Husky 1800 Series Pressure Washer User Manual
Contents
1. N S 9312 6 16 MODEL 1820R PARTS LIST Item 1 C NO A 10 11 12 13 14 15 16 17 9312 022194 022971 012267 041384 041383 021374 017931 003835 022193 022970 022988 022979 040754 040811 068080 068281 051072 026575 053516 017578 033748 063209 052314 Description Cover 1820R CRS Cover 1820R SS Beze Panel Assy Right CRS Panel Assy Right SS Conduit 1 2 x 5 Thread Protector 1 2 MNPT Install a Socket Panel Assy Left CRS Panel Assy Left SS Panel Assy Left CRS Pulser Panel Assy Left SS Pulser Panel Back CRS Not Shown Panel Back SS Not Shown Washer 5 16 plated Washer Spring 7 16 Switch Arm Assy Frame Assy Set Screw Soc Hd 10 32x1 4 HF Cam Assy Switch Actuator Assy Eccentric Stop Flathead Screw Parts GASBOY Series 70 amp 1820 1820R PULSER AND JUNCTION BOX ASSEMBLIES pod HJ 3 E A 1 I Item Part No Description 1 021788 Pulser 10 1 2 014646 Bracket Pulser 3 043211 Spirol Pin 4 021943 Pulser Coupling 5 025045 Elbow 1 2 x 90 M F 6 021532 Conduit 1 2 x 1 3 4 7 025030 Elbow 1 2 x 90 F F 8 021378 Conduit 1 2 x 9 1 2 9 039130 Conduit Locknut ITEMS NOT2. cae e e e es 2 9 WIRING Wiring PreGa0li ng u a a ma U S O entente nennen nnt aga kaq s Ek 3 1 Circuit Breakets ie en ee i ua a 3 1 eee emm 3 2 The Pump Motor eire Pee Ure rg ado ce Ene De pi 3 2 SIZO 1 h uum 3 2 Pulser Wiring uae a ln a aly 3 3 e fex Ted kt 3 3 Pump Wiring Diagrams mene enennnnes 3 4 STARTUP AND OPERATION Pre Startup Checklist 4 1 SIENTES 4 1 Post Startup Tests uenti ended aereas tei d ete unco augus 4 2 Ec ETE 4 2 Tiglitliess u u un u a G I eee ed ete Hie Der to eee eine e 4 2 Meter Calibration U 4 2 Strainer Cleaning fi u u u unu SGS ha qashan 4 3 Daily Operation cicero c voee Rte ell Ge ae ee 4 3 MAINTENANCE AND TROUBLESHOOTING Maintaining Trouble Free Operation sse 5 1 When Your Pump Needs Service sse 5 2 Contents 1 GASBOY Series 70 amp 1800 Section 6 Warranty Contents 2 Troubleshooting ave en RU eese eee ene a tenets 5 3 Disassembly of P IDDB uu au 5 5 Meter Register Disassembly a u uuu 5 5 1860 3 Wheel Register Service and Maintenancee 5 6 4
3. O Ring Viton Adjusting Screw Cap O Ring Register Assembly See below for list Adjusting Screw New Style replaces items 10 12 Parts NOTE All meters are calibrated for gasoline Older style meters may have a D for diesel or a G for gasoline REGISTER ASSEMBLIES Compatible with new or old style adjusting screw design 3 Wheel Disc Register Shown Above Phenolic Chamber 035963 US Gallons Gas 035964 US Gallons Diesel 036293 Full Liter Gas 036130 Full Liter Diesel 048478 1 10 Liter Gas 036131 1 10 Liter Diesel 4 Wheel Push Button Register Not Shown Phenolic Chamber 036400 US Gallons Gas 036401 US Gallons Diesel 036404 Liter Gas 036405 Liter Diesel 4 Wheel Push Button Register Not Shown Bronze Chamber 048901 US Gallons Gas 048900 1820RC US Gallons Diesel 6 9 GASBOY Series 70 amp 1820 1860 3 WHEEL METER REGISTER FOR MODEL 1820 Gearing arrangement 3g for full litre disc register models 44 37 P4 00 48 Replaces parts 35 amp 36 for pumps with Rev P cast inside housing p 6 10 9312 Parts 1860 3 WHEEL METER REGISTER FOR MODEL 1820 035634 US Measure 035640 Liter Measure 1 10 Item Part No Description 1 052840 Screw 2 028615 Totalizer Drive Gear 3 065305 Totalizer Assembly items 4 7 Not sold separately 8 024280 L H Number disc 9 024310 R H Number disc 10 024220 Center Number disc 11 063220 Overthrow stop cente
4. SERIES 70 AND 1800 CONSUMER ELECTRIC PUMPS INSTALLATION OPERATION PARTS MANUAL 035219 REV 0259 INSTALLERS IMPORTANT In addition to installation information this manual contains warnings safeguards and procedures on the use and care of the Series 70 and 1800 pumps Please leave this manual with the pump owner after the installation is complete Copyright 1999 by Gasboy International Inc All rights reserved The information in this document is confidential and proprietary No further disclosure shall be made without permission from Gasboy International Inc Gasboy International Inc believes that the information in this document is accurate and reliable However we assume no responsibility for its use nor for any infringements of patents or other rights of third parties resulting from its use We reserve the right to make changes at any time without notice GASBOY INTERNATIONAL TOKHEIM SUBSIDIARY LANSDALE PA IMPORTANT WARNINGS AND SAFEGUARDS Gasoline and petroleum products are flammable To avoid injury or death to persons or damage to equipment or property follow these listed warnings and other warnings and precautions outlined in this manual when installing using or working around this equipment materials Check with GASBOY Technical Services for compatibility of liquids with pump TURN OFF AND LOCK OUT ALL POWER TO PUMP BEFORE PERFORMING SERVICE MAINTENANCE OR IN THE EVENT All products mus
5. 9312 6 1 GASBOY Series 70 amp 1820 SERIES 70 ASSEMBLY MOTE Meter shown is an 1860 Meter Current model 725 uses 4860 Meter See 4860 4 wv heel Register for parts 16 6 2 9312 Parts SERIES 70 ASSEMBLY Item 1 2 3 10 11 12 13 14 15 16 17 044089 003597 024934 052000 027055 003542 003544 052105 068020 039085 000325 029410 053900 030539 038471 034121 066534 Description Pump Assembly See Direct Drive Motor Parts List 3 4 X 6 7 8 Pipe Nipple Flanged Inlet 72S Elbow 72X amp 73 Screw Gasket 3 4 Horiz Dschg for Vacuum Breaker 1 Horiz Dschg for Vacuum Breaker Screw Meter Register Assy See breakdown for your model Washer Hex Nut Nozzle Boot Reset Lever Handle Reset Lever Screw Hose 5 8 x 12 ft Not Shown Nozzle 3 4 EBW unl Not Shown Motor Switch Lever Vacuum Breaker Not Shown OPTIONAL ACCESSORIES PART 032814 017270 043960 003043 024940 026005 030340 030355 9312 DESCRIPTION PART DESCRIPTION Filter Kit 1820 1820R 037461 Motor for 50 cycle 230V Contains items shown below 038471 Nozzle 3 4 Manual Unleaded Bushing 3 4 x 1 038475 Nozzle 3 4 Manual Leaded Pipe tube 3 4 x 2 038519 Nozzle Automatic Unleaded Husky Adapter Filter 3 4 038520 Nozzle Automatic Leaded Husky Elbow street 3 4 x 90 038510 Hook Assy OPW 11A Filter Wix 24006 dsl gas 038511 Hook Assy EMCO A2000 Hose 3 4
6. Gasoline or Diesel 39 012491 Control Block 12T 012490 Control Block Bronze 12T 40 028129 Cluster Gear 32T 11T 41 028448 Drive Gear 36T Description CHANGE GEARS U S GALLONS Old Style 39 012491 Control Block 12T 012490 Control Block Bronze 12T 40 027715 Cluster Gear Gas 33T 11T 027655 Cluster Gear Dsl 34T 11T 41 028448 Drive Gear Gas 36T 028450 Drive Gear Dsl 37T CHANGE GEARS IMPERIAL GALLONS 39 012491 Control Block 12T 012490 Control Block Bronze 12T 40 027670 Cluster Gear Gas 34T 10T 027685 Cluster Gear Dsl 35T 10T 41 028465 Drive Gear Gas 38T 028480 Drive Gear Dsl 39T CHANGE GEARS LITERS TENTHS New Style Gasoline or Diesel 39 012505 Control Block 26T 40 027705 Cluster Gear Gas 18T 11T 41 028448 Drive Gear Gas 36T CHANGE GEARS LITERS TENTHS Old Style 39 012505 Control Block 26T 40 027705 Cluster Gear Gas 18T 11T 027700 Cluster Gear Dsl 19T 11T 1820S only 41 028448 Drive Gear Gas 36T 028465 Drive Gear Dsl 38T CHANGE GEARS LITERS FULL 999 LITERS 3 065309 Totalizer Assembly All Black Wheels 9 024315 R H Number disc Full Liter 27 053318 Register Drive Gear amp Shaft 32 035381 Dial Mask Full Liter 43 068454 Spacer Washer 44 012491 Control Block 12T 012490 Control Block Bronze 12T 45 028129 Cluster Gear Gas 32T 11T 027655 Cluster Gear Dsl 34T 11T 46 028229 Gear 38T 47 028230 Gear 24T 48 028231 Cluster Gear 14T 25T 49 028232 Drive Gear G
7. Local codes National Electrical Code NFPA 70 NFPA 30 Automotive and Marine Service Station Code NFPA 30A and NFPA 395 codes and regulations 3 Useonly threaded rigid metal conduit 4 Use only UL approved insulated gasoline and oil resistant stranded copper wiring of the proper size 5 Wire connections should be tightly spliced and secured with a wire nut close off the open end of the wire nut with electrical tape 6 The line to the motor should be on a separate circuit and installed on a 15 AMP breaker This should be sufficient for either 115V 60 cycle or 230V 50 cycle operation 7 The unit must be properly grounded 8 Install an emergency power cutoff if the pump is used for other than personal use In addition to circuit breaker requirements of NFPA 70 and NFPA 30A a single control which simultaneously removes AC power from all site dispensing equipment is recommended This control must be readily accessible clearly labeled and in accordance with all local codes In order to provide the highest level of safety we recommend that all employees be trained as to the location and procedure for turning off power 9 When DC pulsers are used in the pump the AC and DC wires must not share any conduits junction boxes or troughs CIRCUIT BREAKERS Power to the unit should be supplied from a dedicated 15 AMP circuit breaker No other equipment should be powered from this breaker This motor draws the following current 115VA
8. NOTE Tubing can be piped to any available opening on top of tank Use reducer bushings as required The illustration on the next page shows vacuum breaker tubing for installations where the pump is installed below the fluid level of the tank For these installations the tubing must run directly to the tank top The tubing must be horizontal or must slope either toward the pump or the tank so there are no traps or low spots Traps or low spots can severely affect vacuum breaker performance Tubing length should not exceed eight feet 9312 2 9 GASBOY Series 70 amp 1820 5 MAXIMUM NOTE Tubing can be piped to any available opening on top of tank Use reducer bushings as required Testing the Vacuum Breaker 1 Charge tubing completely with fluid 2 Turn on pump and run for several minutes to purge any air from the system 3 Turn off pump 4 With nozzle at ground level and discharging into a container open nozzle A small quantity of fluid several cups should drain and then stop 2 10 9312 Section 3 WIRING WIRING PRECAUTIONS The quality of the electrical installation is a major factor in maintaining proper safety levels and providing trouble free operation of your GASBOY pump To assure a quality installation follow these rules 1 Have the pump installed by a competent installer electrician 2 All wiring must be installed to conform with all building fire codes all Federal State and
9. 036353 US Measure Ext Shaft 1820R 036373 Liter Measure Ext Shaft 1820R Item Part No CHANGE GEARS US GALLONS New Style Gasoline or Diesel 22 012491 Control Block 12T 012490 Control Block Bronze 12T 23 028168 Cluster Gear 12T 39T 24 028172 Cluster Gear Gas 15T 38T 25 028448 Drive Gear 36T CHANGE GEARS U S GALLONS Old Style 22 012491 Control Block 12T 012490 Control Block Bronze 12T 23 028168 Cluster Gear 12T 39T 24 028172 Cluster Gear Gas 15T 38T 028173 Cluster Gear Dsl 15T 39T 25 028450 Drive Gear Gas 37T 028465 Drive Gear Dsl 38T IMPERIAL GALLONS New Style 22 012491 Control Block 12T 012490 Control Block Bronze 12T 23 028168 Cluster Gear 12T 39T 24 028449 Gear 37T 25 028174 Cluster Gear 13T 39T IMPERIAL GALLONS Old Style 22 012491 Control Block 12T 012490 Control Block Bronze 12T 23 028168 Cluster Gear 12T 39T 24 028174 Cluster Gear 13T 39T 25 028449 Gear Gas 37T 028163 Drive Gear Dsl 39T Description LITER MEASURE New Style Gasoline or Diesel 22 012491 Control Block 12T 012490 Control Block Bronze 12T 23 028172 Cluster Gear Gas 15T 38T 24 028175 Cluster Gear 29T 36T 25 028151 Drive Gear Dsl 25T LITER MEASURE Old Style 22 012491 Control Block 12T 012490 Control Block Bronze 12T 23 028172 Cluster Gear Gas 15T 38T 028173 Cluster Gear Dsl 15T 39T 24 028175 Cluster Gear 29T 36T 25 028171 Drive Gear Dsl 26T 028151 Drive Gear Gas 25T 6 13 P
10. Aux AC Control wire capped or connected to a solenoid valve or fuel management system V Isthere power at pump Check at junction box Voltage cannot be below 104 volts on a 115V pump 204 on a 230V pump V Is switch rod turning the switch on and off at the motor V Is motor overheated thermal switch cutoff Be careful the external motor surface could be hot enough to be painful or cause injury Let cool and re try Replace motor if above checks do not solve the problem Pump hums but won t start V V V Is voltage adequate Check voltage with pump on bypass with nozzle closed Voltage cannot be below 104 volts on a 115V pump 204 on a 230V pump Is the Aux AC Control wire is capped or connected to a solenoid valve or fuel management system Check rotor vanes and bypass valve for free operation Check motor with rotor and vanes removed shaft should turn easily and smoothly by hand Spin shaft by hand clockwise quickly start motor hand clear of shaft and observe shaft shaft should stop clockwise motion and turn in a counterclockwise direction if it does not replace motor Replace motor if above checks do not solve the problem Pump runs but won t prime or deliver product V 4 SS Is there gas in tank Do you have a nozzle with the anti drain valve removed Must be able to blow air through the nozzle in the direction the fuel flows through it when the nozzle handle is held open Use GASBOY P N 038519 for unlea
11. Code NFPA 30A and NFPA 395 codes and regulations Plan your installation carefully Dispensing troubles which seem to be pump related are frequently traced to faulty installation Review the following list of installation DO s and DON T s to avoid potential problems 1 10 11 12 13 14 DO read the WARNINGS page at the front of this manual preceding the Table of Contents It contains important information regarding the safe use of your pumps DO install an emergency power cutoff if the pump is used for other than personal use In addition to circuit breaker requirements of NFPA 70 and NFPA 30A a single control which simultaneously removes AC power from all site dispensing equipment is recommended This control must be readily accessible clearly labeled and in accordance with all local codes In order to provide the highest level of safety we recommend that all employees be trained as to the location and procedure for turning off power to the dispensing equipment DO use breakaway couplings on discharge hose While not required for tanks under 1100 gallons use is recommended for safety reasons DO have the pump installed by a competent installer electrician DO NOT experiment with a pump if you are not sure the installation is correct DO NOT overload sub or main breaker panels DO NOT install any underground piping without proper swing joints Always use shoulder nipples never close nipples DO NOT cover an
12. For liter measure the drive gear 41 controls this ratio and the drive key 37 must be removed to replace this gear For full liter models the cluster gear 45 controls the gasoline diesel ratio change To replace this gear both the retaining ring 38 and drive key 37 must be removed and gears 44 49 47 and 48 removed in that order Replacing Bearing and Seal Assembly Item 36 Old Style To replace bearing and seal assembly 36 remove all gears in gear train 39 40 41 or 44 47 48 and 49 Do not lose spacer washer 43 Disassemble items 8 19 and 28 32 from register Withdraw gear and shaft 27 bearing and seal assembly 36 and O ring 35 Slide new O ring 85 over bearing and seal 36 like a ring on a finger Insert gear and shaft 27 through housing 83 from front to rear and through O ring seal assembly 35 and 36 Press seal and shaft together to seat bearing and seal firmly into square cavity in back of housing Reassemble in reverse order Replacing Bearing and Seal Assembly Item 36 New Style To replace bearing and seal assembly 52 remove all gears in gear train 39 40 41 or 44 47 48 amp 49 Do not lose spacer washer 43 Disassemble items 28 32 and 8 19 from register Withdraw gear and shaft 27 Remove the nylon washer which is part of item 52 and note its location Remove both oilite bearings and both O rings from bore in register housing Using new parts which consist of a new nylon wa
13. Ring Floating Seal Ring Carbon O Ring Pump Block Slinger Ring Motor 115V 60 cycle 70 Motor 115V 60 cycle 1800 Motor 230V 50 cycle 70 Motor 230V 50 cycle 1800 Base Check Valve Assembly Consists of items 21 25 amp 28 Valve Guide Valve Guide 1800R Washer Hex Jam Nut Washer Valve Disc Check Valve Cover Assy Cotter Pin Valve Stem w Relief Valve Relief Valve By Pass Stem Assy Square Ring By Pass Cover Tube Square Ring Strainer 100 Mesh Gasoline Strainer 30 mesh Diesel Strainer Cover Vane Square Ring Parts 6 7 GASBOY Series 70 amp 1820 NL 2 yo Sp 5 CON M 4 SIDER KAD 5 IF DIRECT MOUNT INSTALLATION PARTS Item Part No Description 1 003835 Install a Socket 2 021970 2 Coupling 3 045010 2 x 40 Pipe underground 4 045535 2 x 80 Pipe pedestal 5 044380 1 x 32 1 2 Suction Pipe 6 053320 Set Screws 7 066445 1 Union 8 003055 Pedestal Base 6 8 9312 1860 AND 4860 METER REGISTER Item Part No AUN OO 12 14 15 012790 051835 049075 025851 019016 019015 053080 048865 048866 052195 048895 053081 9312 Description Meter Body Meter Body Screw O Ring Screw Meas Chamber Assy sold as assembly only includes items 6 9 Bronze Meas Chamber Meas Chamber Top Measuring Disc Baffle Meas Chamber bottom Adjusting Screw Old Style O Ring Buna
14. SHOWN 003340 Junction Box 003515 Junction Box Cover 067506 Washer Brass Cupped 052976 Screw 10 32 x 3 8 slotted ground 6 18 0144 GW98 4 13 98 Rev 1 WARRANTY General Statements Gasboy International Inc warrants all new equipment manufactured by Gasboy against defective material and or workmanship for the warranty period specified below when the equipment is installed in accordance with specifications prepared by Gasboy e This warranty does not cover damage caused by accident abuse Acts of God lack of surveillance of automatic recording systems negligence mis application faulty installation improper or unauthorized maintenance installation or use in violation of product manuals instructions or warnings Under no circumstance shall Gasboy be liable for any indirect special or consequential damages losses or expenses to include but not limited to loss of product loss of profits litigation fees or the use or inability to use our product for any purpose whatsoever e Parts Only During the warranty period Gasboy will at its option repair or replace defective parts returned transportation prepaid to its factory On Site Labor Included Gasboy will also provide within the Continental United States and during the warranty period the services of an Authorized Service Representative ASR for on site repair or replacement of defective parts Replacement Parts Any system components that ar
15. UL Listed hose assembly with integral static discharge wire manual self closing nozzle Connections 2 5 08 cm NPT for tank opening 1 2 54 cm suction 3 4 1 91 cm NPT discharge Strainer 100 mesh nylon Delivery Rate 18 GPM at 115V 60 Hz 60 LPM at 60 Hz 68 LPM at 50 Hz Finish High gloss red urethane or color of choice 1820 only Stainless steel extra cost option Approvals UL CSA Additional extra cost options include vapor recovery vacuum breaker return line longer hoses hose breakaways automatic nozzles external filters wall mounting kits and for Series 1820 only 10 1 pulser or rear or side mount filter kits 9312 i5 GASBOY Series 70 amp 1820 UNDED SQUARED 10 1 STA SUCTION V BEZE DA Sy S IL PULSER A SOC PIPE MOUNTING CUSTOMER SUPPLIED CUSTOMER SUPPLIED CUSTOMER SUPPLIED CUSTOMER SUPPLIED CUSTOMER SUPPLIED CUSTOMER COMES WITH HOSE AND NOZZLE Table 1 1 Series 70 and 1820 Features Stripped down versions of Series 70 pumps which mount on customer supplied piping and fittings are available Model 72X has no attachments or register Model 73 has a hose and nozzle but no meter or register 1 2 9312 Section 2 INSTALLATION INSTALLATION PRECAUTIONS All tanks and installations must conform with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 Automotive and Marine Service Station
16. the direction of the polishing lines in the steel never across them In hard water areas wipe the surface dry with a soft clean cloth to prevent spotting Protect the finish with a coat of paste wax Check and Change Filter If the unit is equipped with a filter check and change it at regular intervals A dirty filter in a pump will cause a slower delivery rate Clean the Strainer Clean the strainer immediately after the pump has been installed and tested and again after a few hundred gallons have been delivered Thereafter once every six months or as required The symptoms of a dirty or clogged strainer in a pump are slow delivery noisy operation and pulsation To clean the strainer turn off AC power to the pump Locate the Suction Strainer Cap on the plumbing unit and unscrew it to access and remove the strainer Use compressed air to blow the dirt out of the strainer Always wear protective safety goggles or glasses when using compressed air Clean the Bypass Assembly The bypass valve assembly should be removed only for cleaning and should be checked if there is notable loss in system performance No adjustment is required To remove the valve turn off AC power to the unit remove the two bolts to the bypass cover and lift out the bypass valve assembly 0144 5 1 GASBOY Series 70 amp 1820 WHEN YOUR PUMP NEEDS SERVICE When your pump needs service follow these guidelines Procedures requiring disassembly of portions of th
17. the ground with a properly designed cathodic protection system Concrete Pad 9312 2 7 GASBOY Series 70 amp 1820 Wall Mount The optional wall mount kit can be used with any Series 70 or 1820 pump to be located remote from the tank The wall mount kit consists of a wall mounting bracket pump mounting flange and hardware to attach the flange to the bracket Hardware to attach the bracket to the wall is not included Fasten mounting bracket to wall using appropriate 3 8 fasteners customer supplied 2 Screw mounting flange to pump inlet The flange with the four holes should be away from the pump Pipe thread compound is not required Tighten flange and align parallel with pump 3 Bolt mounting flange to mounting bracket using the hardware supplied 4 Remove the 1 plastic plug within the 2 pump base inlet and install the 1 inlet NPT inlet line from the tank into the pump Apply gasoline resistant pipe compound to male threads Follow piping instructions shown on previous page for piping to the tank See the Conduit section for correct installation of electrical conduit the pump inlet supplied to the tank A N fy ey 1 z zzz z prege SERIES um IRA E qe S A Z hl Y 7 Product T Outlet fe
18. 860 4 Wheel Register Service 5 7 PARTS Series 70 Assembly U 6 2 Optional Accessories 6 3 Series 1800 Assembly aa 6 4 Optional Accessories 6 5 Direct Drive Motor Pump Assembly sse 6 6 Installation Parts Z eese 6 8 1860 4860 6 9 Register Assemblies 6 9 1860 3 Wheel Meter Register Model 1820 6 10 4860 4 Wheel Register Model 725 and Series 1820R 6 12 Model 1820 Register Setback and Switch Linkage Assembly 6 14 Optional Kits for Series 70 and 1800 Pumps 6 15 Series 1820R Parts List a iaaii ener tne 6 16 1820R Pulser and Junction Box Assemblies 6 18 0144 Section 1 INTRODUCTION PURPOSE The GASBOY Series 70 and 1820 Consumer Electric Pumps Installation Operation Manual is provided to assist the installer in installing and operating the unit Faulty installations are the major cause of unit malfunctions This manual should be supplied to the electrician prior to the installation of conduit and wiring The Series 70 or 1820 pumps must be installed and operated as described in this manual This manual also c
19. C 60 cycle 5 1 amps 230VAC 50 cycle 1 95 amps If two 2 pumps are supplied from one breaker that breaker must be capable of handling the load of both motors Provisions must be made to break both legs of any AC circuit 9312 3 1 GASBOY Series 70 amp 1820 GROUNDING To ensure proper operation of the equipment and provide the necessary safety factors this unit must be grounded A ground wire preferably green must be connected between the unit s AC junction box ground lug and the main electrical service panel One 1 earth ground connection is required per unit The ground rod is to be a solid corrosion resistant conductor and must be installed at the main electrical panel in accordance with the National Electrical Code It should be properly tied into the ground bus strip of the panel We recommend the neutral and ground bus strips be bonded together unless prohibited by local codes THE PUMP MOTOR Pumps are shipped from the factory with motors wired for either 115VAC 60 cycle or 230VAC 50 cycle The pump motor is equipped with thermal overload protection If overheated it will shut itself off without any damage to the windings Be sure to turn off the pump power if this occurs As the motor cools it will start without warning if power is on WIRE SIZE The AC wire size of the AC power lines of a pump depends on the voltage at which the pump will be operated 115 230 and the distance from the circuit breaker panel to t
20. anes so that trailing edge slopes away from direction of pump rotation counterclockwise Reinstall key in shaft slot and rotor keyway Check pump cover for scoring if scored replace Replace square ring 2 and while holding rotor in against spring tension slide cover over opening and tighten screws To replace shaft seal remove rotor and vanes as above Slide spring 7 and both washers 6 off shaft O ring 8 will act as a brake to resist removal of brass rotating seal ring 9 To overcome this resistance lightly grasp brass ring with pliers and pull at the same time turning shaft back and forth with the flat blade of a screwdriver in the keyslot in the end of the shaft Remove O ring from brass ring and spread some grease over machined surface of ring reinsert brass ring over shaft and press greased surface against carbon floating seal ring 10 The carbon ring can now be withdrawn stuck to the brass ring Do not break up the carbon ring to remove it since some of the pieces may get lost in the pump casting and cause the rotor or measuring chamber to jam later in service Use a bent wire as a button hook to hook and withdraw O ring 11 from recess in back of pump cavity Install new seal group 5 in reverse order Make sure recess in back of pump cavity is clean and that O ring 11 is firmly seated and not twisted in this recess NOTE Itis critical that the seal part mating surfaces remain clean and dry Do not touch or allow oil of a
21. arts MODEL 1820 REGISTER SETBACK AND SWITCH LINKAGE ASSEMBLY PARTS LIST Item PartNo Description _ 051206 Switch Rod Assembly consists of items 2 5 034155 Switch Lever 1800 038905 Hex Lock Nut 051730 Adjusting Screw 050755 Switch Rod 021040 Throttle Clip L H 054654 Control Shaft consists of items 8 20 8 054610 Control Shaft 9 042355 Cotter Pin 10 068635 Washer 11 012520 Drive Block Assembly 12 042596 Driv Lok Pin 13 039815 Nyliner Bearing 14 011870 Shaft Bracket 15 012641 Drive Block Reset 16 024776 Reset Arm Driver Assy 17 038875 Hex Nut 18 067270 Washer 19 057925 Spring Reset 20 010827 Reset Arm 21 034804 Reset Link 22 020935 Throttle Clip R H NOOR OPTIONAL KITS FOR SERIES 70 AND 1800 PUMPS PART DESCRIPTION 032765 Kit Wall Mount 1820 1820R 032711 Kit Filter 1820R For use with wall mount kit 032765 032712 Kit Filter 1820 For use with wall mount kit 032765 032814 Kit Filter 1820 1820R Diesel Gas 032888 Kit Repair 70 1800 032701 Kit Vacuum Breaker 1820R 032700 Kit Vacuum Breaker Tubing and Fittings Does not include Vacuum Breaker 047575 Kit Vapor Recovery 72VR 032889 Register Rebuild Kit 1860 033026 Register Rebuild Kit 4860 9312 6 15 GASBOY Series 70 amp 1820
22. as 34T 028228 Drive Gear Dsl 35T GASBOY Series 70 amp 1820 4860 4 WHEEL REGISTER FOR MODEL 72S AND SERIES 1820R REPLACES PARTS 15 amp 17 FOR PUMPS WITH REV G CAST ON REAR OUTSIDE OF HOUSING 6 12 9312 Parts 4860 4 WHEEL REGISTER FOR MODEL 72S AND SERIES 1820R 036341 U S Measure 72S 036343 Liter Measure 72S 036345 Imperial Measure 72S Item Part No Description 1 012236 Bezel 012267 Bezel 1820R 2 052693 Bezel Screw 035309 Dial Mask 035307 Dial Mask 1820R AR 5 017269 Reset Button 6 057985 Spring setback 7 053737 Reset Bearing Screw 8 011816 Reset Bearing 9 028736 Dial Glass 10 500758 Register Assembly incl glass 500765 Reg Assy Ext Shaft incl glass 11 053901 Register Screw 12 054513 Drive Shaft Assy 13 053626 Drive Shaft Assy Screw 14 054522 Drive Shaft and Gear 15 056791 Spacer 16 014095 Bearing and Seal Assy Use if no letter is cast onto rear of housing 18 If Rev G see item 26 17 048865 O Ring 18 031020 Register Housing 048426 Register Housing 1820R 19 049075 O Ring 20 049390 Retaining Ring E 21 031345 Drive Key Spring 26 036995 Bearing amp Seal Assy Use only when Rev G is cast onto rear of housing 18 If no Rev see item 16 NOTE Due to meter redesign meters manufactured after May 10 1995 use the New Style change gears Older meters use the Old Style change gears 0259 036357 US Measure 1820R 036361 Liter Measure 1820R
23. ask 4 Reset button 5 and spring 6 are released when the dial mask is removed Remove screws 7 reset bearing 8 and screws 11 to lift register assembly 10 out Drive shaft assembly 12 can be removed by taking out four bearing screws Replacing Bearing and Seal Assembly Item 16 Old Style To replace the shaft seal or service the gear train on back of register housing 18 remove housing from meter body by taking out four screws NOTE The meter housing will be full of liquid so some means should be available to catch what drains from the case and lines To remove gears 22 25 remove three retaining rings 20 and drive key 21 Withdraw the drive shaft and gear 14 spacer 15 meter stuffing box 16 and O ring 17 Slide new O ring over new bearing seal like you would slide a ring on your finger Insert shaft 14 through spacer 15 and bearing 16 as shown in the exploded view Press entire assembled shaft and seal through housing and seat the square of the bearing firmly into the recess in the register housing 18 Reassemble the balance of the register in reverse order of disassembly 0144 5 7 GASBOY Series 70 amp 1820 Replacing Bearing and Seal Assembly Item 26 New Style To replace the bearing and shaft seal assembly 26 or service the gear train on back of register housing 18 remove housing from meter by taking out four screws NOTE The meter housing will be full of liquid so some means should be avai
24. back into a shut off dispenser when dispensers share a common submersible pump or starter relay Also block islands so no vehicles can pull up to the dispenser when the dispenser is being worked on Federal DOT regulations dispensing flammables gasoline from portable tanks prohibit such as 035282 OF A FUEL SPILL DO NOT use Teflon tape for any pipe threads in the product DO NOT use consumer pumps for pumping fuel or additives into aircraft DO NOT use commercial pumps for direct fueling of aircraft without filters and separators necessary to ensure product purity DO NOT use where sanitary design is required for food products for human consumption or with water based liquids DO NOT smoke near the pump or when using the pump DO NOT use near open flame or electrical equipment which may ignite fumes DO NOT permit the dispensing of gasoline or other petroleum products into a vehicle with its motor running DO NOT permit the dispensing of gasoline or other petroleum products into unapproved containers or into approved containers in or on vehicles including trucks All containers must be filled on the ground to prevent static discharge Always use Approved and Listed hoses and nozzles with electric pumps and dispensers DO NOT block open the nozzle in any manner Nozzles shall conform to UL and NFPA code requirements for attended or unattended service DO ensure that the pump is equipped with pr
25. cabinet 2 Pull front panel assembly forward at bottom As it clears the pumping unit lift up to remove 3 To replace front panel engage pins at top in matching holes in rear panel With front panel assembly tilted back pins may be seen through dial opening Front panel assembly will now drop back into position 4 Reinstall two screws in sides Cabinet Removal for Installation or Service Series 1820R Only Squared Cabinet 1 Remove two screws on lower front of cabinet 2 Remove two screws from upper back of cabinet 3 Push and hold the reset button and pivot the cabinet front panel upward until it clears the button Be careful not to damage the button Remove panel 4 For calibration or service remove the lefthand side panel by unscrewing the two screws on the bottom side of the cabinet 5 Toreassemble pump cabinet align side panel screw holes with holes on base of cabinet and screw tight Replace the cabinet top and front panel by positioning the back plate and pivoting the assembly forward Be sure to press in the reset button until the front panel clears it Then replace the screws in the front and back of cabinet Installing Hose and Nozzle To prevent undue stress and possible damage install hose and nozzle after installation of pump Hose must have static wire which provides electrical continuity between hose couplings to dissipate static electrical charge 1 Screw the pipe elbow provided with the pump i
26. ded and 038520 for diesel Loosen pump cover and slide aside so you can observe the rotor and vane movement inside the pump cavity Rotor should be turning freely in a counter clockwise motion If rotor turns clockwise motor is bad If register is recording but no product is being dispensed you may have a supply line air leak Check for an air leak on suction side of pump Is check valve seated properly Reassemble and prime pump using liberal quantity of motor oil in pump cavity if it primes run pump full flow and snap nozzle closed shut off motor and check for leak on suction side of pump above check valve Any observed liquid leakage would indicate an air leak when pump is running with nozzle open and would prevent priming when pump was empty Are bypass strainer and check valve cover plates flat They could be bent from excessive pressure created by a vehicle running over the hose Is there an air leak in the suction line below check valve Make accuracy check using 5 gal Seraphim test can Any clock fast error see Inaccurate Delivery in excess of 2 1 2 indicates an air leak in the suction line The most common source of an air leak in the suction line is the union check union for alignment and tightness before checking balance of suction line If pump does not prime using oil suction line is blocked or has a severe air leak 0144 5 3 GASBOY Series 70 amp 1820 Pump delivers product but won t register V V Is main totaliz
27. e not part of the original system order including Island Card Readers Pump Control Units etc are considered replacement parts Commercial Pumps and Dispensers One year from date of installation or 18 mos from date of Gasboy Parts and Labor Full Cabinet Consumer Pumps International s invoice to the purchaser whichever comes first Small Transfer Pumps Meters One year from date of installation or 18 mos from date of Gasboy Parts Only Pressure Regulators International s invoice to the purchaser whichever comes first Excepting the Model 2020 Hand Pump which has a 90 day warranty from date of Gasboy International s invoice Keytrol One year from date of installation or 18 mos from date of Gasboy Parts and Labor International s invoice to the purchaser whichever comes first Fuel Management Systems One year from date of start up or 15 mos from date of Gasboy Parts and Labor CFN Profit Point International s invoice to the purchaser whichever comes first Series 1000 FleetKey The basic warranty only applies to systems which have been TopKAT started up by a Gasboy Authorized Service Representative ASR Fuel Point Readers sold with new systems Additional Fuel Point Items One year from date of start up or 15 mos from date of Gasboy Parts Only Fuel Point Readers sold for International s invoice to the purchaser whichever comes first retrofitting existing systems Fuel Point vehicle and dispenser co
28. e pump should be performed by competent service personnel GASBOY has a distributor network which services fuel dispensing equipment in every part of the country Turn off all power to the pump to reduce the risk of electrical shock when servicing including changing of fuel filters or strainers Also block islands so no vehicles can pull up to the pump when it is being worked on Replace worn rusted or corroded parts immediately with new authorized service parts supplied by GASBOY Replacing parts with incorrect or substandard substitutes will result in unsatisfactory pump operation Always use new gaskets or seals when servicing or rebuilding Gasboy equipment do not re use old ones Using authorized parts will insure the continuity of the Underwriters Label on your pump Section 6 lists parts and service procedures for the Series 70 and 1820 pumps Using part numbers when ordering will expedite your order and reduce the possiblility of the wrong parts being shipped The remainder of this section contains troubleshooting information and assembly disassembly procedures for various components that may need service 0144 Service and Troubleshooting TROUBLESHOOTING If problems are encountered in operation of the pump follow the procedures below in an attempt to isolate the problem When the problem is detected follow the procedures for disassembly of the pump Pump Won t Start V Isthe breaker at the panel turned on V Is the
29. ensure that any unused openings are plugged SUPPLY LINE UNDERGROUND TANKS If you are using an underground tank pitch the tank away from suction end Horizontal runs of suction line should slope down from the pump toward the tank Do not exceed an equivalent lift of 12 for gasoline or 14 for diesel to the center line of the pumping unit including friction resistance in the suction pipe The end of the suction pipe must be at least three inches from bottom of tank The tank or piping should not be located under traffic areas Swing joints two ells will prevent damage to piping due to frost heave or ground settlement Use nonhardening gasoline resistant pipe compound on male threads of all pipe joints for liquid handling piping 2 2 9312 Installation PUMP DIMENSIONS SERIES 70 MODEL 1820 Pump diagrams shown are for Model 1820 Pump dimensions are the same for all Series 70 pumps Product Outlet Female Threads NP PUMP DIMENSIONS MODEL 1820R Pump diagrams shown are for Model 1820R Pump dimensions are the same for these Model 1820 pumps 1820R 1820RSS 1820RC 1820RCSS Product Outlet Female Threads 3 4 NPT 9312 2 3 GASBOY Series 70 amp 1820 INSTALLATION INSTRUCTIONS Cabinet Removal for Installation or Service Series 1820 Only Rounded Cabinet 1 Remove two screws one on each side of the
30. er If an optional pulser kit is attached it will be supplying pulses which may be recorded by an external monitoring system Repeat Steps 2 through 5 several times to ensure that the pump is operating satisfactorily 9312 4 1 GASBOY Series 70 amp 1820 POST STARTUP TESTS Voltage The incoming voltage to the pump should be checked and any reading not within 10 of rated voltage should be corrected before testing is continued When dealing with suction pumps it is good practice to take voltage readings while the suction pump is operating on bypass turned on but not dispensing product and also while making a delivery Any voltage drop in excess of 10 during either of these operating states should be considered a low voltage condition Corrective action should be taken to insure an adequate power supply to the pump Tightness After determining that the pump is operating satisfactorily and the system is fully primed check the pump and piping to make sure that all connections are tight We recommend that the tank and all piping not be covered until this has been completed Meter Calibration NOTE This meter was redesigned causing the calibration procedure to be different depending on the age of your meter Meters made after May 10 1995 are referred to as new style meters meters made before that date are referred to as old style All GASBOY pumps are adjusted for accurate measure for gasoline within 05 gallons at the factory Howeve
31. er 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 working the problem is a broken or jammed measuring chamber Pump delivery is slow N lt NNN Check for dirty strainer If pump has a filter change filter An automatic nozzle will reduce flow rate about 2596 Check flow rate without nozzle or with standard nozzle A farm type automatic nozzle such as Husky 1GS swivel provides the best flow Check for supply line restriction by testing the pump with a vacuum gauge If vacuum is abnormally high there is a restriction Pump loses prime V V V Inspect check valve poppet and seat for clean mating surfaces If after a period of non use a pump delivers product initially followed by air and then full flow there is an air leak in the suction line Install pressure gauge between hose and nozzle Operate pump at full flow Snap nozzle closed and turn off pump If pressure falls to zero rapidly replace check valve and clean and inspect valve seat Inaccurate delivery V Calibrate the meter See Section 4 A clock fast error more on the register than is delivered in excess of 2 1 296 is due to air in the suction line or vaporization of gasoline in the pump Check pump for loss of prime and suction line for air leak A clock slow condition may result from any slowing of the register or measuri
32. gtd 0 CNXEReI ILC x J H l L 2 Ed F l 11 1 A E 7 X ies ma AS L L CN 37 cal 00 2 DES m th por i u TI CI Installation Vacuum Breaker The vacuum breaker tubing kit can be used with any Series 70 or 1820 pump The vacuum breaker is used to break a siphon should the nozzle drop below the fluid level in the tank while the pump is stuck in the open position A threaded vacuum breaker P N 066570 is shipped installed in the pump GASBOY recommends that the vacuum breaker be tubed back to the tank The illustration below shows two methods for installing tubing for the vacuum breaker In all instances the vacuum breaker must be tubed using 1 4 tubing to the vapor space at the top of the tank if the tube is installed below the fluid level of the tank the ability to break vacuum and prevent siphoning will be lost Using the illustrated methods the tube end may terminate into the annular vapor space between the 1 suction pipe and the 2 mounting pipe or into an opening in the top of the tank All components shown are provided when you order the kit P N 032700 a PUMP HOUSING EM a A c 8 NPT FITTING HREADED ut VACUUM BREAKER LI SUPPLIED W PUMP 1 4 COPPER TUBING N a PS 3 4 TEE ALTERNATE TUBING 8 X 3 4 BUSHING Ill 3 LONG TANK Mm d TOF
33. he meter to exact zero For new style meters start with the screw turned all the way in clockwise For gasoline calibration turn the screw approximately two full turns counter clockwise For diesel turn 3 the screw approximately two full turns counter clockwise Replace the cap screw old style only Deliver about 1 2 gallon through the meter before resetting to zero and retesting Allow a ten second drain period each time the test measure is emptied to assure accurate measure Adjust and retest until register is zeroed at desired flow Strainer Cleaning 4 2 9312 Start Up and Operation Clean the strainer immediately after the pump has been installed and tested and again after a few hundred gallons have been delivered Thereafter once every six months or as required The procedure for cleaning the stainer can be found in the Maintenance and Troubleshooting section DAILY OPERATION 1 begin fueling remove the nozzle from the boot and turn on the pump handle 2 f your model has an automatic reset the register resets to zeros If your model has a reset button push it to zero the register 3 Dispense fuel 4 the pump handle off The amount delivered is displayed on the register 9312 4 3 Section 5 MAINTENANCE AND TROUBLESHOOTING MAINTAINING TROUBLE FREE OPERATION Operating your pump with reasonable care will prolong its life and provide better service GASBOY pumps are designed and built to prov
34. he pump When two pumps are powered from the same breaker through the same wires the gauge of the wires should be increased to handle the added load according to the distance from the breaker panel Use the chart below to select the proper wire size for your installation Table 3 1 Wire Size WIRE GAUGE SIZES FOR 1 3 HP MOTOR DISTANCE 115 VAC 230 VAC FEET METERS GAUGE GAUGE 25 7m 14 14 50 15m 14 14 100 30m 12 12 150 46m 10 12 200 61m 8 12 250 76m 8 12 300 91m 8 12 The AC wire size for the reset complete switch detect line should be 14 AWG when it is used 3 2 9312 Wiring PULSER WIRING An optional pulser available on the Series 1820R only is used when external monitoring of the dispensing unit operation is desired The pulser transmits one electrical signal pulse for each predetermined amount of fuel dispensed Reed 10 1 pulsers operating with DC voltages are used Pulser wiring must be 18AWG and installed in metal conduit separate from all AC wiring It cannot share a common junction box wiring trough or conduit with any AC wiring CONDUIT All wiring to the GASBOY pump must be installed in 1 2 threaded rigid metal conduit Do not use knockout boxes and flexible conduit If equipped with a DC pulser AC power wires must be installed in a separate conduit from the DC pulser and the AC power wires and DC pulser wires must not be run in any sort of comm
35. ide years of uninterrupted service however certain parts of a pump are bound to wear To keep your pump running at maximum efficiency GASBOY recommends a periodic inspection at least twice a year Remove Water from Tank After every fill up check your tanks for water Water can accumulate in both underground and aboveground storage tanks due to condensation or defective fill openings that are not properly protected with watertight covers Remove any water with a sump pump to forestall serious damage to equipment Water sediment and other foreign matter that accumulates in the tank can be drawn up into the pump and cause failures Clean the Dial Face Use a soft clean damp cloth as needed Preserve the Pump s Finish GASBOY pump housings are finished with a coating of urethane paint To preserve this finish thoroughly clean all painted surfaces at regular intervals with a high grade automobile polish and protect with a coat of paste wax Do not use abrasive cleaners or polish Do not use high pressure spraying equipment Stainless steel cabinets also require regular cleaning especially in corrosive environments such as coastal areas Wash with mild detergent or soap and water followed by a clean water rinse Avoid abrasive cleaners which may scratch the finish Stubborn stains such as oil or grease will require a stronger cleaner DO NOT use ordinary steel wool as iron particles may adhere to the surface and cause corrosion Always clean in
36. it turns freely and replace in meter body Do not overtighten screws 4 A torque of 20 25 ft lbs is sufficient When reassembling register to meter body use a new O ring 3 For calibration procedure see Meter Calibration in Section 4 0144 5 5 GASBOY Series 70 amp 1820 1860 3 WHEEL REGISTER SERVICE AND MAINTENANCE NOTE Numbers in parentheses correspond to the numbers shown on the parts illustration and parts list in Section 6 labeled 1860 3 Wheel Meter Register To service or replace parts in the disc register remove the self tapping screws and lift off the front panel assembly With the register now exposed remove three screws with fiber washers 28 amp 29 Lift off dial glass 30 and dial mask 82 This permits withdrawal of all parts 8 through 22 While removing parts observe the position and relationship of the parts to each other to assist reassembly Totalizer assembly 3 can be taken out by removing screw 1 Replace as an assembly To gain access to the gear train 39 40 41 or 44 through 49 the register 1 through 33 can be removed as an assembly by taking out 4 screws and lifting it off the meter body This is a liquid carrying section of the meter Be prepared to catch any liquid drained from the system at this point The cluster gear 40 controls the gear ratio change for gasoline or diesel fuel in U S or Imperial measure and is removed by taking off the retaining ring 38 and control block 39
37. k Flange 4 102mm Minimum 9312 2 5 GASBOY Series 70 amp 1820 Direct Mount on Aboveground Tank Aboveground tanks require both a pressure vacuum vent and an emergency vent The pressure vacuum vent reduces losses due to evaporation and is an air quality control measure The emergency vent provides a relief from the pressure resulting from heating and boiling of the tank contents during a fire situation Both vents must be properly sized for a given tank 1 Screw 1 suction pipe into install a socket Suction pipe should be long enough to allow 3 clearance from bottom of tank Apply gasoline resistant pipe compound to male threads Screw install a socket directly into 2 flange in the aboveground tank Lift the pump to the height of the tank and tighten it into the install a socket Apply gasoline resistant pipe compound on male thread NOTE If using an automatic nozzle with the extended nozzle hanger you may need to use a 2 coupling and close nipple in between the pump and the install a socket This will prevent interference of the hanger with the top of the tank See the Conduit section for correct installation of electrical conduit sure Vacuum NOTE Aboveground tanks located at commercial industrial governmental or manufacturing establishments and intended for fueling vehicles used with their business cannot exceed a capacity of 6000 gallons 2 6 9312 I
38. lable to catch what drains from the case and lines To remove gears 22 25 remove three retaining rings 20 and drive key 21 Withdraw the drive shaft and gear 14 spacer 15 and all parts of bearing and seal assembly 26 Remove the nylon washer from item 26 and note its location Remove both oilite bearings and both O rings from bore in register housing Using new parts which consist of a new nylon washer 2 oilite bearings and 2 O rings reassembly parts in reverse order Be sure to lubricate both O rings with an O ring lubricant before assembling Reassemble gear train in following sequence gear 25 key 21 cluster gear 24 retaining ring 20 control block 22 and retaining ring 20 5 8 0144 Section 6 PARTS Using part numbers when ordering will expedite your order and reduce the possibility of the wrong parts being shipped When ordering replacement parts be sure to give the complete name and part number as shown in the appropriate parts lists Procedures requiring disassembly of portions of the pump should be performed by competent service personnel Do not depend upon the repair service of a general mechanic unless he is thoroughly familiar with the mechanism GASBOY has a distributor network which services fuel dispensing equipment and management systems in every section of the country WARNING To reduce the risk of electrical shock when servicing turn off and lock out all power to the pump
39. ly tightened Mating surfaces between the box and cover must be free of dirt nicks and scratches All unused entries into the junction box must be properly plugged Rev 0215 707 North Valley Forge Rd Lansdale PA 19446 215 855 4631 FAX 215 855 0341 CONTENTS IMPORTANT WARNINGS AND SAFEGUARDS FOR CONSUMER PUMPS Section 1 Section 2 Section 3 Section 4 Section 5 0144 INTRODUCTION PUDO Oaai e a en Le 1 1 SPECICATION err e rd deba e o ee dac ide aedi purto doge 1 1 INSTALLATION Installation Precautions 2 1 Supply Line Underground 2 2 Pump Dimensions Series 70 Model 1820 2 3 Pump Dimensions Series 1820R sss 2 3 Installation Instructions 2 4 Cabinet Removal for Installation or Service Series 1820 only Rounded Cabinet a 2 4 Cabinet Removal for Installation or Service Series 1820 only Squared Cabinet nenene 2 4 Installing Hose and Nozzle u mm 2 4 Direct Mount on Underground Tank a 2 5 Direct Mount on Aboveground 2 6 Pedestal Mount Pump u uu 2 7 Wall MOU OPE ETE 2 8 Vacuum Breaker ecce
40. mponents Encoders Embossers Purchased with Fuel Management System Encoders Embossers only Purchased with System Modems CRTs and Logger Printers 90 days from the date of start up by a Gasboy ASR or 180 days from Encoders Embossers only date of Gasboy International s invoice whichever occurs first Parts Only Purchased with Fuel Management System Purchased with System Modems CRTs and Logger Printers only Modems CRTs Logger Printers only Matches system warranty Parts Only Purchased Separately Purchased Separately 90 days from date of Gasboy International s invoice to the purchaser Parts Only Air Diaphragm Pumps Three years from date of purchase for full warranty description see Parts Only Price List Items not manufactured by Not warranted by Gasboy International Not Applicable Tokheim Gasboy consult original manufacturer s warranty ex Automatic nozzles hoses swivels etc Replacement Parts One year from date of Gasboy International s invoice to the purchaser Parts Only To the extent permitted by law this warranty is made in lieu of all other warranties expressed or implied including warranties of freedom from patent infringement or merchantability or fitness for a particular purpose or arising from a course of dealing or usage of trade No one is authorized to vary the terms of the warranty nor may anyone make any warranty of representation or assume any liability other than that herei
41. n stated in connection with the sale described herein The acceptance of any order by Gasboy International is expressly made subject to the purchaser s agreement to these conditions GASBOY INTERNATIONAL INC A Tokheim Subsidiary Box 309 Lansdale PA 19446 800 444 5579 FAX 800 444 5569
42. ng chamber due to excessive friction resistance or mechanical failure inadvertent bypassing of the measuring chamber Check register for zero setback check reset lever return to top of slot in meter cover after setback check for hang up of number wheels in register or gears not meshing Pump delivers product when not turned on V V In aboveground storage tank if fluid level is higher than pump positive head pressure may force product through pump Install a pressure regulating valve or a solenoid valve in the supply line to the pump Check for defective vacuum breaker Vacuum breaker spits product V 5 4 Clean and replace If problem persists install return line kit 0144 Service and Troubleshooting DISASSEMBLY OF PUMP NOTE Numbers in parentheses correspond to the numbers shown on the parts illustration and parts list in Section 6 labeled Direct Drive Motor Pump Assembly When the front panel is removed all the working parts of the pump are accessible under clearly marked cover plates Since pump may contain product be prepared to catch product in an appropriate container when removing any cover Remove pump cover screws and remove cover plate 1 and square ring 2 Note orientation of rotor 4 and of vanes 36 in rotor slots Remove key 3 and withdraw rotor and vanes from pump block 12 Since rotor is spring loaded make sure washer 6 and spring 7 remain on pump shaft Insert new rotor and replace v
43. nstallation Pedestal Mount Pump 1 Screw 2 coupling onto threaded end of 2 standard pipe 2 Slide cast iron pedestal base up over the unthreaded end of 2 standard pipe 3 Screw 1 suction pipe into install a socket Suction pipe should be long enough to allow 3 clearance from bottom of tank Apply gasoline resistant pipe compound to male threads 4 Insert 1 suction pipe into 2 pipe and screw install a socket into coupling on end of 2 pipe 5 Assemble union onto lower end of 1 suction pipe conforming to your site s piping layout Note that the GASBOY base is provided with an opening on one side so that an elbow can be used and the suction brought out horizontally aboveground if desired instead of straight down through the island 6 Slide base down to proper position at the lower end of the pedestal tighten six set screws 7 Screw the 2 male thread on the base of the pump into the upper end of the install a socket Apply gasoline pipe compound to all male threads 8 Securely mount pedestal base to concrete If the pump is not securely fastened to the foundation supply line leaks at unions and pipe joints may occur See the Conduit section for correct installation of electrical conduit All underground piping and swing joints are supplied by the customer All metallic piping should be at least Schedule 40 wrapped coated black steel pipe with extra heavy malleable iron screw type fittings Protect metallic piping in contact with
44. nto the product outlet on the back of the pump Apply gasoline resistant pipe compound to male threads NOTE Elbow fitting is not required however it provides strain relief for the hose 2 Screw the hose into the open end of the elbow and tighten Apply gasoline resistant pipe compound to male threads 3 Screw nozzle onto hose NOTE 1820R models are shipped with a vacuum breaker assembly P N 032701 consisting of a tee pipe nipple and vacuum breaker This assembly should be installed in the pump outlet before connecting the hose 2 4 9312 Installation Direct Mount on Underground Tanks 1 Screw 2 coupling onto 2 standard pipe 2 Screw 2 standard pipe into 2 tank flange Apply compound to threads at bottom of base to prevent surface water from entering the tank 3 Screw 1 suction pipe into install a socket Suction pipe should be long enough to allow 3 clearance from bottom of tank Apply gasoline resistant pipe compound to male threads 4 Lower 1 suction pipe through 2 standard pipe into tank Tighten install a socket into coupling at top of standard pipe 5 Screw pump 2 threaded base into install a socket This is a suction line connection and must be tight Apply gasoline resistant pipe compound to male threads See the Conduit section for correct installation of electrical conduit Instoll A Socket Screwed Into 2 Coupling 77 Coupling 2 NPT Tan
45. ny type to contaminate the carbon or brass mating surfaces If the seal inadvertently becomes contaminated both mating surfaces must be carefully cleaned with a lint free cloth and methyl alcohol The bypass valve 29 is preset to provide maximum performance without overloading the motor and can be withdrawn by removing the bypass cover plate 31 When reassembling make sure the holed end of the tube 32 and bullet shaped nose of the valve 29 are inserted toward the pump The check valve is attached to the check valve cover 26 and will come out when the cover is removed If you can hear the product in the suction line running back into the storage tank when this assembly 20 is removed the check valve is holding and keeping the pump primed When reassembling make sure the rubber valve disc is facing down toward the valve seat METER REGISTER DISASSEMBLY NOTE Numbers in parentheses correspond to the numbers shown on the parts illustration and parts list in Section 6 labeled 1860 and 4860 Meter Register The B size measuring chamber 5 can be removed for cleaning by taking out four meter body screws 2 lifting off register assembly 14 and removing three measuring chamber screws 4 After separating and cleaning top and bottom half reassemble making sure baffle is seated in grooves in top and bottom halves and through slot in measuring disc 7 Do not drop or sharply strike chamber parts while handling Rotate disc to make sure
46. on conduit or trough All wiring and conduit runs must also conform with the National Electrical Code NFPA 70 and the Automotive and Marine Service Station Code NFPA 30A All wiring and conduit runs must conform to local codes The conduit layout drawing on the left is for all Series 70 and 1820 rounded cabinet models The drawing on the right is for 1820R models The junction boxes shown below the 1820R are supplied with the pump T 1 2 Threaded Rigid Meta DC Pulser Conduit Junction Box With Pulsers 9312 3 3 GASBOY Series 70 amp 1820 PUMP WIRING DIAGRAMS 115VAC Pumps Series 70 and 1820 left and Series 1820R right Control Lead Aux AC Circuit Breaker Full Speed Circuit Circuit Breaker NOTE FOR 230V MOTORS Some motors may contain different wire colors than those shown In this case Hot is Black Neutral is White and Aux AC Control is Brown 1 8 4 All wiring and conduit runs must conform with all building fire codes all Federal State and Local codes National Electrical Code NFPA 70 NFPA 30 Automotive and Marine Service Station Code NFPA 30A and NFPA 395 codes and regulations For the Series 70 and Series 1820 rounded cabinet models make the field wire connections in the m
47. ontains warnings safeguards and procedures on the use and care of the pump Be sure to leave this manual with the pump owner after the installation is complete Customers and installers having any questions pertaining to the installation should contact their GASBOY distributor SPECIFICATIONS Series 70 and Series 1820 pumps are made specifically for private use on vented tanks While their outward appearance differs they basically offer the same features These pumps can be mounted on aboveground skid tanks directly mounted above underground tanks or mounted on pedestals for remote underground installations Table 1 1 summarizes the features for each model Pumping Unit Self priming direct drive rotary vane 23 PSI 1 6 bars stainless steel bypass check valve with pressure relief valve Motor 1 3 HP 1725 RPM motor with thermal overload protection and auxiliary AC line Standard 115 VAC 60 Hz optional 230 VAC 50 Hz AC junction box included Register 70 4 wheel push button reset 7 digit master totalizer 1820 3 wheel volume only lever type reset with interlock 6 digit master totalizer Optional except for 1820R 4 wheel push button Registers show delivery in US gallons Imperial gallons or liters and change gears are available to convert registers for unit of measure Meter Nutating disk phenolic measuring chamber in aluminum die cast housing adjustable calibration 5 at full flow Hose amp Nozzle 12 3 66 m
48. oper filters based on the product being dispensed and its intended use DO wear safety goggles and protective clothes when dispensing any liquid which may be potentially harmful or hazardous DO keep all parts of body and loose clothing clear of belts pulleys and other exposed moving parts at all times GASBOY INTERNATIONAL INC A TOKHEIM SUBSIDIARY DO require washing and changing of clothes if fuel is spilled on a person or his her clothing Keep away from open flames sparks or people smoking DO provide a receptacle for catching product from pump meter when servicing DO clean up product spills on the driveway Turn off and lock out all power prior to cleanup DO insure pump is properly grounded DO insure hose is compatible with fluid being dispensed DO inspect hose nozzle and pump on a regular basis for wear damage or other conditions which may create a safety or environmental hazard DO make sure all pipe threads are properly cut and the inside reamed to remove burrs Use UL classified gasoline resisting compound all joints of gasoline handling piping Sealing compound must also be resistant to Gasohol Ethanol and Methanol Use gasoline resistant pipe compound on male threads only pipe compound used on female threads can be squeezed into the supply line where it can enter the product stream and become lodged in the pump or meter DO ensure that junction box covers are in place and proper
49. otor junction box The 1820R models with the squared cabinet come with the wires already extended through the end of a factory installed conduit The 1820R models also come with a junction box which is to be mounted directly beneath the pump The field wire connections for the 1820R models should be made in this junction box not the pump motor junction box Wire connections should be tightly spliced and secured with a wire nut Close off the end of the wire nut with electrical tape The Aux AC Control Lead wire is shipped capped from the factory When used it connects to a solenoid valve or fuel management system Do not connect this wire without first checking the ON voltage of this line to ascertain compatibility with the equipment being connected Pulser wiring must be 18AWG and installed in metal conduit separate from all AC wiring It cannot share a common junction box wiring trough or conduit with any AC wiring 9312 Section 4 STARTUP AND OPERATION PRE STARTUP CHECKLIST The information below should be reviewed to help verify the proper installation of your GASBOY pump If the installation does not meet criteria listed as well as any Federal State and Local codes and requirements correct the problem before powering on the unit 1 The unit must be properly secured 2 All plumbing must be complete and tight All liquid carrying lines must be checked for leaks 3 When DC pulsers are used in the pump the AC and DC wires mu
50. r amp L H Wheels 12 028225 L H Count Wheel 12A 068994 L H Wheel Assembly Includes items 12 14 15 13 027580 Center Count Wheel 13A 068993 Center Wheel Assembly Includes items 13 16 17 14 028245 L H Reset Gear 15 042070 L H Reset Pawl 16 027600 Center Reset Gear 17 042040 Center Reset Pawl 18 068995 Wheel and Clutch Assembly 19 042055 Overthrow Stop Pawl 20 048805 Detent Spring Retainer 21 057580 Detent Spring 22 054325 Reset Sector Gear 23 056425 Reset Lever Shoe 24 033822 Reset Lever 25 057895 Reset Lever Spring 26 012085 Reset Lever Bearing 27 054955 Register Drive Gear amp Shaft 28 052840 Dial Mask Screw 29 067780 Fiber Washer 30 028780 Dial Glass 32 035394 Dial Mask US Gallons amp Imperial Gallons 035380 Dial Mask Liter Tenths 33 022675 Register Housing 34 049075 O Ring 35 048865 O Ring 36 014095 Bearing and Seal Assy Use only when Rev K is cast inside of housing 33 If other Rev see item 52 37 031345 Drive Key 38 049390 Retaining Ring 50 012250 Bezel 70 series 51 053605 Bezel Screw 70 series 52 036995 Bearing amp Seal Assy Use only when Rev P is cast inside of housing 33 If other Rev see item 36 NOTE Due to meter redesign meters manufactured after May 10 1995 use the New Style change gears Older meters use the Old Style change gears 9312 036296 Liter Measure Full 035638 Imperial Measure Item Part No CHANGE GEARS U S GALLONS New Style
51. r since the conditions of the installation can affect pump accuracy it is the responsibility of the installer to check the pump for accuracy and make any needed adjustments Where required it is the owner s responsibility to report this device to the local Weights and Measures officials for their inspection before the unit is put into service Choose the flow rate at which the meter will be used most often for the zero calibration point For example if the pump is being used with an automatic nozzle calibrate with the nozzle set on the middle or top notch position whichever is used most frequently Use a certified five gallon measure with a sight glass and scale showing cubic inches over or under an exact five gallons Fill and drain the test measure to completely wet the interior surfaces Reset the register to zero and deliver an exact measured five gallons into the test measure at the selected flow Read the level of the liquid in the sight glass on the scale in cubic inches Follow the instructions in Section 3 Cabinet Removal for Calibration Installation or Service to access the calibration screw Use a ap dm narrow blade screw driver to turn the adjusting screw clockwise to correct for plus cubic inches or counterclockwise for minus cubic inches in the test measure Count the number of full turns and fractional turns each time for f reference in judging the number and direction of any additional turns required to calibrate t
52. rol Shaft Assy 28 See breakdown Direct Drive Motor Assy See Direct Drive Motor parts breakdown 29 051206 Switch Rod Assembly See breakdown 30 003597 Flanged Inlet 72S amp 1820 003601 Flanged Inlet 1820R 31 044089 3 4 x 6 7 8 Nipple 32 030539 Hose 5 8 x 12 ft Not shown 33 038471 Nozzle Manual Unl Not Shown 35 032912 Dial Face Kit consists of items 1 2 amp 10 36 066534 Vacuum Breaker Not Shown PART 037461 038471 038475 038519 038520 038510 038511 038503 DESCRIPTION Motor for 50 cycle 230V Nozzle 3 4 Manual Unleaded Nozzle 3 4 Manual Leaded Nozzle Automatic Unleaded Husky Nozzle Automatic Leaded Husky Hook Assy OPW 11A Hook Assy EMCO A2000 Hook Assy OPW 7H 6 5 GASBOY Series 70 amp 1820 DIRECT DRIVE MOTOR PUMP ASSEMBLY 6 6 0259 DIRECT DRIVE MOTOR PUMP ASSEMBLY Item O GQ 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 9312 Part No 003490 049004 031285 051475 054024 067210 057956 048941 049510 048820 048956 003210 049525 F37332 F37697 F37616 F37461 003065 066655 029155 029005 068680 038980 068650 024356 022271 042370 062620 062365 062335 049001 022315 065725 049002 063268 063266 022900 067030 049003 Description Pump Cover Square Ring Key 70 Rotor Seal Group Consists of items 6 11 Washer Spring O Ring Rotating Seal
53. rs lefthand pawl red center pawl white Seat count gear 13 over hub of and down against reset gear 16 Listen to it snap into place 6 Install righthand overthrow stop 19 on post with lower arm engaged in rectangular cutout in reset lever 24 Install center and lefthand overthrow stop 11 on post so that upper arm of 19 fits in the recess in 11 and both stops are driven simultaneously by reset lever 24 during reset 7 df detent spring 21 and retainer 20 become separated reassemble on post so that short leg of spring points toward top of register 8 f all parts are removed from the register reassemble in the reverse order the following sequence 27 35 36 41 37 40 39 38 2 3 1 26 24 25 23 22 19 16 17 14 15 12 18 13 11 21 20 10 9 8 32 31 30 29 28 9 Test register for zero reset one short downward stroke of the reset lever resets register to zero and turn control block 39 by hand to record at least one gallon on the register Make sure O ring seal on the rear of the housing is clean and the O ring 34 is free of nicks or cuts and will lay flat within the seat Reassemble the meter to the register 4860 4 WHEEL REGISTER SERVICE NOTE Numbers in parentheses correspond to the numbers shown on the parts illustration and parts list in Section 6 labeled 4860 4 Wheel Register To service push button register remove two one on each side screws 2 from bezel 1 Remove bezel and dial m
54. sher 2 oilite bearings and 2 O rings reassemble parts in reverse order Be sure to lubricate both O rings with an O ring lubricant before assembling When assembling the disc register observe the following precautions 1 For full liter models make sure the spacer washer 43 lies between the control block and gear 44 and the rear of the housing 33 on the control block post The function of the remaining plate is to stabilize the shaft 27 and ensure full engagement of gears in the drive train 44 49 Reassemble the full liter train in the order 46 45 48 47 49 and 44 The gears drive in their number sequence i e 44 drives 45 45 drives 46 etc 2 Anew drive key 37 is L shaped as shown in drawing After insertion through hole in shaft 27 and slot in gear 41 or 49 hub the long leg of L must be bent up to form a U shape and capture the key and drive the gear train 5 6 0144 Service and Troubleshooting 3 Hook spring 25 over post so that hook lies flat against rear of housing 4 sure lower arm and overthrow stop pawl 19 fits into slot in reset lever 5 To time the register for zero reset pry apart the center wheel and 13 and 16 and place 16 on middle post with two red marks pointing toward the other two posts Line up the red arrows on the lefthand and righthand wheels with marks on the center wheel as shown in drawing Make sure pawls 15 and 17 remain in grooves of lefthand and center 16 reset gea
55. st not share any conduits junction boxes or troughs 4 All conduit work must be complete All junction box covers must be secured Conduit seals should not be sealed until the wiring is verified through proper operation 5 The unit must be properly grounded 6 Before any testing begins remove any water in the tank through a fill opening using a suitable pump Do not use the GASBOY pump to remove water Serious damage may occur 7 sufficient volume of fuel must be put in the tank to insure that the liquid level is above the bottom of the suction pipe 8 Before placing nozzle into service apply a few drops of light machine oil such as 3 in 1 on the stem Operate the lever several times so that the oil penetrates the packing This offsets the drying action of gasoline and keeps the packing soft and pliable STARTUP After successfully verifying the installation against the completion check list the unit is ready for startup Follow the procedure listed below to perform an orderly start up 1 2 3 Turn on the circuit breaker for the pump Remove the nozzle from the boot and turn on the pump handle If your model has an automatic reset verify that the register resets to zeros If your model has a reset button push it to zero the register Dispense fuel Check all plumbing for leaks at this time Turn the pump handle off Open the nozzle No fuel should be dispensed The amount delivered should be displayed on the regist
56. t be installed by a qualified installer and used conformance with all building fire and environmental codes and other safety requirements applicable to its installation and use including but not limited to NFPA 30 NFPA 30A NFPA 395 amp NFPA 70 A qualified installer is familiar with fuel systems installations under the above stated building fire and environmental codes and other safety requirements for the particular type of installation This product is only part of a fuel dispensing system and additional equipment and accessories such as but not limited to breakaway connectors shear valves pressure regulators flow limiters and other safety devices may be necessary to meet the applicable codes For maximum safety we recommend that all employees be trained as to the location and procedure for turning off power to the entire system Instructions regarding proper operation of the equipment along with the appropriate safety warnings should be posted in plain view at the fuel island Before performing service or maintenance including changing of fuel filters or strainers or in the event of a fuel spill turn off and lock out all power to the system In battery powered pumps disconnect power source In submersible pump applications turn off and lock out power at the master panel and close any impact valves to the submersible pump and other dispensers which use that submersible pump AC power can feed
57. x 14 ft 038503 Hook Assy OPW 7H Hose 3 4 x 15 ft 032700 Kit Vacuum Breaker Tubing and Fittings 6 3 GASBOY Series 70 amp 1820 SERIES 1820 ASSEMBLY 6 4 9312 SERIES 1820 ASSEMBLY Item PartNo Description 025393 Dial Face Assembly 028850 Dial Glass 012265 Bezel 040630 Front Panel Assembly 029620 Nozzle Hanger 029590 Nozzle Hanger 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 Panel Assembly 12 039815 Nyliner Bearing 13 003717 Control Lever 14 053170 Set Screw 15 038860 1 4 20 Hex Nut 16 068891 1 4 Lock washer 17 063970 Pump and Meter Support 18 051880 Cap Screw 19 013030 Carriage Bolt 20 052105 Machine Screw Horiz Dischg 052555 Machine Screw Flgd Dischg 21 003542 Horiz Dischg 3 4 for vac breaker 003544 Horiz Dischg 1 for vac breaker Q Q I OPTIONAL ACCESSORIES PART DESCRIPTION 032814 Filter Kit 1820 1820R Contains items shown below 017270 Bushing 3 4 x 1 043960 Pipe tube 3 4 x 2 003043 Adapter Filter 3 4 024940 Elbow street 3 4 x 90 026005 Filter Wix 24006 dsl gas 030340 3 4 x 14 ft 030355 3 4 x 15 ft 9312 Parts Item Part No Description 22 027055 Gasket 23 052855 Machine Screw 24 052000 Cap Screw 25 053725 Self Tapping Screw 26 Meter Register Assy See breakdown for your model 27 054654 Cont
58. y lines until they have been both air and liquid tested DO NOT back fill the tank or supply line with cinders or ashes Back fill with clean sand crushed rock or pea gravel DO NOT use black iron pipe or fittings for underground installations Use only new galvanized or fiberglass pipe and fittings Install all fiberglass pipe and fittings according to manufacturer s specifications and requirements DO NOT use power line wiring of inadequate capacity Use gauge specified by the wiring diagram or wire chart provided in Section 3 DO NOT use a circuit breaker of improper size See Section 3 DO NOT install fill pipe to tank where it can be submerged with standing water DO NOT use the GASBOY fuel dispensing equipment to remove water ballast from the storage tank 9312 2 1 GASBOY Series 70 amp 1820 15 DO NOT use gaskets on covers of explosion proof type boxes The sealing compound found around wires at all junction box entrances is a requirement of the National Electrical Code and should not be disturbed Tighten junction box covers before replacing panels 16 DO NOT use knock out boxes or flexible conduit for installing this unit All power and lighting wires should be run in threaded rigid metal conduit All threaded connections must be drawn up tight with five 5 threads minimum engagement Only one opening in the AC junction box is provided At completion of the installation it is the installer s responsibility to
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