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Gasboy 1800 Series manual

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Table of contents for the manual

  • Page 1

    SERIES 70 AND 1800 CONSUMER ELECTRIC PUMPS INSTALLATION/OPERATION/PARTS MANUAL 035219 REV. 0259 INSTA LLERS - IMPORTA NT In addition to installation information, this manual contains warnings, safeguards and proced ures on th e use and care of the Series 70 and 1800 pumps. Please leav e this manual with the pump ow ner after the installation is com[...]

  • Page 2

    035282 Rev. 0215 GA SBOY INTERNA TIONA L, INC. A TOKHEIM SUBSIDIARY 707 North Valley Forge Rd. Lansdale, PA, 19446 ● (215) 855-4631 ● FAX : (215) 855-0341 IMPORTA NT WA RNINGS A ND SA FEGUA RDS Gasoline and petroleum products are flammable. To avoid injury or death to persons or damage to equipment or property , follow these listed warnings and[...]

  • Page 3

    0144 Contents-1 CONTENTS IMPORT ANT WA RNINGS A ND SA FEGUA RDS FOR CONSUM ER PUM PS Section 1: INTRODUCT ION Purpose..................................................................................................... 1-1 Specific ations* .......................................................................................... 1-1 Section 2: INS [...]

  • Page 4

    GASBOY Series 70 & 1800 Contents-2 0144 Troubles hooting ........................................................................................ 5-3 Disassem bly of Pump ............................................................................... 5-5 Meter-Register Disass embly ...............................................................[...]

  • Page 5

    9312 1-1 Section 1 INTRODUCTION PURPOSE The G ASBOY Series 70 and 1820 Consumer Elec tric Pumps Installation/Operation Manual is provided to assis t the installer in ins talling and operating the unit. Faulty installations ar e the ma jor cause of unit malf unctions . This m anual should be supplied to the elec trician prior to the installation of [...]

  • Page 6

    GASBOY Series 70 & 1820 1-2 9312 Table 1- 1. Series 70 and 1820 Feat ures Stripped-down versions of Series 70 pum ps, which m ount on c ustom er-s upplied piping and fittings, are available. Model 72X has no attachm ents or regis ter, Model 73 has a hose and nozz le, but no m eter or regis ter.[...]

  • Page 7

    9312 2-1 Section 2 INSTA LLA TION INSTA LLA TION PRECA UTIONS All tanks and installations m us t conf orm with all building/fire c odes, all Federal, State, and Loc al codes, National Electrical Code, (NFPA 70), NFPA 30, Autom otive and Mar ine Service Station Code (NFPA 30A) and NF PA 395 codes and regulations . Plan y our ins tallation caref ully[...]

  • Page 8

    GASBOY Series 70 & 1820 2-2 9312 15. DO NOT use gaskets on covers of explosion- proof type boxes. T he sealing com pound found around wires at all j unction box entr ances is a requirem ent of the National Electr ical Code and should not be disturbed. T ighten junc tion box cover s befor e replacing panels . 16. DO NOT use knoc k -out box es or[...]

  • Page 9

    Installation 9312 2-3 PUMP DIM ENSIONS - SERIES 70, MODEL 1820 Pump diagram s shown are f or Model 1820. Pum p dim ensions are the sam e for all Ser ies 70 pumps . PUMP DIMEN SIONS - MODEL 1820R Pump diagr am s shown are f or Model 1820R. Pum p dim ensions are the sam e f or these Model 1820 pumps : 1820R, 1820RSS, 1820RC, 1820RCSS.[...]

  • Page 10

    GASBOY Series 70 & 1820 2-4 9312 INSTA LLA TION INSTRUCTIONS Cabinet Removal for Installation or Service (Series 1820 Only) - Rounded Cabinet 1. Rem ove two screws, one on each s ide of the cabinet. 2. Pull front panel as sem bly forward at bottom . As it clears the pum ping unit, lift up to r em ove. 3. To replace fr ont panel, engage pins at [...]

  • Page 11

    Installation 9312 2-5 Direct Mount on Underground Tanks 1. Screw 2" coupling onto 2" s tandard pipe. 2. Screw 2" standard pipe into 2" tank flange. Apply compound to thr eads at bottom of base to prevent surf ace water f rom entering the tank . 3. Screw 1" suc tion pipe into install-a- sock et. Suct ion pipe should be long [...]

  • Page 12

    GASBOY Series 70 & 1820 2-6 9312 Direct Mount on A boveground Tank Aboveground tank s require both a pr essur e/vacuum vent and an em ergency vent. The pressur e/vacuum vent reduc es loss es due to evaporation and is an air quality control m easure. The em ergency vent provides a relief fr om the pressu re resulting f rom heating and boiling of[...]

  • Page 13

    Installation 9312 2-7 Pedestal Mount Pump 1. Screw 2" coupling onto threaded end of 2" standar d pipe. 2. Slide cast ir on pedestal base up over the unthreaded end of 2" s tandard pipe. 3. Screw 1" suc tion pipe into install-a- sock et. Suct ion pipe should be long enough to allow 3" clearance f rom bottom of tank . Apply g[...]

  • Page 14

    GASBOY Series 70 & 1820 2-8 9312 Wall Mount The optional wall m ount k it can be used with any Series 70 or 1820 pum p to be located r em ote from the tank . T he wall mount k it cons ists of a wall m ounting brac ket, pum p m ounting flange, and hardware to attach the flange to the br ack et. Hardware to attach the brac ket to the wall is not [...]

  • Page 15

    Installation 9312 2-9 Vacuum Breaker The vac uum br eaker tubing k it can be used with any Series 70 or 1820 pump. T he vacuum break er is us ed to break a s iphon should the nozzle drop below the fluid level in the tank while the pump is stuck in the open position. A threaded vacuum break er, P/N 066570 is s hipped installed in the pump. G ASBOY r[...]

  • Page 16

    GASBOY Series 70 & 1820 2-10 9312 NOTE: Tubing can be piped to any av ailable opening on top of tank. Use r educer bushings as required. Testin g the Vacu um Breaker 1. Charge tubing com pletely with fluid. 2. Tur n on pum p and run for several m inutes to purge any air from the s y stem. 3. Tur n off pump. 4. W ith nozzle at ground level and d[...]

  • Page 17

    9312 3-1 Section 3 WIRING WIRING PRECA UTIONS The quality of the electric al installation is a m aj or f actor in m aintaining pr oper saf ety levels and providing trouble-f ree operation of your GASBOY pump. T o ass ure a quality installation, f ollow these rules: 1. Have the pum p installed by a competent ins taller/electr ician. 2. All wiring m [...]

  • Page 18

    GASBOY Series 70 & 1820 3-2 9312 GROUNDING To ensure pr oper operation of the equipm ent and provide the necess ary safety factors, this unit mus t be grounded. A ground wire (pref erably green) mus t be connected between the unit's AC junction box ground lug and the main electric al servic e panel. One (1) earth ground connec tion is requ[...]

  • Page 19

    Wiring 9312 3-3 PULSER WIRING An optional pulser (available on the Series 1820R only) is used when external m onitoring of the dispensing unit operation is desired. T he pulser transm its one elec trical s ignal (pulse) f or each predeterm ined amount of fuel dispens ed. Reed 10:1 pulsers operating with DC voltages are used. Pulser wiring must be 1[...]

  • Page 20

    GASBOY Series 70 & 1820 3-4 9312 PUMP WIRING DIAGRA MS 115VA C Pumps Series 70 and 1820 (left) and Series 1820R (right) 230VA C Pumps Series 70 and 1820 (left) and Series 1820R (right) NOTE FOR 230V M OTORS: Some motors may contain differ ent wire colors than those shown. In this case, Hot is Black, Neutral is White and Aux AC Control is Brown.[...]

  • Page 21

    9312 4-1 Section 4 STA RTUP A ND OPERA TION PRE-STA RTUP CHECKLIST The infor m ation below should be reviewed to help verify the proper installation of your GASBOY pump. If th e installation does not meet criteria listed , as well as an y Federal, State, and Local codes and requirements, correct the proble m before powering on the unit. 1. The unit[...]

  • Page 22

    GASBOY Series 70 & 1820 4-2 9312 POST-STA RTUP TESTS Voltage The incom ing voltage to the pump should be c heck ed and any reading not w ithin 10% of r ated voltage should be corr ected bef ore testing is continued. W hen dealing with suction pum ps it is good practice to tak e voltage readings while the suction pum p is oper ating on bypass (t[...]

  • Page 23

    Start-U p and Operation 9312 4-3 Clean the strainer im m ediately after the pum p has been ins talled and tested, and again after a f ew hundred gallons have been delivered. Thereaf ter, onc e every six months, or as requir ed. The procedure f or cleaning the s tainer can be f ound in the Maintenance and Troubleshooting secti on. DA ILY OPERA TION [...]

  • Page 24

    [...]

  • Page 25

    0144 5-1 Section 5 MA INTENA NCE A ND TROUBLESHOOTING MA INTAINING TROUBLE-FREE OPERA TION Operating your pump with reasonable c are will prolong its lif e and provide better s ervice. GASBOY pumps are designed and built to provide y ears of uninterrupted s ervice; however, certain parts of a pum p are bound to wear. T o k eep your pump running at [...]

  • Page 26

    GASBOY Series 70 & 1820 5-2 0144 WHEN Y OUR PUMP NEED S SERVICE W hen y our pum p needs s ervice, f ollow these guidelines: ● Procedures requiring disassem bly of portions of the pum p should be perf orm ed by com petent service personnel. GASBOY has a dis tributor network which servic es fuel dispensing equipm ent in every part of the countr[...]

  • Page 27

    Service and Tr ou bleshooting 0144 5-3 TROUBLESHOOTING If problem s are encounter ed in operation of the pump, follow the proc edures below in an attempt to isolate the problem . W hen the problem is detected, f ollow the procedur es for disass em bly of the pump. Pump W on' t Start ✓ ✓ ✓ ✓ Is the breaker at the panel turned on? ✓ ?[...]

  • Page 28

    GASBOY Series 70 & 1820 5-4 0144 Pump delivers produc t but won't register. ✓ ✓ ✓ ✓ Is main totalizer recording? If yes, problem is in register assembly. Check to be sure the lever on the side of the register is returning back to the record position. ✓ ✓ ✓ ✓ If the main totalizer is not w orking, the problem is a broken or [...]

  • Page 29

    Service and Tr ou bleshooting 0144 5-5 DISA SSEMBLY OF PUMP NOTE: Numbers in parentheses corres pond to the numbers shown on the parts illustration and parts list in Sec tion 6 labeled Direct Drive Motor-Pump Assembly . W hen the front panel is rem oved, all the w ork ing parts of the pum p are acces sible under clear ly mar ked cover plates. Since[...]

  • Page 30

    GASBOY Series 70 & 1820 5-6 0144 1860 3-WHEEL REGISTER SER VICE A ND MA INTENA NCE NOTE: Numbers in parentheses corres pond to the numbers shown on the parts illustration and parts list in Sec tion 6 labeled 1860 3-Wheel Meter-Register . To servic e or replace parts in the disc r egist er, r em ove the self -tapping s c rews and lif t of f the [...]

  • Page 31

    Service and Tr ou bleshooting 0144 5-7 3. Hook s pring (25) over pos t so that hook lies f lat against rear of housing. 4. Make s ure lower arm and overthr ow stop pawl (19) fits into s lot in reset lever. 5. To tim e the register for zero reset, pry apart the center wheel and (13 and 16) and place 16 on middle post with two red mar ks pointing tow[...]

  • Page 32

    GASBOY Series 70 & 1820 5-8 0144 Replacing Bearing an d Seal Assembly (Item 26, New Style) To replace the bearing and shaft seal assem bly ( 26), or service the gear train on bac k of regis ter housing (18), rem ove housing f rom m eter by taking out four s crews. NOTE: The meter housing will be full of liquid so some means should be available [...]

  • Page 33

    9312 6-1 Section 6 PA RTS Using part num bers when ordering will expedite your order and r educ e the pos sibility of the wrong parts being shipped. W hen ordering r eplacem ent parts, be s ure to give the com plete nam e and part num ber as s hown in the appropriate parts lis ts. Procedures requiring disas sem bly of portions of the pump s hould b[...]

  • Page 34

    GASBOY Series 70 & 1820 6-2 9312 SERIES 70 A SSEMBLY[...]

  • Page 35

    Parts 9312 6-3 SERIES 70 A SSEMBLY Item Part No. Description 1 Pump Assembly (See Direct Drive Motor Parts List) 2 044089 3/4" X 6-7/8" Pipe Nipple 3 003597 Flanged Inlet, 72S 024934 Elbow, 72X & 73 4 052000 Screw 5 027055 Gasket 6 003542 3/4" Horiz. Dschg for Vacuum Breaker 003544 1" Horiz. Dschg for Vacuum Breaker 7 052105[...]

  • Page 36

    GASBOY Series 70 & 1820 6-4 9312 SERIES 1820 A SSEMBLY[...]

  • Page 37

    Parts 9312 6-5 SERIES 1820 A SSEMBLY Item Part No. Description 1 025393 Dial Face Assembly 2 028850 Dial Glass 3 012265 Bezel 4 040630 Front Panel Assembly 5 029620 Nozz le Hanger 029590 Nozzle H anger - Automatic Nozzle 6 038605 Keps Lock Nut 7 003820 Scuff Plate 8 052856 Machine Screw 9 039070 Keps Lock Nut 10 039461 Speed Nut 11 041545 Rear Pane[...]

  • Page 38

    GASBOY Series 70 & 1820 6-6 0259 DIRECT D RIVE MOTOR-PUMP A SSEMBLY[...]

  • Page 39

    Parts 9312 6-7 DIRECT D RIVE MOTOR-PUMP A SSEMBLY Item Part No. Desc ri pt ion 1 003490 Pump Cover 2 049004 Square-Ring 3 031285 Key, 70 4 051475 Rotor 5 054024 Seal Group (Consists of items 6-11) 6 067210 W asher 7 057956 Spring 8 048941 O-Ring 9 049510 Rotating Seal Ring 10 048820 Floating Seal Ring-Carbon 11 048956 O-Ring 12 003210 Pump Block 13[...]

  • Page 40

    GASBOY Series 70 & 1820 6-8 9312 INSTA LLA TION PA RTS Item Part No. Descri pt ion 1 003835 Install-a-Socket 2 021970 2" Coupling 3 045010 2" x 40" Pipe (underground) 4 045535 2" x 30" Pipe (pedestal) 5 044380 1" x 32 1/2" Suction Pipe 6 053320 Set Screws 7 066445 1" Union 8 003055 Pedestal Base[...]

  • Page 41

    Parts 9312 6-9 1860 A ND 4860 METER -REGISTER Item Part No. Descri pt ion 1 012790 Meter Body 2 051835 Meter Body Screw 3 049075 O-Ring 4 025851 Screw 5 019016 Meas. Chamber Assy. (sold as assembly only; includes items 6-9) 019015 Bronze Meas. Chamber 6 Meas. C hamber Top 7 Measuring D isc 8 Baffle 9 Meas. Chamber-bottom 10 053080 Adjusting Screw ([...]

  • Page 42

    GASBOY Series 70 & 1820 6-10 9312 1860 3-WHEEL METER REGISTER (FOR MOD EL 1820)[...]

  • Page 43

    Parts 9312 6-11 1860 3-WHEEL METER REGISTER (FOR MOD EL 1820) 035634 US Measure 035640 Liter Measure, 1/10 036296 Liter Measure, Full 035638 Imperial Measure Item Part No. Desc ri pt ion 1 052840 Screw 2 028615 Totalizer D rive Gear 3 065305 Totalizer Assembly (items 4-7. Not sold separately.) 8 024280 L H Number disc 9 024310 R H Number disc 10 02[...]

  • Page 44

    GASBOY Series 70 & 1820 6-12 9312 4860 4-WHEEL REGISTER (FOR MODEL 72S A ND SERIES 1820R)[...]

  • Page 45

    Parts 0259 6-13 4860 4-WHEEL REGISTER (FOR MODEL 72S A ND SERIES 1820R) 036341 U.S. M easure, 72S 036343 Liter Measure, 72S 036345 Imperial Measure, 72S 036357 US M easure, 1820R 036361 Liter Measure, 1820R 036353 US M easure, Ext. Shaft, 1820R 036373 Liter Measure, Ex t. Shaft, 1820R Item Part No. Desc ri pt ion 1 012236 Bezel 012267 Bezel, 1820R [...]

  • Page 46

    GASBOY Series 70 & 1820 6-14 9312[...]

  • Page 47

    Parts 9312 6-15 MODEL 1820 REGISTER SETB A CK A ND SWITCH LIN KA GE A SSEMBLY PA RTS LIST Item Part No. Description 1 051206 Switch Rod Assembly (consists of items 2-5) 2 034155 Switch Lev er, 1800 3 038905 Hex Lock Nut 4 051730 Adjusting Screw 5 050755 Switch Rod 6 021040 Throttle Clip - L H 7 054654 Control Shaft (consists of items 8-20) 8 054610[...]

  • Page 48

    GASBOY Series 70 & 1820 6-16 9312[...]

  • Page 49

    Parts 9312 6-17 MODEL 1820R PA RTS LIST Item Part No. Descri pt ion 1 022194 Cover-1820R, CR S 022971 Cover-1820R, SS 2 012267 Bezel 3 041384 Panel Assy.-Right, CRS 041383 Panel Assy.-Right, SS 4 021374 Conduit 1/2 x 5 5 017931 Thread Protector 1/2" M NPT 6 003835 Install-a-Socket 7 022193 Panel Assy-Left, CRS 022970 Panel Assy-Left, SS 022988[...]

  • Page 50

    GASBOY Series 70 & 1820 6-18 0144 1820R PULSER A ND JUNCTION BOX A SSEMBLIES Item Part No. Desc ri pt ion 1 021788 Pulser, 10:1 2 014646 Bracket Pulser 3 043211 Spirol Pin 4 021943 Pulser Coupling 5 025045 Elbow, ½ x 90 M/F 6 021532 Conduit, ½ x 1-3/4 7 025030 Elbow, ½ x 90 F/F 8 021378 Conduit, ½ x 9-1/2 9 039130 Conduit Locknut ITEMS NOT [...]

  • Page 51

    GW 98- 4/13/ 98 Rev. 1 WARRANTY General Statements: • Gasboy I nternational, Inc. warrants all new equipment manufactured by Gasboy against defective material and/or work manship, fo r the warranty period specified below, when the equipment is install ed in accordance with specifications prepared by Gasboy . • This warranty does not cover damag[...]