Gasboy XU2A User Manual

Introduction

Purpose of this Manual

This manual contains information on the installation of the Blackmer® XU2A rebuild kit as
used in Gasboy
This manual is written for Gasboy Authorized Service Contractors (ASCs) who will be
installing the kit. It is recommended that only ASCs install this ki t.

Important Notice

Blackmer XU2A pumps must only be installed in systems which have been designed by
qualified engine er ing personnel. The system mu st conf orm to all applicable local and national
regulations and safety standards.
All parts and required kits are listed in the Blackmer Parts List at the rear of this document.
This manual MUST be kept with the pump.

®

self-contained products.

MDE-4320

Gasboy UHF Pump, Blackmer® XU2A

Rebuild Kit Installation Manual

June 2004

Required Reading

Before servicing the pump, the technician must read, understand, and follow
this manual .
Failure to do so may adversely effect the safe use and operation of the equipment.

Related Documents

Document Number Document Name GOLD® Library

035297 Series 9800A Pump/Dispensers

Note

The "Note" designation indicates within the manual special instructions which are very
important and must be followed.

Parts List

Gasboy Commercial & Retail Pumps

MDE-4320 Gasboy UHF Pump , Blac k m er® XU2A Rebuild Kit Installatio n Ma nu al • Jun e 20 04 Page 1

Introduction

Required Tools

Acronym Table

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

• 5mm Allen® wrench

• 1/4-inch allen wrench

• heavy snap ring pliers

• ratchet wrench

• 16mm sock et

• 13mm or 1/2-inch socket

• rubber mallet

• torque wrench

Acronym Definition

ASC Authorized Service Contractors
cmhg centimeter of mercury
CW Clockwise
CCW Counterclockwise
GDP Global Dispenser Pump
gpm gallons per minute
inhg inch of mercury
lbs pound-force
lbs-in pound-inch
lpm liters per minute
mm millimeter
N/A not applicable
Nm newton-meter
OIML International Organization of Legal metrology*
Opt. Optional
PCV Pressure Control Valve
psi pounds per square inch
Std Standard
UHF Ultra High Flow
*OIML Switch (optional) monitors air to fuel mix and is used primarily in

Europe.

Page 2 MDE-4320 Gasboy UHF Pump, Blackmer® XU2A Rebuild Kit Inst allat ion Ma nual • June 2004

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

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 brea kers that shu t-off all power to all fueling
equipment, dispensing devices, 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.”

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. Know the function and location of this switch or
circuit breaker before in specting, installing, maintaining, or s ervicing Gilbarco

®

equipment.

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 and any associated STPs.

MDE-4320 Gasboy UHF Pump, Blackmer® XU2A Rebuild Kit Installation Manual • June 2004 Page 3

Important Safety Information

Read the 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 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 citations with
penalties or affect the safe use and operation of the equipment.

Replacement Parts

Use only genuine Gilbarco replacement parts and retrofit kits on your pump/dispenser. Using
parts other than genuine Gilbarco 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 al ert you to a haza rd to uns afe pract ice whic h 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 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.

Page 4 MDE-4320 Gasboy UHF Pump, Blackmer® XU2A Rebuild Kit Ins tallat ion Ma nual • June 2004

Important Safety Information

No Open Flames

Open flames from matches , l i ght ers , we ldi ng torches or other sources can ignite fuels

and their vapors.

No Sparks - No Smoking

Sparks from starting ve hicl es, sta rting or usi ng power tool s, burni ng cig arett es, ci gars
or pipes can also ignite fuels and their vapors. Static electricity, including an electrostatic
charge on your body, can cause a spark suffic ient t o ignite fuels and their vapors. Afte r 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 th at someone who is capabl e of render ing fi rst aid be present during
servicing. Be f amili ar with Car diopulmonar y Resusc itat ion ( CPR) met hods i f yo u are worki ng
with or around high voltages. This information is available from the American Red Cross.
Always advise the st ation perso nnel a bout whe re you will be wor kin g, and c autio n them not to
activate power while you are working on the equipment. Use the OSHA tag out and lock out
procedures. If you are no t familiar with this requirement, refer to information in the service
manual and OSHA documentation.

Working With Fuel Safely

Be sure to follow information in this manual, related materials and approved industry standard
practices in handling fuel and fueling equipment.

Protect Your Eyes

Spraying fuel from residual pressure in lines can cause serious eye injuries. Always
wear eye protection. Gasoline spilled in eyes may cause burns to eye tissue. Rinse eyes with
water for approximately 15 minutes. Seek medical advice immediately. It is not necessary to
wear eye protection unless performing hydraulic service.

Use Proper Fuel Handling Techniques

• Be sure breakaways, shear valves and other emergency devices are properly installed.
Refer to manufacturer’s instructions for proper installation.

• Collect, transport and dispose fuel only in approved containers specifically designed for
this purpose.

• Before working with any chemicals or fuels in and around a dispensing facility, read the
MSDS pertaining to those chemicals as prescribed in the Occupational Safety and Health
Administration Standard, 29 CFR 1910.1200. Refer to the supplier’s literature.

MDE-4320 Gasboy UHF Pump, Blackmer® XU2A Rebuild Kit Installation Manual • June 2004 Page 5

Important Safety Information

Hydraulic Pressure Releases and Fuel Leakage

Working on hydraulic systems can result in leakage of fuel that may also be under pressure.

grades of fuel, and all associated STPs.

Do not allow unauthorized or untrained individuals to service hydraulic equipment.

Shear valves, require d by NFPA 30A, are inten ded t o s hut -off the flow of fuel at the dispenser
base (hydraulics area ) during vehicl e impact or fir es. A single-poppe t shear valve pr events fuel
from flowing from the underground tank. A double-poppet shear valve prevents fuel from
flowing from the underground tank and from the dispenser.

React Quickly to Fuel Spills, Fires or Vehicle Impact

Follow these steps in th e event of a fuel spill, fire, or vehicle impact.

Turn off all circuit breakers for unit being worked on, all dispensers using the same

1 Use station EMERGENCY TOTAL ELECTRICAL SHUT-OFF immediately. Turn off all

system circuit breakers to the island. Refer to “

page 3 for more information.

2 Call emergency numbers for fires, vehicle impact or any significant spills.

3 Use safety tape, cones or barricades to block the work area. Do not go near fuel spill or allow

anyone else in the area.

4 Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area and

immediately stop use of open flames, smoking or power tools in the area.

5 Provide emerge ncy and f irst aid a ssistanc e. If a ny g asoli ne has b een inh aled or spil led on s kin,

seek emergency help immediately.

6 Use approved and safe procedures to clean up all spills with a “fuel or gasoline absorbent”

material approved b y your local r egulator y agenci es. (Dispo se of f uel and h azardous absorb ent
material promptly and according to the requirements of the fire department, local EPA, and
federal, state or local resources.)

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 wire s when repla cing 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.

T otal Electrical Shut-Off Before Access” on

Page 6 MDE-4320 Gasboy UHF Pump, Blackmer® XU2A Rebuild Kit Ins tallat ion Ma nual • June 2004

Hazardous Materials

Some materials prese nt inside e lectroni c enclosur es may pre sent a heal th hazard i f not handl ed
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.

Emergency First Aid Infor mation

!

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.

Important Safety Information

!

WARNING

WARNING

!

!

WARNING

Gasoline inhaled may cause unconsciousness and burns to lips, mouth
and lungs.
Keep airway open.
Seek medical advice immediately.

Gasoline spilled in eyes may cause burns to eye tissue.
Irrigate eyes with water for approximately 15 minutes.
Seek medical advice immediately

Gasoline spilled on skin may cause burns.
Wash area thoroughly with clear/water.
Seek medical advice immedi ately.

MDE-4320 Gasboy UHF Pump, Blackmer® XU2A Rebuild Kit Installation Manual • June 2004 Page 7

Important Safety Information

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 i f gasoli ne has b een ingest ed or inha led. Seek
medical advice immediately.

Page 8 MDE-4320 Gasboy UHF Pump, Blackmer® XU2A Rebuild Kit Ins tallat ion Ma nual • June 2004