PT-1957 TopKAT Fuel Management System Parts Manual
Contents
1. Page 10 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Bezel Parts as Viewed from Front and Rear Illustrated Parts List Bezel Parts Front and Rear fcrre Par Number Oeserplon S see Figure 2 4 Part Number Description 8 feon Dew Gays 8 om65 Gasket 1 8 x 1 2 s fese mee Hinge Bere OOO Gasket 1 16 x 1 6 x 3 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Page 11 Illustrated Parts List Mechanical Interface 2 Hose Mechanical Interface 2 Hose Figure 2 5 Series 900 Mechanical Interface 2 Hose View iS SERIES 900 Gg xs PUMP CONTROL PCH IG s J N amy i Als CONE a S i m LJ o SR 3t U NO2. VIEW E sesocosesa TPDH Beales ales es L za bee B o shii 2 S221 T i L2 Cun RIEL ai EFT SIDE L Page 13 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Illustrated Parts List Mechanical PCU 4 to 8 Hose Mechanial PCU Parts 4 8 Hose Item OR PR SCR 8 oeme panssa OOOO 8 ee eese 9 oer omesso Page 14 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Phillips is a registered trademark of the Phillips Screw Company Rubatex is a registered trademark of Rubatex International LLC 2006 GASBOY 7300 West Friendly Avenue Post Office Box 22087 G AS B OY Greensboro North Carolina 27420 QZ Phone 1 800 444 5529 http www gasboy com Printed in the U S A PT 1957 TopKAT Fuel Management System Parts Manual January 2006
3. EUA EW CCHASSIS Page 6 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Parts as Viewed from Right and Rear Sides Illustrated Parts List Parts Right Side See Fowe22 Partnumber Descrpion O see Figure 2 2 Part Number Description ne caste Leck vatspowny e m pone e ow feaeasemy codasa O 9 feses Rain Guter Lower Senes900 OOOO Gasket 1 16 x 1 2 Rubatex R411N Standoff 1 4 turn 1 4 Plastic 21 C09849 Card PCMCIA 256K SRAM with Battery one of the indented parts below is a part of this assembly C09625 Battery Lithium Coin 2BR2325 not shown S OR C09417 Battery Lithium Coin CR2025 not shown C06813 Cable Assembly System Heaters 115 VAC C06757 Cable Assembly Surge Protector 115 VAC Parts Right Rear Side Item see Figure 2 2 Part Number Description 240 C06815 Cable Assembly System Heaters 230 VAC 5 C06820 Cable Assembly Surge Protector 230 VAC PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Page 7 Illustrated Parts List Parts as Viewed from Top and Front Side Parts as Viewed from Top and Front Side Figure 2 3 Series 900 Top and Front View
4. Mechanial Interface Parts 2 Hose Terminal Block Cover 8 position Cable Assembly 8 position Terminal Block to Relays Relay Solid State 240 VAC 40A SPST Relay Solid State 240 VAC 25A SPST C08809 Connector 6 position TB PG C01846 Fuse 2 Amp Quick Blow Pico Axial C03315 Connector 2 position Jumper Female 0 100 Page 12 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 C06752 Cable Assembly Ribbon 20 position 4 length OO B o C06749 Cable Assembly Mechanical Pump Control DC Power Illustrated Parts List 2 6 Series 900 Mechanical PCU 4 8 Hose View Figure Mechanical PCU 4 to 8 Hose Mechanical PCU 4 to 8 Hose WR TOTALIZER POWER BRACKET VIEW IGHT SIDE YR_TOTALIZER POWER BRACKET _ AB eo
5. C07037KTKxxx L ASSY Page 6 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Parts as Viewed from Top and Front Side Illustrated Parts List Parts Top 8 fos cable ssemby Ribbon Opi O 8 J O060753 Cable Assembly Ribbon 20 position 8 essee Mounting Bracket Assert Power Sopp TKT 10 PCB Assembly Series 900 CPU indented parts below are part of this assembly C07037KTKxxx TopKAT Programmed IC PROM two required for locations U1 and U5 where xxx one of the following ENG for English version HTZ for Hertz version SPN for Spanish version Parts Front View Item see Figure 2 3 Part Number Description Cable Assembly AC Input Harness Power Supply with Ground Wire Cover Perforated Int Hsg z OR a OR PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Page 9 Illustrated Parts List Bezel Parts as Viewed from Front and Rear Bezel Parts as Viewed from Front and Rear Figure 2 4 Series 900 Front and Rear Views
6. Mechanical PCU 4 to 8 Hose 13 Mechanial PCU Parts 4 8 Hose 0 0 0 0 ccc eee 14 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Page i Table of Contents This page intentionally left blank Page ii PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Using This Parts List Introduction 1 Introduction Using This Parts List This manual is designed to aid the authorized service contractor ASC or technician in ordering replacement parts for the Series 900 TopK AT system Z WARNING Electrical shock hazards exist in Gasboy Series 900 components Gasboy systems are to be serviced only by properly trained personnel During the warranty period Gasboy systems must be serviced and repaired only by trained ASCs see the Warranty for details or contact your Gasboy representative To reduce the risk of electrical shock when servicing turn off and lock out all breakers which supply power to the Series 900 System all components at the master electrical panel The drawings and part lists starting with Illustrated Parts List on page 5 provide an easy reference for identifying Series 900 parts and their corresponding part numbers Use the part numbers when ordering to expedite your order and reduce the possibility of the wrong parts being shipped Multiple views of the system are provided to ensure all parts are identified Figure 1 1 Typical TopKAT Installation PT 1957 Top
7. chemical or other energy but does not cover electrical hazards Reference Subpart S of 29 CFR Part 1910 Electrical Hazards 29 CFR Part 1910 333 contains specific Lockout Tagout provision for electrical hazards PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Wrapper Assembly Illustrated Parts List 2 Illustrated Parts List Wrapper Assembly Figure 2 1 TopKAT Wrapper Assembly Wrapper Assembly Parts 2e Fowe21 Part numer pesenipun 00 see Figure 2 1 Part Number Description s come Gasket Buk aT w serade OOOO Optional Field Kits Part Number C06966 Field Installation Internal Modem 2400 Baud see Figure 2 3 item 21 C07198 Field Installation Internal Modem 33600 Baud see Figure 2 3 item 21 C07063 Field Installation Report Printer C06968 Field Installation PCMCIA PCB PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Page 5 Illustrated Parts List Parts as Viewed from Right and Rear Sides Parts as Viewed from Right and Rear Sides Figure 2 2 Series 900 Partial Right Side View and Right Rear View Ew SELLERS S d S EZEL ASSY SNE Y ol f CHASSIS
8. Code NEC OSHA regulations and federal state and local codes which must be followed Failure to install inspect maintain or service this equipment in accordance with these codes regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment Replacement Parts Use only genuine Gasboy replacement parts and retrofit kits on your pump dispenser Using parts other than genuine Gasboy replacement parts could create a safety hazard and violate local regulations Safety Symbols and Warning Words This section provides important information about warning symbols and boxes Alert Symbol A This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prevent potential personal safety hazards Obey safety directives that follow this symbol to avoid possible injury or death Signal Words These signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards The precautions that follow must be followed to prevent death injury or damage to the equipment DANGER This signal word is used to alert you to a hazard to unsafe practice which will result in death or serious injury WARNING This alerts you to a hazard or unsafe practice that could result in death or serious injury CAUTION with Alert symbol This signal word designates a hazard or unsafe practice which may resul
9. working on the equipment Use the OSHA tag out and lock out procedures If you are not familiar with this requirement refer to information in the service manual and OSHA documentation Working With Electricity Safely Be sure to use safe and established practices in working with electrical devices Poorly wired devices may cause a fire explosion or electrical shock Be sure grounding connections are properly made Make sure that sealing devices and compounds are in place Be sure not to pinch wires when replacing covers Follow OSHA Lock Out and Tag Out requirements Station employees and service contractors need to understand and comply with this program completely to ensure safety while the equipment is down Hazardous Materials Some materials present inside electronic enclosures may present a health hazard if not handled correctly Be sure to clean hands after handling equipment Do not place any equipment in mouth WARNING This area contains a chemical known to the State of California to cause cancer A WARNING This area contains a chemical known to the State of California to cause birth defects or other reproductive harm IMPORTANT Oxygen may be needed at scene if gasoline has been ingested or inhaled Seek medical advice immediately Page 4 Emergency First Aid Informing Emergency Personnel Compile the following information for emergency personnel Location of accident for example address front back o
10. A C A GASBOY TopKAT Fuel Management System Parts Manual PT 1957 formerly C35755 Computer Programs and Documentation All Gasboy computer programs including software on diskettes and within memory chips and documentation are copyrighted by and shall remain the property of Gasboy Such computer programs and documents may also contain trade secret information The duplication disclosure modification or unauthorized use of computer programs or documentation is strictly prohibited unless otherwise licensed by Gasboy Federal Communications Commission FCC Warnin This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense Changes or modifications not expressly approved by the manufacturer could void the user s authority to operate this equipment Approvals Gasboy Greensboro is an ISO 9001 2000 registered facility Underwriters Laboratories
11. KAT Fuel Management System Parts Manual January 2006 Page 1 Introduction Abbreviations and Acronyms Abbreviations and Acronyms omm expansion O Acronym Page 2 PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Important Safety Information This section introduces the hazards and safety precautions associated with installing inspecting maintaining or servicing this product Before performing any task on this product read this safety information and the applicable sections in this manual where additional hazards and safety precautions for your task will be found Fire explosion electrical shock or pressure release could occur and cause death or serious injury if these safe service procedures are not followed Preliminary Precautions You are working in a potentially dangerous environment of flammable fuels vapors and high voltage or pressures Only trained or authorized individuals knowledgeable in the related procedures should install inspect maintain or service this equipment A Emergency Total Electrical Shut Off The first and most important information you must know is how to stop all fuel flow to the pump and island Locate the switch or circuit breakers that shut off all power to all fueling equipment dispensing devices and submerged turbine pumps STPs AX WARNING The EMERGENCY STOP ALL STOP and PUMP STOP buttons at the cashierOs station WILL NOT shut off electrical power to the pum
12. UL New York City Fire Department NYFD California Air Resources Board CARB UL Files Products listed with UL NYFD C of A Product Executive Order Product MH4314 All dispensers and self contained pumping 4823 9100A 9140A 9152A 9153A G 70 52 AM Balance Vapor Recovery units 9800A 9840A 9850A 9852A G 70 150 AE Vabotyao Power operated Transfer Pump Models 25 9853A 9140 MH6418 25C 26 27 28 72 72S 72SP 72X 73 and 4997 9822A 9823A 1820 5046 9100Q 9140Q 9152Q 9153Q MH7404 Hand operated Transfer Pump Models 1230 9800Q 9840Q 9852Q 9853Q Series 1243 Series 1520 and 1720 Series MH10581 Key control unit Model GKE B Series Card reader terminals Models 1000 1000P Site controller Model 2000S CEN Series Data entry terminals Model TPK 900 Series Fuel Point Reader System National Conference of Weights and Measures NCWM Certificate of Compliance CoC Gasboy pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program NTEP NCWM has issued the following CoC CoC Product Model CoC Product Model CoC 9100 Retail Series 8700 9100 Commercial 95 179A2 Dispenser Series 9700 Series 91 019A2 Dispenser Saad 1000 Series FMS Product Model 95 136A5 Dispenser 9800 Series 91 057A3 Controller 2000S CEN Series Patents Gasboy products are manufactured or sold under one or more of the following US patents Dispensers 5 257 720 Point of Sale Back Office Equipmen
13. f building and so on Nature of accident for example possible heart attack run over by car burns and so on Age of victim for example baby teenager middle age elderly Whether or not victim has received first aid for example stopped bleeding by pressure and so on Whether or not a victim has vomited for example if swallowed or inhaled something and so on A WARNING Gasoline ingested may cause unconsciousness and burns to internal organs Do not induce vomiting Keep airway open Oxygen may be needed at scene Seek medical advice immediately AY WARNING Gasoline inhaled may cause unconsciousness and burns to lips mouth and lungs Keep airway open Seek medical advice immediately AY WARNING lt Gasoline spilled in eyes may cause burns to eye o tissue Irrigate eyes with water for approximately 15 minutes Seek medical advice immediately AY WARNING a Gasoline spilled on skin may cause burns o Wash area thoroughly with clear water Seek medical advice immediately IMPORTANT Oxygen may be needed at scene if gasoline has been ingested or inhaled Seek medical advice immediately Lockout Tagout Lockout Tagout covers servicing and maintenance of machines and equipment in which the unexpected energization or start up of the machine s or equipment or release of stored energy could cause injury to employees or personnel Lockout Tagout applies to all mechanical hydraulic
14. p dispenser This means that even if you activate these stops fuel may continue to flow uncontrolled You must use the TOTAL ELECTRICAL SHUT OFF in the case of an emergency and not only these cashier station Ostops O Total Electrical Shut Off Before Access Any procedure requiring access to electrical components or the electronics of the dispenser requires total electrical shut off of that unit Know the function and location of this switch or circuit breaker before inspecting installing maintaining or servicing Gasboy equipment Evacuation Barricading and Shut Off Any procedures requiring accessing the pump dispenser or STPs requires the following three actions OAOA An evacuation of all unauthorized persons and vehicles using safety tape cones or barricades to the effected units A total electrical shut off of that unit PT 1957 TopKAT Fuel Management System Parts Manual January 2006 Important Safety Information Read the Manual Read understand and follow this manual and any other labels or related materials supplied with this equipment If you do not understand a procedure call a Gasboy Authorized Service Contractor or call the Gasboy Service Center at 1 800 444 5529 It is imperative to your safety and the safety of others to understand the procedures before beginning work Follow the Regulations There is applicable information in NFPA 30A Automotive and Marine Service Code NFPA 70 National Electrical
15. t D335 673 Additional US and foreign patents pending Trademarks Non registered trademarks Registered trademarks Atlas ASTRA Consola Fuel Point Infinity Gasboy Additional US and foreign trademarks pending EON Other brand or product names shown may be Slimline trademarks or registered trademarks of their respective holders This document is subject to change without notice For information regarding Gasboy Literature call 336 547 5661 E mail literature gasboy com Internet http www gasboy com 2006 GASBOY All Rights Reserved AQULad 7ITUTE EUM EQUIPMENT INS Table of Contents Table of Contents 1 Introduction Using This Parts List 1 Abbreviations and Acronyms 2 Important Safety Information 3 2 Illustrated Parts List 5 Wrapper Assembly 5 Wrapper Assembly Parts nnan anaana 5 Oplional Field KiE ECCLE TEILT I DITE 5 Parts as Viewed from Right and Rear Sides 6 Parts higlib Sds aspina ni So apt CRUS 5 Ramee Ged otek wie Gace 7 Parts Right Rear Side 0 0 ccc eens 7 Parts as Viewed from Top and Front Side 8 Fats TODs adosados edi depen ta abet te dri code dius cau dide dodi dti dodici oeil 9 Pals JOH VIOW cien a uec ace RR ATA dee aC ESI AUR QU Ioue EH ns qup dao 9 Bezel Parts as Viewed from Front and Rear 10 Bezel Parts Front and Rea d oa aed eae hs Gas E dot el ea 11 Mechanical Interface 2 Hose 12 Mechanial Interface Parts 2 Hose 0 0 ee es 12
16. t in minor injury CAUTION without Alert symbol When used by itself CAUTION designates a hazard or unsafe practice which may result in property or equipment damage gt gt Working With Fuels and Electrical Energy Prevent Explosions and Fires Fuels and their vapors will become explosive if ignited Spilled or leaking fuels cause vapors Even filling customer tanks will cause explosive vapors in the vicinity of dispenser or island Page 3 Important Safety Information No Open Flames S Open flames from matches lighters welding torches or other sources can ignite fuels and their vapors No Sparks No Smoking e3 Sparks from starting vehicles starting or using power tools burning cigarettes cigars or pipes can also ignite fuels and their vapors Static electricity including an electrostatic charge on your body can cause a spark sufficient to ignite fuels and their vapors After getting out of a vehicle touch the metal of your vehicle to discharge any electrostatic charge before you approach the dispenser island Working Alone It is highly recommended that someone who is capable of rendering first aid be present during servicing Be familiar with Cardiopulmonary Resuscitation CPR methods if you are working with or around high voltages This information is available from the American Red Cross Always advise the station personnel about where you will be working and caution them not to activate power while you are
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