasb oy P ulser K its M042 30K0 0X I nstalla tion • J uly 2005

Installing the Pulser Kit in Twin Unit

3 Repeat previous step for second pulser and coupling assembly.

4 Install the 023944 conduit on the front pulser and coupling assembly (the one with the black

band near the end of the wires) and the 023945 on the back pulser and coupling assembly.

Note: The front of the dispenser is the side with the junction box.The front pulser (mounts on

the left computer) is the one with the black band near the end of the wires.

5 On the left computer, remove and discard two assembly screws and replace with the two

spacers in positions shown in following figure. Notice the difference in part numbers and positions of the spacers.

M056895 Spacers

M056877 Spacers

6 Place the front pulser (one with 023944 conduit mounted on it) in position (installs on the left

computer) by positioning the conduit mounted on the pulser through the slot in the unit between the computers. Ensure that the pinned shaft on the pulser aligns with the center hole in the idler gear and the pin seats in the slot in the gear. The mounting holes in the mounting plate must align with th e holes in the spacers.

7 Loosely secure in place with two washers and two screws.

8 After careful examinat ion to ensure that the parts a r e meshed properly, tighten the screw s.

9 Repeat procedures in Steps 2 through 5 for the second pulser and coupling assembly (installs

on the right computer).

Remounting the Computers

To remount the computers, proceed as follows:

1 At the side shaft mounting, turn the rotating wheel (on the computer) until the mark on the

wheel is pointing upward.

2 Mount the shaft on the computer and pin with pin saved during removal.

3 Mount the vertical shaft in the slot noted during removal (pin in shallow slots).

MDE-4282B Gasboy Pulser Kits M04230K00X Instal lation • July 2005 P age 21

Installing the Pulser Kit in Twin Unit

4 Move the computer in place aligning the mounting holes and ensuring that the two shafts are

properly seated (as noted prior to moving the computers).

5 Secure the computer in place with the mounting bolts saved during the initial moving

procedure.

Installing the Remaining Conduit

1 In the kit, locate the foll owing parts:

• four 066400 conduit unions

• one 064830 conduit tee

• one 025045 conduit elbow

• one 023946 conduit - bent pulser twin

Note: Feed wires through conduit and fittings as it is assembled.

2 Install a 066400 conduit union on the 023945 conduit and 023944 conduit (mounted to the

pulser and coupling assemblies).

Conduit from Pulsers

064830 Conduit

Tee

023946 conduit

025045 elbow

066400 Unions

3 Install the 023946 conduit on the 064830 conduit tee (orient as shown in figure above).

4 Install the 025045 conduit elbow on the 023946 conduit (on end with bend near the end).

5 Install the 064830 conduit tee/023946 conduit assembly on the two unions installed in step 2.

6 Install a 066400 union on the M025045 conduit elbow

7 Install conduit/elbow/union assembly between tee and junction box. Be sure the wires are

extending into junction box.

Page 22 MDE-4282B Gasb oy P ulser K its M042 30K0 0X I nstalla tion • J uly 2005

Connecting Wires in Junction Box

1 Remove the 12 screws securing the cover on the junction box. Save screws for remounting.

2 Inside the junction box, connect the two green ground leads from the pulsers to a secure

known ground.

3 T o conne ct the leads for th e pulser s, foll ow the wir ing d iagram in the ins tallat ion manual of the

specific fuel management system you are using to connect wires properly.

4 Using the recommended grease to seal the cover, remount the junction box cover and secure

with the 12 screws removed in Step 1.

Testing/Checking Operation

Only the 10:1 pulser can be tested for operation. Test the 10:1 pulser as follows:

Note: To test other pulsers, a standard transaction must be run. Look at the transaction print

out from the system to ensure proper operation.

Installing the Pulser Kit in Twin Unit

1 Restore power to the unit.

2 Connect a mechanical voltmeter on the two orange signal wires.

3 Set the voltmeter to read Ohms.

4 Slowly dispense fuel and observe that the needle d eflects upsc ale for each 1/10 gallon fuel.

Completing Installation

1 After determining that the pulsers are functioning properly, remount the dial faces on the two

computers and secure with the screws saved during removal.

2 Remount the bezels on both sides of the unit and sec ure with th e screws sav ed during removal.

3 Remount the doors on both sides of the unit and secure with the keylocks.

4 Inform the manager/owner that the unit can be returned back to service.

MDE-4282B Gasboy Pulser Kits M04230K00X Instal lation • July 2005 P age 23