Introduction
This document explains how to install the totalizer and cable in Atlas™ Ultra-Hi (Series
9850K) pumps and dispensers. The available mechanical totalizer kits are listed in
Kits. Refer to the Parts List table to determine the contents in each kit. Ensure that you follow
all warnings and safeguards as outlined in the Important Safety Information section before
working on the unit.
Required Reading
Before installing a kit, the installer 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
MDE-4568
Atlas™ Ultra-Hi Mechanical Totalizer Kit
Installation Instructions
April 2006
Available
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 required to install the totalizer in kits:
Available Kits
Description Kit Number Quantity Per Meter
Mechanical totalizer kit, Gallons,
9-digit, Atlas Ultra-Hi
Mechanical totalizer kit, Liters,
9-digit, Atlas Ultra-Hi
warranty.
• Wrench Set
• Flat tip screwdriver
• Cross tip screwdriver
• Punches (to remove and install pins)
M06943K001 1
M06943K002 1
MDE-4568 Atlas Ultra-Hi Mechanical Totalizer Kit Installation Instructions · April 2006 Page 1
Introduction
Parts List
The following table specifies the parts for the Atlas Utra-Hi Mechanical Totalizer Kits
(M06943K001 and M06943K002).
Description Part Number
Bracket, Odometer - 9800A 015129 1 1
Cable Assembly 017365 1 1
Nut KEPS® LW 6 Q12068-02 2 2
Nut, Metric, Flange M00414B005 2 2
Odometer 9DIG CCW “GAL” 9 039830 1 Odometer 9DIG CCW “LIT” 9 039829 - 1
Pin, Cotter 3/64 X 1/ 2 STL K02137-29 1 1
Screw MH PNH PHL 6-32X Q11270-36 2 2
Spirol® Pin .062 X .500 Q10038-29 1 1
Tie Cable Q10178-10 2 2
Totalizer Window 9800A 069077 1 1
Installation Instructions, Atlas Ultra-Hi Mechanical
Totalizer Kit (this document)
MDE-4568 1 1
M06943K001
Quantity
M06943K002
Quantity
Page 2 MDE-4568 Atlas Ultra-Hi Mechanical Totalizer Kit Installation Instructions · April 2006
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 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 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 power to the
pump/dispenser.
Total Electrical Shut-Off Before Access
Any procedure requiring access to electrical components or
the electronics of the dispenser requires total electrical shutoff of that unit. Know the function and location of this switch
or circuit breaker before inspecting, installing, maintaining, or
servicing Gasboy equipment.
Evacuation, Barricading and Shut-Off
Any procedures requiring accessing the pump/dispenser or
STPs requires the following three actions:
This means that even if you activate these
stops, fuel may continue to flow uncontrolled.
You must use the TOTAL ELECTRICAL SHUTOFF in the case of an emergency and not only
these cashier station “stops.”
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 1800-444-5529. It is imperative to your safety and the safety of
others to understand the procedures before beginning work.
Follow the Regulations
There is applicable 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 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
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 an d 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 alert you to a
!
hazard to unsafe practice which will 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
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.
- An evacuation of all unauthorized persons and vehicles
using safety tape, cones or barricades to the effected units
- A total electrical shut-off of that unit
MDE-4568 Atlas Ultra-Hi Mechanical Totalizer Kit Installation Instructions · April 2006 Page 3
Working With Fuels and Electrical Energy
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.
Important Safety Information
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.
Working Alone
It is highly recommended that someone who is capable of
rendering first aid be present during servicing. Be 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 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 tag out and lock out
procedures. If you are not familiar with this requirement, refer
to information in the service manual and OSH A
documentation.
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.
Hazardous Materials
Some materials present inside electronic enclosures may
present a health hazard if not handled correctly. Be sure to
clean hands after handling equipment. Do not place any
equipment in mouth.
!
WARNING
This area contains a chemical known to the State of
California to cause cancer.
WARNING
!
This area contains a chemical known to the State of
California to cause birth defects or other reproductive
harm.
IMPORTANT: Oxygen may be needed at scene if gasoline
has been ingested or inhaled. Seek medical advice
immediately.
Emergency First Aid
Informing Emergency Personnel
• Compile the following information for 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.
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. Reference Subpart S of 29 CFR Part 1910
- Electrical Hazards, 29 CFR Part 1910.333 contains specific
Lockout/Tagout provision for electrical hazards.
Page 4 MDE-4568 Atlas Ultra-Hi Mechanical Totalizer Kit Installation Instructions · April 2006
Installing the Mechanical Totalizer Kits M06943KXXX
Installing the Mechanical Totalizer Kits M06943KXXX
Preparing for the Installation
1 Request permission from the manager/owner to remove power from the unit and then remove
power using normal procedures. Perform the lockout/tagout safety procedures.
2 Ensure that you have the proper kit for the model unit to be retrofitted.
3 Follow all applicable safety rules and procedures.
Installing the Mechanical Totalizer Kits
1 Unlock and remove the lower panel.
2 Remove the existing hardware from the totalizer window.
3 Assemble and install the new totalizer assembly with the existing hardware, as shown in
Figure 1.
Figure 1: Totalizer Assembly
Spirol Pin (Q10038-29)
Odometer (039829/30)
(2) Screw PPHD 6-32 x .50
(Q11270-36)
(2) Nut Hex W/Ext Lockwsr 6-32
(Q12068-02)
(2) Nut Hex Flg M4
(M00414B005)
Shielded Flex Cable Assembly
Totalizer
Bracket
(015129)
(017365)
4 Install the cable assembly with the Spirol pin to the odometer assembly.
MDE-4568 Atlas Ultra-Hi Mechanical Totalizer Kit Installation Instructions · April 2006 Page 5
Installing the Mechanical Totalizer Kits M06943KXXX
5 Install the other end of the cable assembly (with larger mounting hole) to the existing meter
with the Cotter pin, as shown in
Figure 2: Meter/Pulser Assembly
Figure 2.
Totalizer Drive
Tie-Wrap
(Q10178-10)
Cotter Pin (K02137-29)
6 Attach the tie-wraps around the plastic cable cover and the conduit.
Allow some slack in the cable (at the meter end) to prevent excessive stress and premature
breakage during operation. Loop should be gradual with no less than a 6” radius.
Completing the Installation
1 Replace and lock the lower panel.
2 Inform the manager/owner that power will be restored to the unit and then restore power using
normal procedures.
3 Remove the lockout/tagout and return to normal operation.
IMPORTANT INFORMATION
Atlas™ is a trademark of GASBOY.
®
KEPS
is a registered trademark of Illinois Tool Works Inc. Spirol® is a registered trademark of Spirol International Holding Corporation.
© 2006 GASBOY
7300 West Friendly Avenue - Post Office Box 22087
Greensboro, North Carolina 27420
Phone 1-800-444-5529 - http://www.gasboy.com -Printed in the U.S.A.
MDE-4568 Atlas Ultra-Hi Mechanical Totalizer Kit Installation Instructions · April 2006
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