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Index.......................6-1 — 6-3
Tokheim Corporation has determined that because more than one disconnect may
be required, Consoles and/or Dispensers equipped with Emergency Stop Switches
do not guarantee shutting off all power to the dispensers. In order to provide the
highest level of safety to you, your employees and customers, we recommend that
all employees be trained as to the location and procedure of turning off power to
the entire system. This is in keeping with N.F.P.A. 30A, 1990 Edition, Code #4-1.2:
"A clearly identified and easily accessible switch(es) or circuit breaker(s) shall be
provided at a location remote from dispensing devices, including remote pumping
systems, to shut off the power to all dispensing devices in the event of an
emergency."
In addition, in accordance with N.F.P.A. 30A, 1990 Edition, Code #9-4.5:
"Emergency controls specified in 4-1.2 [listed above] shall be installed at a location
acceptable to the authority having jurisdiction, but controls shall not be more than
100 ft. (30m) from dispensers."
DISCLOSURE NOTICE
This document contains information proprietary to Tokheim Corporation. The data
contained herein, in whole or in part may not be duplicated, used or disclosed outside the
recipient or purchaser for any purpose other than to evaluate or operate the equipment
described within the document.
IMPORTANT
THIS EQUIPMENT MUST BE INSTALLED AND USED IN ACCORDANCE WITH ALL
APLICABLE FEDERAL, STATE, AND LOCAL CODES AND REGULATIONS INCLUDING
BUT NOT LIMITED TO THE NATIONAL ELECTRICAL CODE (N.F.P.A. NO. 70) AND
AUTOMOTIVE AND MARINE SERVICE STATION CODE (N.F.P.A. 30A).
DISCLAIMER
ALTHOUGH TOKHEIM CORPORATION, HAS ATTEMPTED TO COMPILE THE MATERIAL
IN THIS MANUAL WITH ACCURACY, NEITHER IT, ITS' EMPLOYEES, NOR ITS' AGENTS
CAN MAKE ANY WARRANTY OR REPRESENTATION, EXPRESSED OR IMPLIED, WITH
RESPECT TO THE LIABILITY WITH REGARD TO THE USE OF THIS MATERIAL OR
ASSUME ANY LIABILITY FOR DAMAGES RESULTING FROM THE USE OF ANY
INFORMATION, APPARATUS, METHOD OR PROCEDURE DESCRIBED IN THIS
MANUAL.
Tokheim equipment must be Always turn off all power to the It is the owner’s and operator’s
installed and used in dispenser and submerged pumps responsibility to ensure that the
conformance with all building/ at the master panel and close any proper warning signs are posted
fire codes and all other safety impact valve before performing per N.F.P.A. 30A, 1990 Edition,
requirements applicable to its any maintenance or service to the Code #9-9. These include, but are
installation and use. dispenser, including the changing not limited to,
of any fuel filters or strainers. •“STOP MOTOR”
Also block islands so no vehicles
Tokheim dispensers shall not be can pull up to the dispenser when •“NO SMOKING”
used for direct fueling of aircraft the dispenser is being worked on. •“WARNING -- IT IS
without filters, separators and UNLAWFUL AND
other equipment necessary to DANGEROUS TO
ensure product purity. DISPENSE GASOLINE
Never permit the dispensing of INTO UNAPPROVED
gasoline or other petroleum CONTAINERS”.
products into a vehicle with its
motor running.
Check all liquid-carrying joints
of the dispenser and piping If fuel is spilled on a person or
system for proper tightness to their clothing, the person must
avoid product leaks prior to initial Never permit the dispensing of wash and their clothing must be
operation and daily thereafter. gasoline or other petroleum changed immediately. Do not go
products into unapproved near open flames, sparks or people
containers or into approved smoking.
containers in or on vehicles
including trucks. All approved
Dispensers must be anchored to containers must be filled on the
a concrete island as specified per ground to prevent static discharge.
appropriate foundation plan. Always use Tokheim approved and Do not reuse gaskets or seals when
U.L. listed hoses and nozzles with servicing or rebuilding Tokheim
this dispenser. equipment. Always use new
Tokheim furnished gaskets or
To reduce the risk of electrical seals.
shock when servicing, turn off all Never permit smoking or the use
power to all equipment. In of open flames in the dispensing
submersible pump applications area.
turn off power to the submersible
pump and any other dispensers Ensure dispensers are properly
which use that submersible Never permit hoses to drag on the grounded before using.
pump. AC power can feed back island or dispensing area.
into a shut-off dispenser when Someone may trip or fall.
dispensers share a common
submersible pump or starter Don’t destroy these pages. These
relay. Always clean up product spills on warnings are for your safety.
the driveway.
Section 1
Introduction
Scope
This section introduces the types of re-fueling dispensers and stand alone
dispensing components covered in this manual.
General
There are two types of dispensers used, Mechanical and Electronic. This
refers to the computer/displays used in the dispenser, (mechanical has
numeric wheels and electronic has liquid crystal displays).
All systems used for re-fueling have three basic components. Each
system must have a technique for moving the fuel from a storage tank to
the dispenser (pumping device), a measuring unit (meter for accurate
measurement of fuels), and a registration unit (computer/displays) to
translate fuel flow thru the meter into a volume and/or monetary display.
Contents
Dispensers ................................................................. 1-2 — 1-3
Mechanical Dispensers ................................. 1-2
Electronic Dispensers ................................... 1-3
System Component Block Diagrams ........................ 1-4 — 1-8
Mechanical System Component Block
Diagrams....................................................... 1-4 — 1-5
Electronic System Component Block
Diagrams....................................................... 1-6 — 1-8
Dispensers
Some of the Tokheim dispensers are shown below:
Mechanical Dispensers
The Tokheim 785, 1248 and 1250 are mechanical dispensers. Any of
these dispensers can be ordered for Suction or Remote Pump operation.
1248
785
1250
Electronic Dispensers
The Tokheim 262A, TCSA Series, and Premier are Tokheim's Electronic
Dispensers. These dispensers are available in remote operation and
selected models may be available in suction pump operation.
262A
TCSA
Premier
Reset Mechanical
Mechanism Computer Registration
System
Meter Meter
Typical component diagram for Mechanical Suction system with Above Ground Tank
Reset Mechanical
Registration
Mechanism Computer
System
Meter Meter
Model 52 Pressure
Regulator
Reset Mechanical
Registration
Mechanism Computer
System
Meter Meter
Typical component diagram for Electronic Suction system with Above Ground Tank
Model 52 Pressure
Regulator
Typical component diagram for Electronic Remote system with Below Ground Tank
Meter Meter
Meter Meter
Model 52 Pressure
Regulator
OR
Section 2
Typical Installations
Scope
This section covers some typical installation practices associated with
Tokheim dispensers and ancillary equipment used for stand alone appli-
cations.
General
Different factors will determine the type of system and installation re-
quired. Considerations will include overall system cost, flow rate re-
quirements (GPM), regulations and site lay-out , just to name a few.
IMPORTANT
ALL INSTRUCTIONAL DIAGRAMS SHOWN IN THIS
SECTION ARE INTENDED FOR REFERENCE ONLY.
CONTACT AN AUTHORIZED SERVICE REPRESENTATIVE
OR A LICENSED ENGINEER FOR DETAIL INSTRUCTIONS.
Contents
Installation Problems ................................................. 2-2 — 2-4
Typical Installation Diagrams ................................... 2-5 — 2-12
Installation problems
Don't expect a dispenser to operate satisfactorily unless the installation is
correct. Dispensing problems which at first seem to be caused by the
dispenser, are often traced to the installation. For that reason, it is wise
to check your installation carefully and keep in mind the following
"don'ts":
• DON'T experiment with a dispenser if you are not certain the installation
is correct.
• DON'T install any underground piping without first checking with fed-
eral, state, and local requirements.
• DON'T cover any lines until they have been tested for leaks.
• DON'T use any black iron pipe or fittings for underground installations.
• DON'T install suction pump line in the "low" end of the tank where
water can be introduced to the system.
Too much line friction in the suction pipe can overload the pump by
requiring too great a differential between the pump vacuum and atmo-
spheric pressure. In effect, the longer the pipe, the more ells, the more
valves, etc., the more friction there is and the harder the pump must
work. It is possible in an improper installation requiring to much lift to
actually pull the product apart (also known as Vaporization). If this
occurs you have exceeded the product limitations; your installation must
be changed. Adding more suction will not correct the problem.
The chart on page 2-4 shows friction losses. With this information, you
can make a rough determination if you are within safe criteria for effi-
cient pump operation. Keep in mind that this is for reference only. For
specific information on your application refer to a qualified expert for
systems installation.
.63
4 — Elbows 11/2"
Page 2-4 The ONE Manual Form 1680B Version 1.0
TOKHEIM CORPORATION February 1993
Typical Installation Diagrams
TOKHEIM CORPORATION February 1993
The ONE Manual Form 1680B Version 1.0
The following diagrams are shown for reference only and to familiarize you with some typical installation procedures. Equipment
must be installed and used in accordance with Federal, State, local, and National Electrical code N.F.P.A. No.70 and Automotive
and Marine service station code N.F.P.A. 30A codes and regulations.
Typical Installation #1
Suction dispenser with an above ground tank
TYPICAL INSTALLATIONS
Page 2-5
TYPICAL INSTALLATIONS
Suction dispenser with a below ground tank
Typical Installation #2
Page 2-6 The ONE Manual Form 1680B Version 1.0
TOKHEIM CORPORATION February 1993
TYPICAL INSTALLATIONS
Connecting two suction pumps on one suction line
Typical Installation #3
Typical Installation #4
Booster system with 52 pressure regulator
TOKHEIM CORPORATION February 1993
The ONE Manual Form 1680B Version 1.0
Important :
Submerged pump and dispensers furnished by Tokheim. Piping,
fittings seals, valves, sumps, etc, to be furnished by customer.
WARNING:
Safety shear section must be even with the bottom of the pump
base, and securely anchored to the island so the shear section will
break if conditions warrant.
TYPICAL INSTALLATIONS
For the submerged 585A series pump
Typical Installation #5
The ONE Manual Form 1680B Version 1.0 Page 2-9
TOKHEIM CORPORATION February 1993
TYPICAL INSTALLATIONS
Typical syphon system for 585 & 585A series submersible pump
Typical Installation #6
Page 2-10 The ONE Manual Form 1680B Version 1.0
TOKHEIM CORPORATION February 1993
TOKHEIM CORPORATION February 1993
The ONE Manual Form 1680B Version 1.0
Typical Installation #7
Typical manifold system for 585 & 585A series submersible pump
(example 1 of 2)
TYPICAL INSTALLATIONS
Page 2-11
TYPICAL INSTALLATIONS
Typical Installation #8
Page 2-12
Typical manifold system for 585 & 585A series submersible pump
(example 2 of 2)
TOKHEIM CORPORATION February 1993
The ONE Manual Form 1680B Version 1.0
PROTECTING YOUR INVESTMENT
Section 3
Protecting Your Investment
Scope
This section describes some general procedures used for inspecting,
maintaining and cleaning your dispensers.
General
To protect your investment periodic maintenance and cleaning is re-
quired. Developing a regular maintenance and cleaning schedule will
greatly extend the like-new appearance and operation of your dispenser.
Contents
Hints for Better Pump Performance.......................... 3-2
Regular Inspection Notes .......................................... 3-3
Preserving the Finish of Your Pumps........................ 3-4 — 3-5
Preparing Used Pumps for Storage ........................... 3-6
Note: If water gets into your suction pump, see instructions on Page 4-
15 for eliminating water.
4 Rotary Pump Lubrication
The rotary pump should be lubricated at indicated points every six
months or 100,000 gallons.
• Lubricate pumping unit with a light grade oil (S.A.E. 10.)
• Apply oil to the felt pad located between the pump body and pulley.
Note: Oil used should be suitable for temperatures ranging from minus
400 to plus 1800.
4 Motor Lubrication
All motors used today are self maintenance, sealed motors. Lubricating
is not necessary.
4 Retrev-A-Hose Mechanism
The cable reel assembly does not require lubrication. Check the cable
periodically and replace when worn or frayed.
CAUTION: This assembly contains a strong spring coil. Precautions
should be taken to avoid personal injury
Cleaning Schedule
All locations should maintain a cleaning schedule that includes periodic
cleaning, rinse and wax cycles. You will want to maintain a cleaning
schedule dependent upon the dispensers degree of environmental expo-
sure. When unusual conditions (i.e., air born chemicals, acid rain, hail,
road salt, other road debris, etc.) occur, the exposed surfaces should be
cleaned as much as once a week. Also, consider a similar maintenance
schedule for geographical locations near coasts (salt spray from ocean).
In any degree of exposure, you will want to consider all factors when
adopting a cleaning schedule to give the finish a reasonable amount of
care.
Marks or spots, such as grease, oily fingerprints and smudges that resist
soap or detergents, usually can be removed with Bon-Ami and water,
followed by a clear-water rinse. Two other products that have been
found effective for this purpose are: Lac-O-Nu, manufactured by Nu-
Steel Company, 1714 South Ashland Avenue, Chicago, Illinois; and,
Shaklee Basic 1, manufactured by Shaklee Corporation, 1990 Powell
Street, Emeryville, California. After cleaning, an application of paste
wax is recommended to protect the surface and extend the interval
between cleanings.
UNDER NO CIRCUMSTANCES
SHOULD A HIGH PRESSURE
WASHER OR A PRODUCT
CONTAINING HARSH ABRASIVE
(SUCH AS SCOURING POWDER)
BE USED ON A PAINTED OR
STAINLESS STEEL SURFACE.
Section 4
Scope
This section will provide helpful information for understanding, trouble-
shooting and repairing dispensers and related equipment.
Contents
Mechanical Computer............................................... 4-2
The Reset Mechanisms ............................................. 4-3 — 4-5
Pulsers ...................................................................... 4-6
Meter Assembly ........................................................ 4-7 — 4-12
Pumping Devices ...................................................... 4-13 — 4-31
Suction system.............................................. 4-13
Remote system ............................................. 4-26
Relay control box ...................................................... 4-32
Model 52 Pressure Regulator ................................... 4-33 — 4-34
• Slide the slip cover which encloses the lower part of the
computer (thereby exposing the range setting plates and the
wheel characters — see instructions on slip cover)
• On plate 3, set the sliding gear lever to the hole marked “20”
• On plate 2, set the sliding gear lever to the hole marked “8”
• On plate 1, set the sliding gear lever to the hole marked “9/10”
Manual Reset
The above illustration depicts the Manual Reset assembly. This mecha-
nism, like the Power Reset (described on the next page), is used to reset
the mechanical computer’s numeric wheels to zeroes. Since 1976, the
Power Reset has been standard on dispensers with the mechanical
computer.
27
29
7
9
10
8
17
23
18
14 22
6
21
If the Control Lever (not shown) is turned to the “ON” position and the
dispenser fails to operate, proceed as follows:
1. Check all switches in the service station panel making sure they are
“ON”. This should include checking circuit breakers and/or fuses.
2. Check the 115 volt circuit at the lower pump connection box to make
certain proper voltage is being supplied to the Power Reset. The voltage
check should be taken with the Control Lever in the “ON” position. A
voltage reading of 70 - 80 v. while the computer is resetting indicates
improper installation wiring.
3. Check to make sure the Reset Couplings (not shown) are engaged
properly between the Power Reset and the computer.
a. Rotate Idler Shaft Assembly (22) clockwise until the curved slot in
the Interponent Assembly (21) allows access to the bottom screw.
b. Or, remove the two #6-32 Screws securing the Switch Bracket to the
cover assembly and slide the entire switch assembly forward, which
allows easy access to the Reset Switch screws.
7. To replace Pinion (7) or Idler Shaft Assembly (22) - Rotate Idler Shaft
Assembly (22) counter clockwise until it unscrews itself from Pinion (7).
To replace Pinion (7), remove Gear Cover (17).
10. To replace the Power Reset Motor (27), first remove Idler Shaft Assem-
bly (22) as outlined in Step 7. Next, remove the two screws fastening
the motor to the cover. Disconnect the motor lead to the Reset Switch
(10) and also the lead from the Reset Switch to the Male Plug (14).
Note: All Power Reset motors are furnished with required wiring to the
Male Plug (14).
The cover assembly can be assembled to the case with ease if the Con-
trol Lever is in the “ON” position. NEVER FORCE THE ASSEMBLY
TOGETHER AS DAMAGE COULD OCCUR After the cover assem-
bly is secured to the case, turn the power “ON” and allow the Power
Reset to complete one cycle.
Pulsers
(FOR ELECTRONIC DISPENSERS)
The Pulsers are the heart of the electronic
registration system as indicated in the system
component block diagrams shown in section 1.
Types
By looking at the housing, you can tell
which type of pulser you have. The
Magnetic Wheel pulser has the cover
attached to the side (see left). The Opti-
cal pulser’s cover is attached to the top of
the housing (at right).
Operation
The magnetic wheel pulser uses alternating magnetic poles on the wheel to
create dual-phase pulses. These pulses are detected by two sensors. The
optical pulser uses a slotted wheel to interrupt a beam of light inside an
enclosure to produce the dual-phase pulses. The optical pulser is standard
in Premier series dispensers.
Possible Problems
Magnetic Wheel Pulser
If nuisance pulse errors occur, and there are no problems with the installa-
tion (leaks or large hydrostatic shocks), then the pulser might be at fault.
Items to investigate would include:
• Defective circuit board
• Metal flakes or filings attached to the magnetic wheel (remove
particles by cleaning off the magnetic wheel)
Optical Pulser
Check for pulse output when the shaft is turned. If none are present,
replace the pulser assembly.
Both pulsers
Always check power supplies in the head of the dispenser for proper output
voltages. A low power condition produces erratic behavior.
Meter Assembly
The Meter is included in all Electronic and Mechanical dispensers as
indicated in the system component block diagram shown in section 1.
There are various meter designs in the pump industry. Tokheim has its
own three-piston vertical type positive displacement unit, and through
the years little change has taken place other than material, and the
methods in which the plunger assemblies are attached to the eccentric
plate of the meter.
The following diagram shows the fuel flow through the meter.
After the liquid has been measured and registered on the computer, the
gasoline passes through the discharge tube into the hose and nozzle to
the customer’s tank.
14
11
22
9
15
16
26
19
20
18
17
13
12
21
23
24
8
2
1
25
5
4
6
7
3
Page 4-8 The ONE Manual Form 1680B Version 1.0
TOKHEIM CORPORATION February 1993
SYSTEM COMPONENTS
To Adjust Measurement
The adjustment of measurement is accomplished by breaking the seal wire
and removing Seal Pin, Item No. 1. This will permit the Index Disc, Item
No. 2, to be turned either to the right, decreasing the measurement, or to
the left, increasing the measurement. A variation of approximately one
cubic inch in measurement is obtained by turning the index disc five holes.
After measurement has been properly adjusted, the seal pin and seal wire
should be replaced.
Meter Troubles
The troubles usually experienced with measuring units are caused by
binding and failure to operate, or failure to measure correctly.
Binding
Binding is usually caused by parts that become rusted or corroded when
excessive water is run through the unit, or when a large amount of foreign
matter collects in it. In cold weather, if water is present in the system, ice
formations will stop the operation. Because the Tokheim measuring unit is
designed to handle more than a usual amount of water before corroding or
rusting enough to bind, Tokheim users do not experience as many troubles
along this line as users of other types of gasoline dispensing equipment.
HOWEVER, KEEP YOUR METER ASSEMBLY AS FREE FROM
WATER AS POSSIBLE - AT ALL TIMES! On rare occasions binding
may be caused when the meter is spun to fast, such as when air is purged
from the system upon start-up. Your Authorized Service Representative
may be able to provide helpful techniques for releasing a bound meter.
2 Remove cap screws and lift off Meter Assembly Cover, Item No. 8.
This exposes the entire working mechanism of the Meter. Be careful
not to damage the Cork Gasket, Item No. 9, and do not shellac it when
reassembling.
3 Loosen Screws (Item No. 10) and disconnect Plunger Assembly (Item
No. 11).
4 Remove the three Round-head Machine Screws (Item No. 12) and lift
off Wobble Plate Assembly (Item No. 13). Mark the wobble plate
assembly at some point, because it is necessary that it be replaced in
exactly the same position when reassembling the Meter.
5 The plungers may now be taken out, and any work that needs to be
done on them can be accomplished without further dismemberment of
the Meter. New Plunger Cups (Item No. 14) may be installed if
needed.
6 The next step is dismembering the wobble plate assembly, which can
be done readily by removing the three Fillister-head Machine Screws
(Item No. 15) which hold Bracket to Wobble Plate. This permits the
whole assembly to come apart.
7 The Main Pivot Bearing (Item No. 17) can then be lifted off its loca-
tion, as well as the Compensating Cam Gear (Item No. 18). Adjusting
Screw (Item No. 19) and Compensating Cam Gear are assembled
together, requiring no timing - only engagement with Compensating
Pinion (Item No. 20) and mounted onto Main Pivot Bracket Assembly
(Item No. 21).
8 Do not attempt to remove Valve Seat (Item No. 22) from Meter Body
(Item No. 23) because these two parts are assembled together in the
factory before the valve seat surface is ground. Removal may cause
the seat to warp, causing meter inaccuracy
Replacing Cover
Position the Meter Body (Item No. 23) and mechanism, with Compensat-
ing Pinion Shaft, Item No. 20, to right side. Press Wobble Plate Assembly
(Item No. 13) down on right side.
The correct position of the cover is determined by a dowel pin in the top
flange of the cylinder body and a locating hole in the cover flange. Before
attempting to place the cover on the unit, turn the Compensating Pinion
Shaft (Item No. 24) in a position so that it will readily slide into the Com-
pensating Pinion (Item No. 20); also turn Gear (Item No. 25) in the cover
so that the driving lug is to the left.
Place cover squarely over the unit with the locating hole in the flange
directly over the dowel pin in the cylinder body flange.
If the flanges do not come together, never use force. Instead, turn the
Compensating Disc (Item No. 2) slightly one way or the other in order to
bring the coupling into alignment; or remove the cover and readjust the
parts if necessary.
Overmeasuring
This condition occurs when the meter is putting out more product than is
being registered. There are four conditions that will cause the Tokheim
positive displacement type Meter to over-measure, namely: leakage of
gasoline past sliding valve (item #26), leakage past the plunger cups (item
#14), leakage past valve seat (item #22), and excessive wear of parts.
These troubles can usually be remedied easily and inexpensively. The
following instructions will aid you in overcoming the trouble.
Testing the Sliding valve and Plunger cups
1 Remove meter and disassemble as per instructions 1 through 4 on Page
4-10.
2 Push all plungers to the bottom of the cylinders and cover the top of all
plungers with test fluid (thin oil or solvent). Then carefully center the
sliding valve, so that it closes all ports at the same time. Apply a
stream of SAE 10 oil along all three sides of the valve. Hold valve in
this position, bearing down on it firmly with one hand. With the other
hand, pull up on the three plungers, one at a time. If the plunger pulls
up easily, it indicates that either the sliding valve is not seating (lapped)
properly to the Valve seat (oil being pulled into the side of the valve) or
the plunger cup is leaking (test fluid being drawn into the cylinder).
However, if plunger does not move when you try to pull it up, you can
be sure the plunger cup and sliding valve are reasonably tight and
should not affect the measurement of the meter.
3 Lap the sliding valve by using only a very fine grinding compound such
as Bon-Ami or SAE 10 oil. If the valve seat is badly damaged in any
way so that lapping of low spots is impossible, it would be best to
install a new meter body.
4 If the test proves, replace badly worn plunger cups with new ones
and apply Loctite 271 (or equivalent) to the screw threads. When
tightening the screws, be sure the plunger cup is evenly spaced on
the plunger disc and support.
5 Form the cup by turning the plunger cup assembly in your hand,
using your thumb to roll the edge slightly. After the cup is partially
formed, place the plunger assembly into the meter unit body and
press into the piston cylinder. Turn the assembly in the piston
cylinder to assure the cup is evenly formed to the cylinder.
Pumping Devices
Pumping devices, as indicated by the system block diagrams shown in section 1
include all component sub-assemblies required for the transport of fuel. The
following pages will discuss each of the components used in both Suction systems
and Remote systems.
Adjustment Pulley
Motor
Correct Wiring
Properly cared for, the motors furnished with Tokheim pumps will give
excellent service. Pumps are shipped from the factory with motors wired
according to the specifications given on the order as to kind of current,
frequency and voltage.
Most of the motors can be adjusted by changing the setting on the motor
change-over plate (located near the pulley); however, the ‘World’ motor
must be wired for 115 or 220 volt operation and clockwise or counter-
clockwise rotation. Please see the appropriate documentation for proper
wiring or settings for all motor
Poppet Valve
Assembly
13 64
12
11 60
10
23 59
Strainer screen is to be
cleaned regularly using a
solvent cleaner and soft
brush
9 54
55
7
20 18
When replacing, always be 16
sure to insert the strainer 14
screen into the cap first.
46
15
TOKHEIM CORPORATION February 1993
The ONE Manual Form 1680B Version 1.0
1
SYSTEM COMPONENTS
Rotary Pump
The purpose of the rotary pump is to create a vacuum in the suction line
and allow the atmospheric pressure to push the gasoline up from the
storage tank to the unit. Liquid entering through the suction inlet fills the
spaces between the gear teeth in the idler, and is carried through the pump
body, transforming it into pressure. Because there is small clearance
between the gear teeth on the rotor and the pump body, and because gear
pumps are usually rotated at high speeds, the rotary unit will pump air and
vapor as well as liquid. Thus, the pumping action of gear-type units is
positive.
Priming
A new Tokheim pump will prime itself, unless it is connected to an ex-
tremely long suction line with an excessive vertical lift (over 12 feet),
provided that the suction line is otherwise correctly installed.
If the pump will not prime itself, remove the Strainer Cap, Item No. 20 (in
the Rotary Pump Body - see drawing on Page 4-16), and while turning the
pump pulley in reverse direction by hand, squirt a small amount of heavy
lubricating oil in the strainer cavity, then replace strainer cap and start the
pump. In practically all cases, this will provide a tight seal long enough to
enable the pump to prime. This procedure may be necessary when an old
pump, considerably worn, is moved to a different location.
End Play
Overhauling the Tokheim rotary pump is necessary only when the pump
has lost efficiency due to end play caused by excessive wear or when
damage has resulted from the pumping of foreign matter or water. Ordinary
end play can be taken up by removing Rotary Pump Head, Item No. 13,
and reducing the amount of Gasket material, Item No. 12.
Causes of Sticking
If a pump should stick while in operation, remember that it can be caused
by three things:
If the working parts are rusted, it will be necessary to remove Head, Item
No. 13, and Idler, Item No. 11, as well as the Rotor, Item No. 10. After
the head and idler have been removed, take off the pump pulley from the
opposite end, and file off the burr caused by the pulley setscrew on the
shaft so that it will not damage bearings or packing when the shaft is
removed. Loosen the tension on packing by removing Cap Screws, Item
No. 14, Retainer Plate, Item No. 16, Oil Well Felt, Item No. 18, and
Bearing, Item No. 15. Clean all parts thoroughly with fine sandpaper
and rinse in clean solvent; then reassemble the pump.
If working parts are badly cut by large abrasives, such as sand, or badly
pitted by rust, to such an extent that ordinary cleaning will not correct
the problem, it will be necessary to replace the complete pumping unit.
3 Have pump pulley in position so that the shaft can be turned easily
by hand
Should the pump turn freely, remove one gasket at a time (each time re-
tightening head) until it binds (metal to metal contact is felt). Then
remove head, add one gasket, replace head on rotary pump, and tighten
all cap screws.
The packing glands of this unit are spring-loaded by Spring, Item No. 9, to
keep the proper tension on the packing at all times. For this reason, when
the Bearing, Item No. 15, is removed, the packing will be forced forward
by the Spring, Item No. 9, provided the unit has been properly lubricated,
as recommended by the manufacturer.
When old packing rings are removed, be sure to replace them with a like
number of new ones. This is important in order to prevent leaks in the
stuffing box.
Air Separator
The purpose of the Air Separator is to eliminate the air and vapors from
the gasoline before they reach the measuring unit. The device consists of
two chambers, the supply chamber and the float chamber.
Float Chamber
The float chamber is the area where air and vapors are separated from the
fuel before the discharge to the meter. Approximately 10% of all fuel
discharged enters the float chamber at the rate of one gallon per minute
through an orifice (Item No. 23) along with all air and vapors. The air and
vapor is then vented by means of a copper tubing run to an opening where
the vapors are vented to the atmosphere or to a vapor recovery system.
The Float, Item No. 60, and Needle Valve Assembly, Item No. 59, regu-
lates the liquid level in the float chamber. When the motor is running with
the hose open and the fuel level rises enough to lift the float to open the
needle valve, the fuel will pass back to the suction side of the pump.
Supply Chamber
The Supply Chamber contains two valve assemblies - By-Pass, Item No.
54, and Regulating, Item No. 55. It is easy to distinguish one from the
other because the by-pass valve poppet is all metal., while the regulating
valve poppet has a composition disc. Also, the by-pass valve spring is
heavier than that of the regulating valve.
Because gear pumps are positive in operation, some means must be pro-
vided to limit the pressure they build up when the hose from the pump is
closed. Otherwise, excessive pressure would create strains within the
pump or connecting pipe, and might cause leaks, or blow fuses by over-
loading the motor. By-pass valves are used to prevent excessive pressure;
surplus gasoline is detoured back to the suction side of the pumping unit.
When the pump is started, both the by-pass and regulating valves are
opened by the pressure building up in the supply chamber and acting
against the small piston and cylinder assemblies located at the tops of
the valve assemblies. The cylinder caps have small holes in their tops to
release any gasoline that might leak past the cup disc of the valve pis-
tons, and also to allow the valves to open against atmospheric pressure.
The cup disc prevents an excessive amount of fuel leakage from the
supply chamber to the float chamber.
After starting, and when the hose opens, the pressure drops inside the
supply chamber. When the pressure falls the by-pass valve closes
completely. Fuel pressurized keeps the regulating valve open thus
allowing the fuel between the pressure rating of the regulating valve and
the pressure rating of the by-pass valve to pass through the discharge
area of the pump into the meter.
The spring tensions of the regulating and by-pass valves have no adjust-
ment, and the pressure ratings vary depending on what pump you have.
Fuel discharges at the vent pipe at Float is filled with gasoline or the -Replace the float if it is bad
the top of the pump and the problem corrosion of parts within the needle -Clean the float chamber's needle
is not in the installation. valve mechanism. valve, replace if severely corroded.
The pump delivers the first gallon at Failure of float needle valve to -Make sure tank has product
full speed then slows down. close. -Clean needle valve seat
-Check for air leaks in the supply
line.
Vacuum Test
With the pump running, the nozzle closed, and the rotary pumping unit
primed, the vacuum gauge should show from 4 inches to 6 inches of
vacuum on a normal installation. If the vacuum gauge reading is in
excess of that indicated, the following could be wrong:
• Suction lift too high
• Suction line on bottom of tank
• Suction line restricted - too many elbow fittings in line
• Partially stuck poppet in check valve
• Insufficient venting of storage tank
• Suction line too small in diameter (at least 1-1/2" should be used)
• Check valve equipped with a too-heavy poppet spring
• Check valve poppet stuck shut, or valve strainer clogged at bottom
of tank
• Suction screen in pumping unit contaminated with foreign material.
Pressure Test
To check for sufficient pump pressure, a pressure gauge should be
installed at the pipe plug on top of the meter cover, as shown on Page
4-22. With the pump running and the nozzle closed, the by-pass pres-
sure should read approximately 24-1/2 P.S.I. (this pressure will be a
higher value for the high capacity pumping units). The by-pass valve is a
self-adjusting type for all vacuum lifts, to assure proper delivery rate.
The pressure gauge can also be used to determine whether the regulating
valve is seating properly. Failure of the regulating valve to seat will be
indicated by either one of the following:
• fuel emptying from the system when the pump is standing idle
• advance of the computer when the pump is turned on and the nozzle
is closed.
To perform this test, the pump should be operated with the nozzle open
to make certain that the system is fully primed. As the nozzle is closed,
the pressure gauge should read approximately 24-1/2 P.S.I. This pres-
sure should not immediately drop to zero, but may level off to approxi-
mately 18 P.S.I. after an hour’s time, indicating that the regulating valve
is functioning properly.
Remote Systems
The Remote system is used in applications where it is preferred,
usually to support more than one dispenser and in applications that
require more lift than a suction type pump can provide.
Submerged Pump
The Tokheim submerged pump has become a revolution-
ary factor in service station planning, because of the
tremendous equipment economies and improved service
demonstrated in thousands of installations.
In this improved system of gasoline handling, the Sub-
merged Pump and Motor Unit is completely submerged in
the storage tank where it is tamper-proof, weatherproof
and foolproof. From this central source of supply, gaso-
line is pushed to island dispensers at speeds actually
exceeding the rate of delivery of standard suction pumps.
Operation
The motors and controls used in a Tokheim submerged pumping system
are precision designed instruments and should be handled with care.
Our recommendations must be followed in every detail; otherwise,
damage may occur to the units.
The Tokheim submerged pumping system must not be put into operation
without product in the storage tank. Fuel product serves as both lubri-
cant and coolant. If product is exhausted after initial start up, the sub-
merged motor will heat up and the thermal overload protector in the
motor will open, reducing the chance of damage to the motor windings.
A cooling period of at least one hour will be required after the storage
tank has been filled with product before the thermal overload will close,
and allow the motor to operate.
Use of a Multimeter
Select a reliable multimeter, such as Fluke and Beckman digital
multimeters or equivalent. A wide variety meters are available on the
market today and the choice is yours. A meter which has an auto-
ranging feature as part of the resistance measurement will prove to be
very helpful. A sure way to know a meter is accurate is to have it cali-
brated.
Pressure Tests
After piping is completed and before pipe lines are covered, the com-
plete system should be pressure tested for detection of possible leaks.
Pressure tests may be hydrostatic or pneumatic, depending on code
requirements and customers’ preference. Leaks are readily detected
visually in hydrostatic tests; however, time required for testing will be
longer since the piping system must be completely filled with test liquid.
Leaks are detected in a pneumatic test by brushing of joints with a soap
and water solution.
General Description
The Pressure Monitor is a diaphragm operated valve that is extremely
sensitive to a pressure loss in the pipes. The Pressure Monitor is in-
serted directly into the submerged pumping system’s manifold. It
requires no special adapters or fittings on current model pumps. Should
a pressure loss occur, the flow rate at the dispenser slows to less than 3
GPM, the signal to check the system.
ACC
ACH
Motor
ACH
ACC
Main AC
Power
Circuit L1 M1
Submerged
Breaker L2 M2 Pump
Panel
The Model 52 Pressure Regulating Valve will not allow flow from the
storage tank until vacuum generated by the suction pump pulls the
valve open. The valve is installed directly under the suction pump at its
inlet. It is equipped with a nipple containing a sheer section. If the
pump is accidently knocked from the island, the sheer section will
break — removing vacuum from the 52 valve causing it to close. In
this manner it doubles as an “Impact Safety Valve”.
Each 52 valve is equipped with a strainer screen to keep rust and sedi-
ment from damaging or hampering the operation of the valve.
Flow Chart
A flow chart illustrating fuel flow through the model 52 valve is on the
next page.
Section 5
Possible Troubles & Remedies
Scope
This section describes some problems you may experience and some
possible things you can look for when troubleshooting a dispenser and
the system installation.
General
When trouble does occur it is a good idea to note the specific character-
istics. This will help to isolate the problem so that down time is kept to a
minimum. For more information on the operation of Tokheim equipment
contact your Authorized Service Representative.
Contents
Discharge with the switch turned off ........................ 5-2
Discharge from the vent line (during hot weather) ... 5-2
Mechanical Computer Creeping ................................ 5-2
Slow delivery ............................................................ 5-3
Slow delivery after first gallon of normal delivery .... 5-3
• The pilot valve in the hydraulic valve sticking partially open due to
improper adjustment
• Thermal contraction/expansion.
Slow delivery
Slow delivery may be due to:
• The Rotary pump has a stuck needle valve. Usually caused by foreign
matter getting under the needle valve and holding it open. Remove float
and needle valve assemblies; clean needle valve parts; remove sediment
and foreign matter from the float chamber.
Index
Symbols E
1248 1-2 Electronic Dispensers 1-3
1250 1-2 Electronic System Component Block Diagrams 1-6
168 4-32 Emergency Shutoff Valve 4-27
262A 1-3 End Play, Rotary Pump 4-17
268 4-32
52 4-33 F
785 1-2 Float Chamber 4-20
A Friction Loss 2-3
Friction loss
Adjusting Diagram 2-4
Belt 4-13
Meter 4-9 G
Air Separator 4-20 Gauge, Vacuum 4-23
Assembly 4-15
Removing Water 4-15 H
Troubles 4-22
Amperage Head loss 2-3
Submerged Pump 4-28 Hints for Better Pump Performance 3-2
B I
Belt Impact Safety Valve 4-33
Adjusting 3-3, 4-13 Inspections Notes 3-3
Booster System Block Diagram 1-8 Installation
By-pass valve 4-20 Considerations 2-1
Diagrams 2-5
C DON'Ts 2-2
Friction loss, diagram 2-4
Check Valve 4-21 Problems 2-2
Cleaning Submerged pump 2-9
Dispenser 3-4 Manifold System (A) 2-11
Mechanical Computer 4-2 Manifold System (B) 2-12
Cleaning Schedule 3-4 Syphon System 2-10
Components, System 1-1 Suction
Computer, Mechanical 4-2 Above ground tank 2-5
D Below ground tank 2-6
Booster system 2-8
Diagram Connecting two to one riser 2-7
Friction loss 2-4 Typical 2-1
Installation 2-5 Introduction 1-1
Meter 4-7
Rotary Pump and Air Separator 4-15 L
System 1-4 Lubrication
Dispenser Mechanical Computer 3-3
Cleaning Schedule 3-4 Motor 3-3
Preserving the Finish 3-4 Rotary Pump 3-3
Storing 3-6
Types 1-1, 1-2
Draining the Pump 3-6
Drive Belt
Adjusting 3-3, 4-13
M
Magnetic Wheel Pulser 4-6
Price
Maintenance of System Components 4-1
Setting on the Mechanical Computer 4-2
Mechanical Computer 4-2
Priming the rotary pump 4-17
Lubrication 3-3
Problems
Maintenance 4-2
Air Separator 4-22
Price setting 4-2
Causes of Sticking 4-17
Mechanical computer
Discharge with the switch turned off 5-2
Creeping 5-2
End Play, Rotary Pump 4-17
Mechanical Dispensers 1-2
Installations 2-2
Mechanical System Component Block Diagrams 1-4
Mechanical computer creeping 5-2
Meter 4-7, 4-9
Meter 4-9
Cover 4-11
Pulser 4-6
Overhauling 4-10
Rotary Pump 4-22
Overmeasuring 4-11
Slow delivery 5-3
Plunger cups, testing 4-11
Vent Line, Discharging 5-2
Removal 4-9
Protecting Your Investment 3-1
Sliding valve, testing 4-11
Pulser 4-6
Valve seat, testing 4-12
Pump
Motor 4-14
Diagram 4-15
Motor Bolt Torque Spec. 4-28
End Play 4-17
Motor Lubrication 3-3
Repacking 4-19
Motor Unit 4-26
Suction 4-17
Multimeter 4-27
Pump Head
N Adjusting 4-18
Replacing 4-18
Needle Valve 4-20 Pumping Devices 4-13
Pumps (Dispensers)
O Preserving the Finish 3-4
Ohms R
Submerged Pump 4-28
Oiling Regulating Valve 4-20, 4-25
Mechanical Computer 3-3, 4-2 Relay Control Box 4-32
Motor 3-3 Remote System 4-26
Rotary Pump 3-3 Repacking, meter 4-9
The pump interior 3-6 Replacing
Optical Pulser 4-6 Pump Head 4-18
Overhauling, Meter 4-10 Valves 4-19
Overmeasuring 4-11 Reset Mechanisms 4-3
Manual 4-3
P Power Reset 4-4
Resistance
Plunger cups, testing 4-11
Submerged Pump 4-28
Possible Troubles & Remedies 5-1
Retrev-A-Hose Mechanism 3-3
Power Reset 4-4
Premier 1-3 Rotary Pump 4-17
Preserving the Finish of Your Pumps 3-4 Diagram 4-15
End Play 4-17
Pressure Gauge 4-23, 4-25
removing water 4-15
Pressure Monitor 4-31
Repacking 4-19
Pressure Regulating Valve 4-33
Troubles 4-22
flow chart 4-33
Pressure Test 4-25, 4-28 Rotary Pump and Air Separator Assembly 4-15
Preventative Maintenance Rotary Pump Lubrication 3-3
Rotary Pumping Unit 4-25
Inspections Notes 3-3
S
Schedule, Cleaning 3-4 W
Shutoff Valve 4-27 Waxing of painted surfaces 3-4
Sliding valve, testing 4-11 Winding Resistance 4-28
Slow delivery 5-3
Storage Tank 4-26
Storing
Preparing the Dispenser 3-6
Submerged Pump 4-26
Amperage 4-28
Head loss 2-3
Operation 4-27
Ratings 4-26
resistance 4-28
Siphon Test 4-29
Suction Screen 3-3
Suction System 4-13
Drive Belt 4-13
Friction Loss 2-3
Motor 4-14
Pump 4-17
Repacking 4-19
Removing Water 4-15
Troubles 4-22
Supply Chamber 4-20
Surge Check Valve 4-21
System
Block Diagrams 1-4
Components 1-1
T
TCSA 1-3
Technical Information 4-1
Troubles
Air Separator 4-22
Discharge with the switch turned off 5-2
Mechanical computer creeping 5-2
Meter 4-9
Rotary Pump 4-22
Slow delivery 5-3
Vent Line, Discharging 5-2
Troubles & Remedies 5-1
Types
Dispensers 1-1, 1-2
Typical Installations 2-1
V
Vacuum Gauge 4-23
Vacuum Test 4-24
Valve, Check 4-21
Valve seat, testing 4-12
Valve, Shutoff 4-27
Valves 4-20
Replacing 4-19
Vent Line, Discharging 5-2