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Installation
Introduction
This manual provides installation instructions for Kits M05023K001 & M05023K002 for
Gasboy
Gasboy Q series commercial pumps and dispensers.
This upgrade will help protect against a possible safety hazard that could be present with
contaminated aviation fuel.
Required Reading
Before installing these kits, the installer must rea d, 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.
MDE-4369
Aviation Tubing Retrofit Kit for Gasboy® Q
Models Kits M05023K001 & K05023K002
October 2004
®
Q Models. These kits contain hardware required for replacing the copper tubing in
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 Gasboy Q Model Kit M05023K001:
warranty.
• Socket set or combination box & open end wrenches
MDE-4369 Aviation Tubing Retrofit Kit for Gasboy® Q Models Kits M05023K001 & K05023K002 • October 2004 Page 1
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Introduction
Parts List
The Gasboy Aviation Tubing Retrofit Kit M05023K001
The following table lists the parts for the above kit.
Description Part Number Quantity
Tubing Assy M04844A001 1
O-Ring 049002 1
O-Ring Q10068 14 1
The Gasboy Aviation Tubing Retrofit Kit M05023K002
The following table lists the parts for the above kit.
Description Part Number Quantity
Tubing Assy M04845A001 1
O-Ring 049002 1
O-Ring Q10068 14 1
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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 working in a potentially danger ous e nvi ronment of flammable fuels , vap o rs , and hi gh
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 and island. Locate the switch or circuit breakers that shut-off all power to all fuelin g
equipment, dispensing de vices, and submerged turbine pumps (STPs).
Important Safety Information
.
!
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 ca se of a n em erg enc y and
not only these cashier station “stops.”
Evacuation and Barricading
Any procedures performed on or near the pump/dispenser (but not requiring accessing the
pump/dispenser or STPs) requires the following actions:
• An evacuation of all unauthorized persons and vehicles
• Using safety tape or cones as barricades to the effected units
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 Gilbarco Veeder-Root 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.
MDE-4369 Aviation Tubing Retrofit Kit for Gasboy® Q Models Kits M05023K001 & K05023K002 • October 2004 Page 3
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Important Safety Information
Follow the Regulations
There is ap plicable information in: N FPA 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
accordance with these c odes, regulations and standards may l ead to legal c itations 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
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
• WARNING - 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 re sult 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.
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 matche s, lighters, welding torches or other s our ces c an ignite fuels
and their vapors.
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No Sparks - No Smoking
or pipes can also ignite fuels and their vapors. Static electricity, including an electrostatic
charge on your body, can cause a spark suffic ie nt to igni te fue ls and the ir vapo rs. Afte r getti ng
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 th at someone who is capabl e of render ing fi rst aid be present during
servicing. Be thoroughly familiar with Cardiopulmonary Resuscitation (CPR) methods if you
are working with or around high voltages. This information is available from the American
Red Cross. Always ad vis e the s ta ti on personnel about where you will be working, and caution
them not to activate power while you are working on the equipment. Use the OSHA Tag-Out
and Lock-Out procedures. If you are not thoroughly familiar with this requirement, refer to
information in the service manual and OSHA documentation.
Important Safety Information
Sparks from starting ve hicl es, sta rting or usi ng power tool s, burni ng cig arett es, ci gars
Working With Electricity Safely
Be sure to use safe and established practices in working with electrical devices. Poorly wired
devices may cause a fire, explosion or electrical shock.
• Be sure grounding connections are properly made.
• Make sure that sealing devices and compounds are in place.
• Be sure not to pinch wires when replacing covers
• Follow OSHA Lock-Out and Tag-Out requirements. Station employees and service
contractors need to understand and comply with this program completely to ensure safety
while the equipment is down.
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 ne eded at sce ne if gaso line has b een ingest ed or inha led. Seek
medical advice immediately.
MDE-4369 Aviation Tubing Retrofit Kit for Gasboy® Q Models Kits M05023K001 & K05023K002 • October 2004 Page 5
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Installing the M05023K001 Kit for Suction Pumps
Installing the M05023K001 Kit for Suction Pumps
The following process explains the removal of copper tubing and installation of approved
piping for aviation fuel.
1 Read all in structions before begin ning installation.
2 Observe and execute all safety precautions and procedures before, during and after
installation.
3 Obtain permission from station Operator/Manager to remove pump/dispenser from service
and obtain key to the suction pump door.
4 Turn off all power to the pump and use Tag-Out and Lock-Out procedures.
5 Using the key, open the doors on both sides of the pump.
6 Trip the shear valve and test to ensure that the line is completely closed. (Test by turning
power back on and verify that no fuel can be dispensed. If unit ca n still function, again retrip
shear valve, making sure that it is completely closed.)
Note: In the next step, before loosing any bolts, reduce the pressure in the lines.
7 Station catch basins and absorbent materials in such a way as to catch any fuel still left in any
open lines (after reducin g pressure in the lines).
8 With eye protection in place, remove the copper tubing between the suction pump and meter.
Save all bolts for later us e. See Figure 1.
Figure 1: Copper Tubing in Suction Pump Unit
Copper Tubing
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Installing the M05023K001 Kit for Suction Pumps
9 Install new steel tubing and new O-Rings, (Q10068 14 at meter flange and 049002 at the
pumping unit flange) and attach steel tubing using existing bolts. (The use of silicone grease
helps to hold O-rings in place during assembly.)
10 Return power to pump and run fuel through the pump and inspect for leaks.
11 Purge all air from unit (usually 10 gallons is recommended).
12 Remove catch basin, tools and absorbent materials. (Dispose of absorbe nt materials and fuels
in a safe manner. Do not dispose of them in station trash receptacles or in the pump pit box.)
13 Re-install the front and back doors to the pump.
MDE-4369 Aviation Tubing Retrofit Kit for Gasboy® Q Models Kits M05023K001 & K05023K002 • October 2004 Page 7
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Installing the M05023K002 Kit for Remote Dispensers
Installing the M05023K002 Kit for Remote Dispensers
The following process explains the removal of copper tubing and reassembly with approved
piping for aviation fuel.
1 Read all in structions before begin ning installation.
2 Observe and execute all safety precautions and procedures before, during and after
installation.
3 Obtain permission from station Operator/Manager to remove pump/dispenser from service
and obtain key to the suction pump door.
4 Turn off all power to the dispenser and use Tag-Out and Lock-Out procedures.
5 Using the key, open the doors on both sides of the dispenser.
Note: In the next step, before loosing any bolts, reduce the pressure in the lines.
6 Trip the shear valve and test to ensure that the line is completely closed. (Test by turning
power back on and verify that no fuel can be dispensed. If unit ca n still function, again retrip
shear valve, making sure that it is completely closed.
7 Station catch basins and absorbent materials in such a way as to catch any fuel still left in any
open lines.In the next step, before loosing any bolts, reduce the pressure in the lines.
8 With eye protection in place, remove the copper tubing between strainer housing and meter,
loosening bolts slowly so as to relieve any fuel pressure gradually. Save all bolts for later use.
See Figure 2.
Figure 2: The existing printer mounted on CIM door.
Copper Tubing
9
Install new steel tubing and new O-Rings, (Q10068 14 at meter flange and 049002 at the
strainer flange) a nd attach steel tub ing usi ng existi ng bolts. ( The use of s ilicone g rease hel ps to
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Installing the M05023K002 Kit for Remote Dispensers
hold O-rings in place during assembly.)
10 Open shear valve.
11 Return power to pump and run fuel through the pump and inspect for leaks.
12 Purge all air fr om the unit (usually 10 gallons is recommended).
13 Remove catch basin, too ls and absorbent materials. (Dispose of absorbent materials an d fuels
in a safe manner. Do not dispose of them in station trash receptacles or in the pump pit box.)
14 Re-install the front and back doors to the pump.
MDE-4369 Aviation Tubing Retrofit Kit for Gasboy® Q Models Kits M05023K001 & K05023K002 • October 2004 Page 9
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Installing the M05023K002 Kit for Remote Dispensers
Gasboy® is a registered Trademark of Gasboy International Inc.
© 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-4369 Aviation Tubing Retrofit Kit for Gasboy® Q Models Kits M05023K001 & K05023K002 • October 2004
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