Installation
Introduction
This manual provides installation instructions for the Gasboy Gear Train Upgrade Kit
M04477K001.
Required Reading
Before installing the ki t, the installe r must read, understand, and 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
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
MDE-4291
Gasboy Gear Train Upgrade Kit M04477K001
March 2004
warranty.
Note: This kit requires approximately 1 hour or less to complete.
Required Tools
The following tools are needed to install the Gasboy Gear Train Upgrade Kit:
Parts List
M04477K001 - Gasboy 9140Q Gear Train Upgrade Kit
• Combination Wrench Set
• #2 Phillips
®
Screw Driver
• Socket & Ratchet Set
• Punch to help align holes
• Two Boards (1 inch x 2 inch x 18 inches long or 1 inch x 4 inches x 18 inch long)
Part Number Description
M04428A001 LINK, ME TER INTERFACE 2
M04433B001 SHAFT, DISPLAY DRIVE 1
057002 STANDOFF 4
042615 DRIV-LOC PIN 1/8 X 3/4 2
Quantity Per
Unit
MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004 Page 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 sections in this manual, where additional
hazards and safety precau ti ons for your task will be found. Fire, 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 working in a potentially dangerous e nvi ronment of flammable fuels, vap ors, 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 swit ch or c ircuit breaker to s hut -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 functi on and
location of this switc h or circuit brea ker before inspe cting, instal ling, maintaini ng, or servic ing
Gilbarco equipment .
Page 2 MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 20 04
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-o ff 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 , ca ll a Gilbarco Authorized S erv ic e
Contractor or call the Gilbarco Call 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 information 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 c odes, regulations and standards may lead to leg al citations 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-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004 Page 3
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 the equipmen t is down.
Page 4 MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004
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-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004 Page 5
Installing the Gear Train Upgrade Kit
Installing the Gear Train Upgrade Kit
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 lower and upper doors from both
sides of the unit. Place doors in a safe place to prevent damage or scratches. (See Figure 1)
Figure 1: GasBoy Cover Removal
Shows Doors
Removed Both Sides
Work Area
Junction Box Denotes
Side 1 or Front
3 Make sure you have the proper kit for the model dispenser to be retrofitted.
Page 6 MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004
Assembly Removal
Before any parts can be installed, the gear train must be removed.
1 Remove the eight bolts that mount the re gister platform to the upper frame rai ls and ret ain the
bolts. (See Figure 2.)
Figure 2: Register Platform Bolt Removal
Installing the Gear Train Upgrade Kit
Remove (8) Bolts Along Rails
2 Remove eight bolts securing the meters to the meter mounting brackets and retain the bolts.
Upper Frame Rails
(See Figure 3.)
Figure 3: Meter Mounting Bracket Bolts
Remove Bolts - Meter Mounting Brackets (each side)
MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004 Page 7
Installing the Gear Train Upgrade Kit
3 Using the two 18 inch 1x4s as spacers, lift the register platform and slide the spacers in
between the platform an d the upper frame rails. (See Figure 4.)
Figure 4: Lifting the Register Platform
Insert Spacer Here (on each side)
4 Remove the four bolts that mount the gear train assembly to the register platform and retain
the bolts. (See Figure 5.)
Figure 5: Gear Train Bolt Removal
Remove Gear Train Assy Bolts (on each side)
Page 8 MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004
Installing the Gear Train Upgrade Kit
5 Remove the display drive shaft (054039) from between the gear train and the register and
discard the shaft.
Figure 6: Drive Tr ain Shaft Removal
Remove Display Drive Shaft
6 Lift the gear tr ai n u p and away from the mete rs and slide it t o the left away from t he di scharge
side of the dispenser. (See Figure 5.)
Figure 7: Removing the Gear Train
Rotate Toward the Front and Remove
Note: the “Discharge Side” and the side that the Junction
Box are on, when referenced, denotes the FRONT of the
Dispenser.
7 Rotate the gear trai n toward the front of the d is pens er in such a manner that it ca n be r emove d.
Slide Gear Train to the Left
MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004 Page 9
Installing the Gear Train Upgrade Kit
Assembly Part Replacement
The following process explains how to replace the indicated parts in the table below.
Gasboy Old Part Replacement List
Old Part No New Part No Description
054039 M04433B001 SHAFT, DISPLAY DRIVE
N/A M04428A001 LINK, METER INTERFACE
056012 057002 STANDOFF
042615 N/A *DRIV-LOC PIN 1/8 X 3/4
Note: *The Driv-Loc Pins are suppled to replace damaged or worn Dr iv-Loc Pins in t he Gear
Train A ssembly.
1 Exchange the four top standoffs (056012) on the gear train with the four shorter standoffs
(057002) and discard the longer standoffs.
2 Install the meter interface link (M04428A001) in the top of each meter in a manner that the
guide pins (see Figure 8 and Figure 9) are in the “longer slots” in the output shaft cups.
Figure 8: Meter Interface Link Guide Pins
Guide Pin in Long Slot
Page 10 MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004
Installing the Gear Train Upgrade Kit
Figure 9: Meter Interface Link
Guide Pins
3 Reversing the removal process, position the gear train back in between the meter mounting
brackets and the meters as before.
4 Install the shorter display drive shaft (M04433B001) (see Figure 10) between the gear train
and the register.
Figure 10: Display Drive Shaft
5 Remove the two 1X4s and set the register platform back down on the frame rails while trying
to align the meter interface links and the four meter-mounting-brackets to the meters.
6 Insert and loosely thread the four bolts that mount the gear train assembly to the register
platform. (Do not tighten until all bolts are threaded into their respective locations.)
7 Insert and thread th e ei ght b olt s se cur ing the meters and the eig ht bo lt s that mount the registe r
platform to the frame, so that they are still loose - not tightened. (This is required so as to
enable the alignment of all the bolts into their respective holes.)
8 Once all the bolts are ins erted and thre aded in loosely, tighten all twenty bo lts.
Testing/Checking Operation
1 Restore power to the unit.
2 Slowly dispense fuel and observe that the digits turn smoothly and that no binding is
occurring.
MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004 Page 11
Installing the Gear Train Upgrade Kit
Completing Installation
1 After determining that the system is functioning properly, replace the upper and lower panels
on both sides of the dispenser and secure with the keylocks.
2 Inform the manager/owner that the unit can be returned back to service.
.
Phillips® is a registered trademark of Phillips Tool Corporation
© 2004 Gilbarco Inc.
7300 West Friendly Avenue • Post Office Box 22087
Greensboro, North Carolina 27420
Phone (336) 547-5000 • http://www.gilbarco.com • Printed in the U.S.A.
MDE-4291 Gasboy Gear Train Upgrade Kit M04477K001 • March 2004
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