Mde 4447B

Gilbarco® Global Pumping Unit
Operation and Service Manual
MDE-4447B
Computer Programs and Documentation
All Gilbarco Inc. and/or Veeder-Root Company computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall
remain the property of, Gilbarco Inc. and/or Veeder-Root Company. 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 Gilbarco Inc. and/or Veeder-Root Company.
Federal Communications Commission (FCC) Warning

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
Gilbarco is an ISO 9001:2008 registered company.
Underwriters Laboratories (UL): California Air Resources Board (CARB):
UL File# Products listed with UL Executive Order # Product
All Gilbarco pumps and dispensers that bear G-70-52-AM Balance Vapor Recovery
MH1941
the UL listing mark. G-70-150-AE VaporVac
MH8467 Transac System 1000 and PAM 1000
E105106 Dell DHM Minitower
E165027 G-SITE and Passport Systems
National Conference of Weights and Measures (NCWM) - Certificate of Conformance (CoC):

Gilbarco 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 #
02-019 Encore Nxx 02-036 Legacy Jxxx
02-020 Eclipse Exx G-SITE Printer (Epson) PA0307
Meter - C Series PA024NC10 G-SITE Distribution Box PA0306
02-025
Meter - C Series PA024TC10 G-SITE Keyboard PA0304
02-037
02-029 CRIND — G-SITE Mini Tower PA0301
TS-1000 Console — G-SITE Monitor PA0303
TS-1000 Controller PA0241 G-SITE Printer (Citizen) PA0308
02-030 Distribution Box PA0242 02-038 C+ Meter T19976
Meter - EC Series PA024EC10 02-039 Passport PA0324
VaporVac Kits CV 02-040 Ecometer T20453
05-001 Titan KXXY Series
Trademarks
Non-registered trademarks Registered trademarks Service mark

Applause™ Media System G-SITE® Link™ SMART Connect™ Ultra-Hi™ CRIND® Making Things Better® VaporVac® GOLDSM
CIM™ G-SITE® Lite™ SMART CRIND™ ValueLine™ Dimension® Series MPD®
C-PAM™ Highline™ SMART Meter™ e-CRIND® Passport®
Ecometer™ Horizon™ SmartPad™ Eclipse® Performer®
ECR™ MultiLine™ Super-Hi™ Encore® The Advantage® Series
EMC™ Optimum™ Series Surge Management System™ G-SITE® Transac®
FlexPay™ PAM™ Tank Monitor™ Gilbarco® Transac® System 1000
G-CAT™ PAM™ 1000 TCR™ InfoScreen® Trimline®
Gilbert™ PAM™ 5000 Titan™ Legacy® TRIND®
Additional US and foreign trademarks pending.
Other brand or product names shown may be trademarks or registered trademarks of their respective holders.
This document is subject to change without notice.

http://www.gilbarco.com
 2016 Gilbarco Inc. All Rights Reserved
Table of Contents
Table of Contents
1 – Introduction 1-1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Determining Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Required Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 – Important Safety Information 2-1
3 – Pumping Unit Operation and Maintenance 3-1

Flow of Liquid Through Pumping Unit and Air Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Float and Air Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Adjustable Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Air Separator Float Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replacing Lip Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Pumping Units with Throwout Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4 – Parts Lists and Kits 4-1

Model M04920B003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Model M04920B003 - Pumping Unit Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Model M04920B015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Model M04920B015 - Pumping Unit Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Kits for M04920B003 and M04920B015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Kit Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Kit Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
5 – Replacing Inlet Check Valve in GPU 5-1

Replacing Inlet Check Valve in GPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6 – Troubleshooting 6-1
General Vacuum and Pressure Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Vacuum Gauge Readings (Inches of Mercury) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Use Gauge Readings to Troubleshoot Self-contained Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Troubleshooting Using Gauge Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Resolving Issues on Pumping Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
7 – Vapor Lock Causes 7-1

Reasons for Vapor Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Vapor Lock Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Index Index-1
MDE-4447B Global Pumping Unit Operation and Service Manual · June 2016 Page i
Table of Contents
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Page ii MDE-4447B Global Pumping Unit Operation and Service Manual · June 2016
Purpose Introduction
1 – Introduction
Purpose
This manual provides operation and service information on the mechanical and hydraulic
components for following Gilbarco® Global Pumping Unit (GPU) models:
• M04920B003 - U.S. Version, Heavy Duty, (20-24 gpm)
• M04920B015 - European Version, Heavy Duty, (20-24 gpm)
• M04920B011 - U.S. Version, Alternate Fuel Version, Heavy Duty, (20-24 gpm)
• M04920B012 - European Version, Alternate Fuel Version, Heavy Duty, (20-24 gpm)
Model Breakdown
The model number appears on the serial number tag attached to the front of the GPU.
Following table lists the features of the models covered in this manual:
Air
Model Heavy Inlet Check Air Vent Separator Bypass
Where Used Number Duty Standard Valve Float Device Spring
United States M04920B003 X - - - - Heavy Duty
Europe M04920B015 X - X X X Heavy Duty
United States M04920B011 X - - - - Heavy Duty
Europe M04920B012 X - X X X Heavy Duty
Revision History
Old Pump New Pump
Part Number Part Number
M04920B001 M04920B003
M04920B002 M04920B003
M04920B008 M04920B015
M04920B010 M04920B015
Determining Model Number

The model number appears on the serial number tag attached to the front of the GPU. Use the
table in “Model Breakdown” to determine your model.
MDE-4447B Global Pumping Unit Operation and Service Manual · June 2016 Page 1-1
Introduction Required Reading
Required Reading
Before servicing or operating the GPU, the service operator must read, understand, and follow:
• This manual
• National Fire Protection Association (NFPA) 30A, The Automotive and Marine Service
Station Code
• NFPA 70®, The National Electrical Code (NEC®)
• Applicable federal, state, and local codes and regulations
Failure to do so may adversely affect the safe use and operation of the equipment.
Note: To ensure valid warranty, the servicing must be performed by a Gilbarco-trained

Authorized Service Contractor (ASC).
Abbreviations and Acronyms

Term Description
ASC Authorized Service Contractor
GOLD Gilbarco Online Documentation
GPU Global Pumping Unit
NEC National Electrical Code
NFPA National Fire Protection Association
OIML International Organization of Legal Metrology
PSI Pounds (of Pressure) per Square Inch
Page 1-2 MDE-4447B Global Pumping Unit Operation and Service Manual · June 2016
Important Safety Information
2 – Important Safety Information

Notes: 1) Save this Important Safety Information section Read the Manual
in a readily accessible location. Read, understand and follow this manual and any other labels
2) Although DEF is non-flammable, Diesel is or related materials supplied with this equipment. If you do not
flammable. Therefore, for DEF cabinets that are understand a procedure, call a Gilbarco Authorized Service
attached to Diesel dispensers, follow all the Contractor or call the Gilbarco Support Center at
notes in this section that pertain to flammable 1-800-800-7498. It is imperative to your safety and the safety of
fuels. others to understand the procedures before beginning work.
This section introduces the hazards and safety precautions Follow the Regulations
associated with installing, inspecting, maintaining or servicing Applicable information is available in National Fire Protection
this product. Before performing any task on this product, read Association (NFPA) 30A; Code for Motor Fuel Dispensing
this safety information and the applicable sections in this Facilities and Repair Garages, NFPA 70; National Electrical
manual, where additional hazards and safety precautions for Code (NEC), Occupational Safety and Health Administration
your task will be found. Fire, explosion, electrical shock or (OSHA) regulations and federal, state, and local codes. All
pressure release could occur and cause death or serious injury, these regulations must be followed. Failure to install, inspect,
if these safe service procedures are not followed. maintain or service this equipment in accordance with these
codes, regulations and standards may lead to legal citations
Preliminary Precautions with penalties or affect the safe use and operation of the
You are working in a potentially dangerous environment of equipment.
flammable fuels, vapors, and high voltage or pressures. Only
trained or authorized individuals knowledgeable in the related Replacement Parts
procedures should install, inspect, maintain or service this Use only genuine Gilbarco replacement parts and retrofit kits on
equipment. your pump/dispenser. Using parts other than genuine Gilbarco
replacement parts could create a safety hazard and violate
Emergency Total Electrical Shut-Off local regulations.
The first and most important information you must know is how
to stop all fuel flow to the pump/dispenser and island. Locate Safety Symbols and Warning Words
the switch or circuit breakers that shut off all power to all fueling This section provides important information about warning
equipment, dispensing devices, and Submerged Turbine symbols and boxes.
Pumps (STPs). Alert Symbol
This safety alert symbol is used in this manual and on

! ! WARNING warning labels to alert you to a precaution which must be
The EMERGENCY STOP, ALL STOP, and
followed to prevent potential personal safety hazards. Obey
PUMP STOP buttons at the cashier’s station
safety directives that follow this symbol to avoid possible injury
WILL NOT shut off electrical power to the
or death.
pump/dispenser. This means that even if you
Signal Words
activate these stops, fuel may continue to flow
These signal words used in this manual and on warning labels
uncontrolled.
tell you the seriousness of particular safety hazards. The
precautions below must be followed to prevent death, injury or
You must use the TOTAL ELECTRICAL
damage to the equipment:
SHUT-OFF in the case of an emergency and not
DANGER: Alerts you to a hazard or unsafe practice
the console’s ALL STOP and PUMP STOP or ! which will result in death or serious injury.
similar keys.
WARNING: Alerts you to a hazard or unsafe practice
Total Electrical Shut-Off Before Access
! that could result in death or serious injury.
Any procedure that requires access to electrical components or CAUTION with Alert symbol: Designates a hazard or
! unsafe practice which may result in minor injury.
the electronics of the dispenser requires total electrical shut off
of that unit. Understand the function and location of this switch CAUTION without Alert symbol: Designates a hazard or
or circuit breaker before inspecting, installing, maintaining, or unsafe practice which may result in property or
servicing Gilbarco equipment. equipment damage.
Evacuating, Barricading and Shutting Off Working With Fuels and Electrical Energy
Any procedure that requires access to the pump/dispenser or
STPs requires the following actions: Prevent Explosions and Fires
Fuels and their vapors will explode or burn, if ignited. Spilled or
leaking fuels cause vapors. Even filling customer tanks will
cause potentially dangerous vapors in the vicinity of the
dispenser or island.
• An evacuation of all unauthorized persons and vehicles from
the work area
DEF is non-flammable. Therefore, explosion and fire safety
• Use of safety tape, cones or barricades at the affected unit(s)
warnings do not apply to DEF fluid lines.
• A total electrical shut-off of the affected unit(s)
No Open Fire In an Emergency
Inform Emergency Personnel
Compile the following information and inform emergency
Open flames from matches, lighters, welding torches or personnel:
other sources can ignite fuels and their vapors. • Location of accident (for example, address, front/back of
No Sparks - No Smoking 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,
Sparks from starting vehicles, starting or using power tools, elderly)
burning cigarettes, cigars or pipes can also ignite fuels and their • Whether or not victim has received first aid (for example,
vapors. Static electricity, including an electrostatic charge on stopped bleeding by pressure, and so on)
your body, can cause a spark sufficient to ignite fuel vapors. • Whether or not a victim has vomited (for example, if
Every time you get out of a vehicle, touch the metal of your swallowed or inhaled something, and so on)
vehicle, to discharge any electrostatic charge before you
approach the dispenser island. ! WARNING
Gasoline/DEF ingested may cause
Working Alone unconsciousness and burns to internal organs.
It is highly recommended that someone who is capable of Do not induce vomiting. Keep airway open.
rendering first aid be present during servicing. Familiarize Oxygen may be needed at scene. Seek medical
yourself with Cardiopulmonary Resuscitation (CPR) methods, if advice immediately.
you work with or around high voltages. This information is
available from the American Red Cross. Always advise the ! WARNING
station personnel about where you will be working, and caution
DEF generates ammonia gas at higher temperatures.
them not to activate power while you are working on the
When opening enclosed panels, allow the unit to air out to
equipment. Use the OSHA Lockout/Tagout procedures. If you
avoid breathing vapors.
are not familiar with this requirement, refer to this information in
If respiratory difficulties develop, move victim away from
the service manual and OSHA documentation.
source of exposure and into fresh air. If symptoms persist,
seek medical attention.
Working With Electricity Safely
Ensure that you use safe and established practices in working ! WARNING
with electrical devices. Poorly wired devices may cause a fire,
explosion or electrical shock. Ensure that grounding Gasoline inhaled may cause unconsciousness
connections are properly made. Take care that sealing devices and burns to lips, mouth and lungs.
and compounds are in place. Ensure that you do not pinch Keep airway open.
wires when replacing covers. Follow OSHA Lockout/Tagout Seek medical advice immediately.
requirements. Station employees and service contractors need
! WARNING
to understand and comply with this program completely to
ensure safety while the equipment is down. Gasoline/DEF spilled in eyes may cause burns to
eye tissue.
Hazardous Materials Irrigate eyes with water for approximately
Some materials present inside electronic enclosures may 15 minutes.
present a health hazard if not handled correctly. Ensure that Seek medical advice immediately.
you clean hands after handling equipment. Do not place any
equipment in the mouth. ! WARNING
Gasoline/DEF spilled on skin may cause burns.
! WARNING Wash area thoroughly with clear water.
The pump/dispenser contains a chemical known to the Seek medical advice immediately.
State of California to cause cancer.
! WARNING
DEF is mildly corrosive. Avoid contact with eyes, skin, and
! WARNING clothing. Ensure that eyewash stations and safety
showers are close to the work location. Seek medical
The pump/dispenser contains a chemical known to the advice/recommended treatment if DEF spills into eyes.
State of California to cause birth defects or other IMPORTANT: Oxygen may be needed at scene if gasoline has
reproductive harm. 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, chemical, or other energy,
but does not cover electrical hazards. Subpart S of 29 CFR Part
1910 - Electrical Hazards, 29 CFR Part 1910.333 contains
specific Lockout/Tagout provision for electrical hazards.
Hazards and Actions
! WARNING
Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a

serious hazard.
Fire or explosion may result, causing serious injury or death.
Follow established emergency procedures.
DEF is non-flammable. However it can create a slip hazard. Clean up spills promptly.
The following actions are recommended regarding these hazards:
Collision of a Vehicle with Unit Fire at Island Fuel Spill
• Do not go near a fuel spill or allow anyone else in the area.

• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the island(s).
• Do not use console E-STOP, ALL STOP, and PUMP STOP to shut off power. These keys do not
remove AC power and do not always stop product flow.
• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow
open flames, smoking or power tools in the area.
• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.
• Call emergency numbers.
Flow of Liquid Through Pumping Unit and Air Eliminator Pumping Unit Operation and Maintenance
3 – Pumping Unit Operation and Maintenance
Flow of Liquid Through Pumping Unit and Air Eliminator

Following is a high level overview of how GPU M04920 functions:
1 The fuel is drawn from the storage tank through the strainer screen or filter.
2 The rotary vane pumping unit pressurizes the fluid.
3 Fuel enters the centrifugal air separator assembly. Any air that is present is forced out of the air
tube along with a small amount of liquid into the atmospheric chamber.
4 When the liquid level in the chamber lifts the float and valve assembly, the liquid collected in
the atmospheric chamber is returned to the pump intake. Air is then vented to the atmosphere
through the end tube.
5 Air-free fuel leaving the air separator opens the control valve and is pumped into the meter.
The control valve includes a built-in relief valve which relieves excess pressure caused by hot
weather expansion.
6 Fuel passes through the meter where it is accurately measured, then through the hose and
nozzle to the vehicle or container being fueled.
7 Whenever the nozzle is not fully opened, some liquid is relieved into the pump through the
bypass valve.
Figure 3-1: Flow Diagram
5
Discharge
Vent Tube
Atmospheric
Chamber
3
4 6
Pressure
Relief Valve
7
8
Inlet
Pumping Unit Operation and Maintenance Float and Air Separator
Following table describes the parts in Figure 3-1 on page 3-1:

Item# Description
1 Strainer Screen or Filter
2 Rotary Vane Pumping Unit
3 Centrifugal Air Separator Assembly
4 Float and Valve Assembly
5 End Tube
6 Control Valve
7 Built-in Relief Valve
8 Bypass Valve
Float and Air Separator
IMPORTANT INFORMATION
Before gasoline can be accurately measured by the meter, air and vapors must be eliminated.
The pumping unit eliminates air and vapor by using the air separator and float assembly. The
float assembly employed is as shown in Figure 3-2.
Figure 3-2: Float Assembly
Enlarge Top Hole to

7/16 inch
Flat Side Pointing

Away from Float
Adjustable Bypass Valve Pumping Unit Operation and Maintenance
Adjustable Bypass Valve

The pumping unit uses an adjustable bypass valve assembly to limit the pumping unit pressure
when the motor is running and no fuel is being dispensed. The adjustable bypass assembly
includes the following:
• Valve spring
• Guide
• Cover
• Adjustment screw
• Brass cap
Note: The same bypass assembly is used on all pumping units (see Figure 3-3).
Figure 3-3: Bypass Valve
Air Separator Float Device

In European International Organization of Legal Metrology (OIML) versions of the pumping
unit, a float assembly is provided on the pumping unit vent opening. This assembly is used to
prevent liquid from escaping through the vent pipe (see Figure 3-4).
Figure 3-4: Air Separator Float Device
Pumping Unit Operation and Maintenance Control Valve
Control Valve
The pumping unit uses a control valve that helps to eliminate air by producing a back pressure
and is also used as a check valve for any fuel above it.
The control valve also contains a pressure relief valve. This valve relieves excess hose
pressure, which may result from the expansion of fuel in the hose during hot weather, to the air
eliminator chamber. This action prevents hoses from bursting and helps prevent pumping unit
leaks.
Figure 3-5: Control Valve
The Control Valve Spring is

Different Between Standard
and Heavy Duty Pumping Units
The Control Valve Assembly is

the Same for Standard and
Heavy Duty Pumping Units
Replacing Lip Seal Pumping Unit Operation and Maintenance
Replacing Lip Seal

To replace the lip seal, proceed as follows:
1 Remove the belt, pulley, and shaft key.
2 Remove the three screws that hold the seal retainer (see Figure 3-6). Carefully pry the old seal
from the recess in the cover plate.
Note: Do not scratch the shaft.
3 Wipe the shaft clean.
4 With a small plastic plug tool (furnished with new seal), slip the new seal over the shaft and
remove the tool.
5 Reinstall the seal retainer screws, key, pulley, and belt.
Figure 3-6: Replacing Lip Seal
Stator
Inner
Lip Seal
Seal
Seal
Retainer
A 52 5702
Screw
Remove Plastic Plug
After Assembling Lip
Seal to Rotor Shaft
Pumping Unit Operation and Maintenance Pumping Units with Throwout Rings
Pumping Units with Throwout Rings

All pumping units have rotors with throwout rings and carbon blades.
Note: Studies conclude that pumping units with throwout rings produce greater vacuum and
are more resistant to vapor lock.
To replace blades in rotors with throwout rings, proceed as follows:
1 Install throwout rings in the recesses of the rotor.
2 Install the rotor in the stator assembly.
3 Rotate the rotor until a blade slot is at the 12:00 o’clock position. Install a blade.
4 Rotate the rotor two slots from the installed blade. Ensure that the second slot is at the
12:00 o’clock position. Install a blade.
5 Repeat step 4 for the third blade.
6 Repeat steps 1 to 3 for the three remaining blades (see Figure 3-7).
Figure 3-7: Pumping Units with Throwout Rings
Blade Slot at 12:00 o’clock Position
Throwout Rings
Stator
Rotor and Shaft

Assembly
Parts Lists and Kits Model M04920B003
4 – Parts Lists and Kits
Model M04920B003
Figure 4-1: Pumping Unit - United States
Model M04920B003 - Pumping Unit Parts List Parts Lists and Kits
Model M04920B003 - Pumping Unit Parts List

Notes: 1) Parts listed in the following table are not available for individual purchase. Repair
kits may be purchased, refer to “Kits for M04920B003 and M04920B015” on
page 4-8.
2) Refer to “Adjustable Bypass Parts Breakdown” on page 4-3 and “Plug and Fitting
Parts Breakdown” on page 4-3 for additional parts and graphics.
Item Part Description Quantity Item Part Description Quantity
1 Body (Non-reverse Float) 1 31 Seal, Lip (with Plug) 1
Body (Reverse Float) 1 32 Seal, Retainer 1
2 Blade, Rotor 10 (see 33 Seal, Square 1
note 2)
3 Clamp (see note 1) 1 34 Rotor and Shaft Assembly 1 (see
note 2)
4 Connector, Male 1 19 • Key 1
5 Cover, Atmospheric Chamber 1 35 • Ring, Retaining 1
6 Cover, Bypass Valve 1 36 Screw (see note 1) 1

7 Cover, Control Valve 1 37 Screw, M8 1.25 X 15 mm 1
8 Cover, Filter 1 38 Screw, M8 1.25 X 20 mm (see note 1) -
9 Float, Non-reversing 1 39 Screw, M8 1.25 X 25 mm 24
11 Gasket, Atmospheric Chamber 1 40 Screw, M6 1 X 20 mm 6
Cover
12 Gasket, Bypass Valve 1 41 Separator and Air Eliminator 1
13 Gasket, Clamping Ring 1 42 Sleeve, Tube (see note 1) 1
14 Gasket, Control Valve Cover 1 43 Spring, Control Valve (H.D.) 1
15 Gasket, Filter Cover 1 44 Spring, Filter 1
16 Gasket, Inlet (separator) 1 45 Stator, H.D. 1
17 Gasket, Outlet (separator) 1 46 Stop, Filter Insert 1
18 Insert 1 47 Strainer Assembly-149 micron 1
19 Key 1 • Strainer, 70 Micron 1
20 Nut, Tube (see note 1) 1 • Paper Filter (not shown) 1
21 Nut 1 48 Tube, Vent Assembly-9024 2

(see note 1)
22 O-ring 1 Tube, Vent Assembly-9033 and 9036 3
23 Plug, Pipe 1/4” 2 Tube, Vent Assembly-9044 and 9048 4
24 Pulley 1 49 Valve Assembly, Bypass 1
25 Ring, Throwout (H.D.) 2 50 Valve Assembly, Control 1
26 Ring, Clamping 1 51 Valve, Relief 30-50 PSI 1
27 Ring, Retaining 1 52 Valve Assembly, Float 1
28 Rotor Support Assembly 1 53 Washer 1
29 Cover, Rotor 1 54 Washer (see note 1) 2
30 Screw, M3.5 Flat Head 3 55 Washer, Lock 1
Notes: 1) Not part of the pumping unit.
2) Current pumping units use a 10-blade assembly. If you have a six or eight-blade rotor assembly, you can
replace blades, but the replacement rotor assembly uses a 10-blade design. When you need to replace the
blades, it is also recommended that you replace six or eight-blade rotor assemblies with a 10-blade rotor
assembly for quieter operation and better performance.
Parts Lists and Kits Model M04920B003 - Pumping Unit Parts List
Adjustable Bypass Parts Breakdown

Refer to the table on page 4-3 for the parts list.
Figure 4-2: Adjustable Bypass Parts Breakdown
60
61
59
58
Plug and Fitting Parts Breakdown
Figure 4-3: Plug and Fitting Parts Breakdown
56
57
Following table lists plug and fitting parts:

Item Part Description
56 Fitting
57 Pipe Plug
58 Nut
59 Screw - Adjustable
60 Cover
61 Gasket - Screw
Model M04920B015 Parts Lists and Kits
Model M04920B015
Figure 4-4: Pumping Unit (Euro and Heavy Duty OIML Euro)
Model M04920B015 - Pumping Unit Parts List

Notes: 1) Parts listed in the following table are not available for individual purchase. Repair
kits may be purchased. Refer to “Kits for M04920B003 and M04920B015” on
page 4-8.
2) Refer to “Adjustable Bypass Parts Breakdown” and “Air Eliminator Parts

Breakdown” on page 4-6, and “Air Eliminator Float Assembly Parts Breakdown” on
page 4-7 for additional parts and graphics.
Item Part Description Quantity Item Part Description Quantity
1 Body (Non-reverse Float) 1 31 Seal, Lip (with Plug) 1
Body (Reverse Float) 1 32 Seal, Retainer 1
2 Blade, Rotor 10 (see 33 Seal, Square 1
note 2)
3 Clamp (see note 1) 1 34 Rotor and Shaft Assembly 1 (see
note 2)
4 Connector, Male 1 19 • Key 1
5 Cover, Atmospheric Chamber 1 35 • Ring, Retaining 1

6 Cover, Bypass Valve 1 36 Screw (see note 1) 1
7 Cover, Control Valve 1 37 Screw, M8 1.25 X15 mm 1
8 Cover, Filter 1 38 Screw, M8 1.25 X 20 mm (see note 1) -
9 Float, Non-reversing 1 39 Screw, M8 1.25 X 25 mm 24
11 Gasket, Atmospheric 1 40 Screw, M6 1 X 20 mm 6
Chamber Cover
12 Gasket, Bypass Valve 1 41 Separator and Air Eliminator 1
13 Gasket, Clamping Ring 1 42 Sleeve, Tube (see note 1) 1
14 Gasket, Control Valve Cover 1 43 Spring, Control Valve (H.D.) 1
15 Gasket, Filter Cover 1 44 Spring, Filter 1
16 Gasket, Inlet (separator) 1 45 Stator, H.D. 1
17 Gasket, Outlet (separator) 1 46 Check Valve 1
18 Insert 1 46A O-ring 1
19 Key 1 47 Strainer Assembly-149 micron 1
20 Nut, Tube (see note 1) 1 • Strainer, 70 Micron 1
21 Nut 1 • Metal Strainer (not shown) 1

22 O-ring 1 48 Tube, Vent Assembly-9024 2
(see note 1)
23 Plug, Pipe 1/4 2 Tube, Vent Assembly-9033 and 9036 3
24 Pulley 1 49 Valve Assembly, Bypass 1
25 Ring, Throwout (H.D.) 2 50 Valve Assembly, Control 1
26 Ring, Clamping 1 51 Valve, Relief 30-50 PSI 1
27 Ring, Retaining 1 52 Valve Assembly, Float 1
28 Rotor Support Assembly 1 53 Washer 1
29 Cover, Rotor 1 54 Washer (see note 1) 2
30 Screw, M3.5 Flat Head 3 55 Washer, Lock 1
Notes: 1) Not part of the pumping unit.
2) Current pumping units use a 10-blade assembly. If you have a six or eight-blade rotor assembly, you can
replace blades, but the replacement rotor assembly uses a 10-blade design. When you need to replace
the blades, it is also recommended that you replace six or eight-blade rotor assemblies with a 10-blade
rotor assembly for quieter operation and better performance.
Model M04920B015 - Pumping Unit Parts List Parts Lists and Kits
Air Eliminator Parts Breakdown

Figure 4-5: Air Eliminator Parts Breakdown
60 61 63
62
Adjustable Bypass Parts Breakdown

Figure 4-6: Adjustable Bypass Parts Breakdown
75
72 73 74
Air Eliminator Float Assembly Parts Breakdown
Figure 4-7: Air Eliminator Float Assembly Parts Breakdown
65 67
68
64 71
69 70
Following table lists the parts in the Air Eliminator Float Assembly:
Item Part Description
56 Clip (not shown)
57 End Plug (not shown)
58 O-ring (not shown)
59 Separator (not shown)
60 Air Separator Tube Variable Orifice
61 Piston Air Separator Tube Variable Orifice
62 Spring
63 End Cap Separator Tube Variable Orifice
64 3/8-inch Pipe Plug
65 Housing Air Valve Float Assembly
66 Gasket Air Valve Float Assembly
67 Needle Air Valve Float Assembly
68 Gland Nut Air Valve Float Assembly
69 Float - Air Valve Float Assembly
70 Retaining Ring - External 3.5 mm
71 Retaining Ring - External 3.5 mm
72 Nut
73 Screw - Adjustable
74 Gasket - Screw
75 Cover
Kits for M04920B003 and M04920B015 Parts Lists and Kits
Kits for M04920B003 and M04920B015

Following table lists the kits available for Gilbarco GPUs. For additional information, refer to
“Kit Component Parts” on page 4-9.
Kit Number Kit Description
M04920K100 Bypass Valve
M04920K101 Strainer
M04920K102 Master Seal
M04920K104 Control Valve
M04920K105 Lip Seal
M04920K107 Sump Float - OIML (B005)
M04920K109 Inlet Check Valve
M04920K110 Overflow Check Valve
M04920K116 Blades
M04920K117 Pumping Element Field Rebuild
M04920K118 Pumping Element Shop Rebuild
M04920K119 Inlet Adapter
Note: Alternate Fuel Pumps M04920B011 and M04920B012 require special kits.
Kit Revision History

Replacement Kit
Kit Number Kit Description Number
M04920K103 Blades M04920K113
M04920K106 Pumping Element Field Rebuild M04920K114
M04920K108 Pumping Element Shop Rebuild M04920K115
M04920K111 Sump Float - Non OIML (B001) M04920K107
M04920K112 Blades M04920K113
M04920K113 Blades M04920K116
M04920K114 Pumping Element Field Rebuild M04920K117
M04920K115 Pumping Element Shop Rebuild M04920K118
Parts Lists and Kits Kit Component Parts
Kit Component Parts

M04920K100 - Bypass Valve M04920K117 - Pumping Element Field Rebuild
Bypass Valve • 10-blade Rotor and Shaft
M04920K101 - Strainer • Blade
70 Micron Strainer • Retaining Ring
M04920K102 - Master Seal • Woodruff Key
• Clamp Ring Gasket • Shaft Seal with Plug
• Bypass Valve Cover Gasket • Square Seal
• Control Valve Cover Gasket M04920K118 - Pumping Element Shop Rebuild

• Filter Cover Gasket • 10-blade Rotor and Shaft
• Atmospheric Chamber Cover Gasket • Blade
• Inlet Gasket • Throwout Ring
M04920K104 -Control Valve • Retaining Ring
• Control Valve • Rotor Cover
• Heavy Duty Spring • Rotor Cover Gasket
M04920K105 - Lip Seal • Woodruff Key
• Lip Seal • Shaft Seal with Plug
• Square Seal • Square Seal
M04920K107 - Sump Float - OIML (B005) M04920K119 - Inlet Adapter

• Float Valve Assembly (Rogers) • Inlet Adapter
• O-ring • Gasket
• Non-reversing Float • Bolt
M04920K109 - Inlet Check Valve

• O-ring
• Inlet Check Valve Assembly
M04920K110 - Overflow Check Valve

• Air Valve Housing
• Air Valve Gasket
• Valve Sub-assembly Air Vent
• Float (Rogers)
• Retaining Ring
M04920K116 - Blades
• Blade
• Shaft Seal with Plug
• Square Seal
Kit Component Parts Parts Lists and Kits
Replacing Inlet Check Valve in GPU Replacing Inlet Check Valve in GPU
5 – Replacing Inlet Check Valve in GPU
GPU is supplied with a check valve located opposite the pulley side, behind the strainer
assembly. Check valves are required for twin hose, single product pumps with a manifold
inlet. All other units from the factory do not include this check valve. Single hose, single
product pumping units do not require this check valve located behind the strainer assembly.
The purpose of the check valve located behind the strainer housing is to prevent siphoning of
fuel from the unused pump when one side of the twin-hose pump is fueling and the other side
is idle.
Following section provides instructions for replacing the inlet check valve in Gilbarco GPU
with the Inlet Check Valve Kit (M04920K109).
Required Tools and Materials

• 13 mm Socket Wrench or equivalent is required to install the Inlet Check Valve Kit
• Multi-purpose Grease Small Brush
Parts List
Following table lists the parts included in the Inlet Check Valve Kit:
Item Description Part Number Quantity
1 O-ring A294212 1
2 Check Valve Assembly 113032 1
3 Instructions 109792 1
Replacing Inlet Check Valve in GPU

Note: These instructions show a GPU that has been removed from the dispenser. However,
you may not be required to remove the GPU from the dispenser to install the kit.
Figure 5-1: Pump Check Valve Warning Label (M13673B001)
Note: This sticker is placed directly on the pumping unit that has factory-installed meter check valves.
If you are working on the GPU without removing it from the dispenser, ensure that you
follow all safety precautions provided in “Important Safety Information” on page 2-1.
Be prepared to catch and contain the fuel inside the unit that could be under pressure. Properly
dispose any spilled fuel.
To replace the existing inlet check valve in the GPU (see Figure 5-2), proceed as follows:
Figure 5-2: GPU
Strainer
Cover
Plug Isometric Rear View

Isometric Front View
1 Remove the plug and gasket from the strainer cover and drain the system.
Note: Retain the plug and gasket for reuse.
Figure 5-3: Removing Plug and Gasket
Strainer Cover
Plug Gasket
(i) (ii)
2 Loosen and remove the four M8 screws (25 X 1.25 pitch) holding the strainer cover to the
GPU.
Note: Retain the screws for reinstalling the GPU.
Figure 5-4: Removing Screws
M8 Screw
3 Remove the strainer cover, O-ring, and spring (see Figure 5-5).
Note: Retain the cover, O-ring, and spring for reinstalling the GPU.
Figure 5-5: Removing Strainer Cover and Spring
Strainer Spring
Cover
O-ring
The spring on the cover pushes on the closed side of the strainer (see Figure 5-5).
Note: This condition must be maintained when you install the new strainer.
4 Remove the existing strainer and strainer gasket (see Figure 5-6).
Note: Retain the strainer and strainer gasket for reinstalling the GPU.
Figure 5-6: Removing Strainer and Strainer Gasket
Strainer
Strainer Gasket
(ii)
(i)
Removing the Strainer Removing the Strainer Gasket
5 Remove and discard the existing inlet check valve and O-ring (see Figure 5-7).
Figure 5-7: Removing Inlet Check Valve and O-ring
O-ring
Inlet Check Valve
A new Inlet Check Valve (M09595A001) and O-ring (M11642B001) are provided in the kit
(see Figure 5-8).
Figure 5-8: New Inlet Check Valve and O-ring
O-ring Inlet Check Valve
6 Using some multi-purpose grease and a small brush, apply some grease to the inlet portion of
the pumping unit body [see Figure 5-9 (i)].
Figure 5-9: Applying Multi-purpose Grease to GPU Inlet
(i) (ii)
7 Ensure to put a layer of grease all along the area of the inlet where the check valve will be set
[see Figure 5-9 (ii)].
Note: Do not over apply the grease. The grease is used to give the new O-ring and the check
valve a good seal.
8 Apply some multi-purpose grease to the new check valve where the O-ring will be put on
(see Figure 5-10).
Figure 5-10: Applying Multi-purpose Grease to Check Valve
9 Put the new O-ring into the groove of the check valve (see Figure 5-11).
Figure 5-11: Inserting New O-ring into Check Valve Groove
10 Brush some multi-purpose grease onto the O-ring (see Figure 5-12).
Figure 5-12: Brushing Multi-purpose Grease onto O-ring
11 Place the O-ring on the check valve as shown in Figure 5-13.
Figure 5-13: Placing O-ring on Inlet Check Valve
Inlet Check Valve
O-ring
12 Install the new check valve and O-ring assembly into the housing. Ensure that the check valve
assembly is pushed all the way down into the opening until it stops and the O-ring rests on the
bottom surface [see Figure 5-14 (ii)].
Figure 5-14: Installing Inlet Check Valve into Housing
(ii)
O-ring
Resting Check Valve Assembly on
Inlet Check Valve the Bottom of the Housing
(i)
Installing Inlet Check Valve into Housing
13 Place the strainer gasket [see Figure 5-15 (i)] removed in step 4 and strainer with the closed
end facing toward you.
Figure 5-15: Installing Strainer Gasket and New Strainer
Strainer
Strainer Gasket
(i)
(ii)
Installing the Strainer Gasket Installing the Strainer
14 Install the spring, O-ring, and strainer cover (removed in step 3 on page 5-3) ensuring that the
spring is pushing toward the closed end of the strainer (see Figure 5-16).
Figure 5-16: Reinstalling Spring and Strainer Cover
Spring
Strainer
Cover
15 Install the screws removed in step 2 on page 5-3. Ensure that the M8 screws (25 X 1.25 pitch)
are tightened with 14-16 Nm torque and there are no leaks (see Figure 5-17).
Figure 5-17: Reinstalling Screws
M8 Screw
16 Install the plug and gasket removed in step 1 on page 5-2. Ensure that the plug is tightened at
8-10 Nm.
Figure 5-18: Installing Plug and Gasket
Strainer Cover
Plug
(ii)
Gasket
(i)
Replacing the strainer in the GPU is now complete.
Figure 5-19: GPU
Reinstall the GPU in the dispenser, if the GPU was removed from dispenser. Run the dispenser
and GPU to purge out the air, if any. Test for proper operation of dispenser.
CAUTION
Tighten the motor/GPU belt to 130 N. Over-tightening the belt will cause premature wear
of the belt and bearing on the GPU, which in turn can cause leakage from the seal and
void the warranty.
General Vacuum and Pressure Information Troubleshooting
6 – Troubleshooting
General Vacuum and Pressure Information

Following components are normally associated with pump pressure:
• Control Valve
• Meter
• Computer or Pulser Drive Linkage
• Hose
• Nozzle
Following components are normally associated with pump vacuum:

• Blades
• Rotor/Stator
• Filter
• Bypass Valve and Seat
• Float (opened)
• Installation piping
• Tank Vent Pipe
• Angle Check Valve or Foot Valve
• Tank burial depth
Vacuum readings can vary with each installation. To calculate pump vacuum, proceed as
follows:
1 An inch of mercury is required to lift gasoline 1-1/2 feet (0.46 m). Divide the total lift by
1-1/2 feet (0.46 m) to obtain vacuum.
2 Allow an inch of mercury for each angle check, foot valve, or vertical check valve.
3 Allow an inch of mercury for each 60 feet (18.3 m) of piping.
4 Add the readings obtained in steps 1, 2 and 3 to determine the approximate vacuum reading at
fast flow.
Note: Excessive vacuum indicates a restriction. Low vacuum indicates a leak.
Troubleshooting Vacuum Gauge Readings (Inches of Mercury)
Vacuum Gauge Readings (Inches of Mercury)

Following table shows normal vacuum gauge readings for a variety of lift vs. run situations.
Notes: 1) Following table shows normal vacuum gauge readings for general lift vs. run
situations. This is intended as a guideline only. Readings will vary depending on
other factors, such as pipeline size, number of bends, elevation, fuel composition and
so on.
2) Readings are listed in inches of mercury (in-hg). Some gauges may read in
centimeters of mercury (cm-hg), PSI, or bar, refer to “Conversion Factors”.
Vertical Lift (Feet) 3 4 5 6 7 8 9 10
Horizontal Run - 0’ 3.0 3.6 4.3 4.9 5.5 6.1 6.8 7.4
Horizontal Run - 60’ 3.9 4.5 5.2 5.8 6.4 7.0 7.7 8.3
Conversion Factors
• 1 in-hg = 2.54 cm-hg
• 1 in-hg = -0.491 PSI
• 1 in-hg = -0.034 bar
• 1 ft = 0.3048 m
Use Gauge Readings to Troubleshoot Self-contained

Dispensers
There are a variety of conditions that can contribute to no delivery or slow delivery. A
pressure/vacuum gauge is an important tool in determining whether the problem is on the
vacuum side or pressure side of the pump.
The vacuum gauge reading can help you determine if there are restrictions of flow in the
suction piping system. It will also help you determine the ability of the pumping unit to pump.
Note: Vacuum gauge readings in the following sections are shown in inches of mercury.
Testing Pump Vacuum

To test the vacuum of the pump, proceed as follows:
1 Remove the pipe plug in the center of the strainer or filter cover. The cover is marked for easy
identification.
2 Install the vacuum gauge.
3 Start the pump and open the nozzle to full flow for a true reading.
Use Gauge Readings to Troubleshoot Self-contained Dispensers Troubleshooting
4 With the nozzle open, a normal vacuum reading is 6-8 inches of mercury for normal suction
(see Figure 6-1).
Figure 6-1: Vacuum Reading - Nozzle Open
5 With the nozzle closed, a normal vacuum reading is 0 (see Figure 6-2).
Figure 6-2: Vacuum Reading - Nozzle Closed
Testing Pump Pressure
To test the pressure of the pump, proceed as follows:
1 Remove the pipe plug in the center of the control valve cover. Covers are marked for easy
identification.
2 Install the pressure gauge.
3 Start the pump and open the nozzle to full flow for a true reading.
4 With the nozzle open, a normal pressure reading is 16-18 PSI pressure.
Troubleshooting Troubleshooting Using Gauge Readings
5 With the nozzle closed, a normal pressure reading is 25-28 PSI pressure (see Figure 6-3).
Figure 6-3: Pressure Reading - Nozzle Closed
Troubleshooting Using Gauge Readings

Following examples help you determine the possible cause of a problem by observing the
gauge readings on the inlet (vacuum) and outlet (pressure) side of the pumping unit. Actual
readings may vary slightly, depending on installation and environmental conditions.
Figure 6-4: Gauge Troubleshooting - 1
Symptoms: No Flow; Nozzle Open
Check Inlet Side
Probable Causes:
• Control Valve Stuck Shut
• Bypass Valve Open
• Atmospheric Float Valve Open
• Stuck Rotor Blades At Strainer
At Control Valve
Cover • Broken Suction Line (or Filter)
• Strainer or Filter Completely Cover
Plugged or in Backwards
• Empty Tank
Troubleshooting Using Gauge Readings Troubleshooting
Symptoms: No Flow; Nozzle Open
Probable Causes:
• Seized Meter
• Jammed Computer or Geared
Box
• Completely Restricted Nozzle or
Hose
At Control Valve At Strainer (or Filter)
Cover Cover
Symptoms: Slow or No Flow; Pump

Laboring; Nozzle Open
Check Inlet Side
Probable Causes:
• Supply Line Restriction
• Stuck Foot Valve (in Tank)
• Angle Check Valve or Vertical
Check Valve
At Strainer (or Filter)
At Control Valve • Restricted Tank Vent
Cover Cover
Symptoms: Slow or No Flow;

Nozzle Open
Check Outlet Side
Probable Causes:
• Control Valve not Opening Fully
• Pump Vapor Locked

Cover Cover
Troubleshooting Troubleshooting Using Gauge Readings
Symptoms: No Flow or Slow

Delivery; Nozzle Open
Probable Causes:
• Worn Bypass Valve or Rotor
Blades
• Worn Rotor or Stator
• Air Leak in Suction Pipe
At Control Valve • Dirty Filter At Strainer (or Filter)
Cover Cover
Symptoms: Slow Flow; Nozzle

Open
Check Outlet Side
Probable Causes:
• Partially Restricted Nozzle or
Hose
• Bind in Computer, Gear Box,
Meter
Cover Cover
• Pulser Drive Linkage
Symptoms: No Flow or Slow

Delivery; Nozzle Open
Probable Cause:
• Tank Burial Too Deep (High Lift)

Cover Cover
Symptoms: Motor Laboring;

Circuit Breaker Trips; Motor
Failing; Nozzle Closed
Probable Cause:
• Bypass Valve Stuck Shut
Reading
May Vary
Cover Cover
Resolving Issues on Pumping Units Troubleshooting
Resolving Issues on Pumping Units

Refer to the following tables for specific troubleshooting information.
Issue: The motor starts but the pump does not deliver fuel
Cause Action
The fuel supply is below the suction stub in Fill the storage tank.
the storage tank.
The vent pipe is plugged in the storage tank. Clean the vent pipe.
The strainer screen or filter assembly has an Remove obstructions from the screen or filter assembly.
obstruction.
The bypass valve is not seated properly due Check the valve for an obstruction causing the valve to stay
to wear or obstruction. open, and/or replace the bypass valve.
The v-belt is loose or broken. Adjust or replace the v-belt.
There is an obstruction in the atmospheric Clean the float and valve area. Check for swelling and binding
float valve. in the linkage.
The pump is out of prime. Check for a faulty foot valve in the storage tank or a faulty check
valve in the suction line.
The suction line is leaking. Start the pump and open the nozzle. If bursts of air are felt while
holding a finger on the vent tube, the suction line is damaged.
Repair or replace.
The intake line, foot valve, angle check Connect a vacuum gauge to the 1/4-inch (6.4 mm) plug on the
valve, or vertical check valve have an filter cover. Turn the pump on and open the nozzle. A reading of
obstruction. 15 or more inches of mercury with no flow indicates a complete
blockage in the suction line. Clean the line or replace.
The suction stub in the storage tank is on the Ensure that there is a 4-inch (10.16 cm) clearance.
bottom of the tank.
The control valve has an obstruction. Clean the control valve. It must slide freely in the valve cavity.
The nozzle is not working. Replace the nozzle.
Two pumps are connected to one storage Disconnect the vent tube on the idle pump. Install a short
tank with one suction line. There is a faulty copper tube. Place the end of the copper tube in a container of
check valve in one of the supply lines*. liquid. If the liquid is drawn out of the container when the
opposite pump is operated with an open nozzle, the line check
valve is faulty. Replace the check valve.
*Not recommended.
Issue: The pump runs, but delivery is slow

Cause Action
The fuel supply level is low. Fill the storage tank.
The vent pipe is partially obstructed. Clean the vent pipe.
The strainer screen or filter assembly has a Remove obstructions from the screen or filter assembly.
partial obstruction.
The bypass valve is not seated properly. Check the valve for any obstructions which may cause the valve to
stay open.
The v-belt is loose. Adjust the v-belt.
The voltage is too low. Check the power supply voltage. The dispenser uses a 115 VAC,
60 cycle electrical circuit. Check for many pieces of equipment on
one electrical line.
A blade or blades in the rotary pump will not Check the rotor and blades for damage. Replace the blades and/
move. or rotor, if necessary.
Troubleshooting Resolving Issues on Pumping Units
Cause Action
The fuel supply level is low. Fill the storage tank.
The vent pipe is partially obstructed. Clean the vent pipe.
An automatic nozzle has been installed. Delivery speed will be reduced by 10-25%. If the maximum speed
is desired, replace with a standard nozzle.
The motor is defective. Inspect the motor for loose connections. If no loose connections
are found, the motor is defective. Repair or replace.
There is a slow leak in the suction line or Start the pump and open the nozzle. If bursts of air are felt while
intake line. holding a finger on the vent tube, the suction line or intake line is
damaged. Repair or replace.
The intake line, foot valve, angle or vertical Connect a vacuum gauge to the 1/4-inch (0.635 cm) plug on the
check valve is partially obstructed. filter cover. Turn the pump on and open the nozzle. A reading of 11
to 13 inches (27.94 to 33.02 cm) of mercury with no flow indicates
a partial obstruction in the suction line. Clean or replace the
suction line components.
The control valve is partially obstructed. Check the valve for an obstruction. Replace if necessary.
The nozzle check valve is sticky. Clean or replace the nozzle check valve.
The hose is defective (flattened). Replace the hose.
Issue: The motor does not run

Cause Action
The power is off. Check the circuit breaker in the station.
The motor is defective. Disconnect the power supply. Inspect the motor for loose connections. If
no loose connections are found, the motor is defective. Repair or replace.
Issue: The dispenser does not deliver an accurate amount of product

Cause Action
There is an obstruction in the control valve. Clean the control valve. It must slide freely in the valve cavity.
There is an obstruction in the air eliminator Clean the vent tube.
vent tube.
The meter needs calibration. Check calibration test equipment for accuracy. Calibrate the meter.
Issue: There is fuel running out of the vent tube opening when the pump
is in operation
Cause Action
There is an obstruction in the atmospheric Clean the float and valve area. Ensure that the float opens completely.
float valve. The valve is being held closed.
The suction chamber in the pump is Check the storage tank level. If it is higher than the pumping unit
flooded (above ground tank)*. (above ground tank)*, the condition will continue. Install Tokheim® 52
valve.
*Not recommended.
Resolving Issues on Pumping Units Troubleshooting
Issue: The computer jumps when the pump is turned on

Cause Action
The control valve is not seated properly. Check the valve for an obstruction between the O-ring and the seat.
Inspect the O-ring for damage. Replace the valve or O-ring, if
required.
There is an obstruction in the expansion Check the valve by pulling the spring loaded seat. Clean any foreign
relief dill valve. matter from the valve. To install the dill valve in the control valve, use
a valve tool.
The gaskets are leaking. Replace worn gaskets.
There is a worn nozzle. Replace the nozzle.
There is a leak in the hose. Replace the hose.
Temperature extremes cause the liquid to Problem will be solved when the pump begins to operate.
expand or contract.
Troubleshooting Resolving Issues on Pumping Units
Vapor Lock Causes Reasons for Vapor Lock
7 – Vapor Lock Causes
Vapor lock is a problem that results from ambient temperatures, vapor pressure of the product
and installation. It is not a characteristic of a pump.
Reasons for Vapor Lock
Atmospheric Pressure
Atmospheric pressure of 14.7 PSI (sea level) presses on the liquid in the tank (see Figure 7-1).
Figure 7-1: Atmospheric Pressure
Atmospheric
Pressure (14.7 PSI)
60º F (15º C)
Reasons for Vapor Lock Vapor Lock Causes
Vapor Pressure
Vapor pressure (the amount of pressure required to keep the product in a liquid form at 60° F
(15° C) of today’s product is approximately 10 PSI (see Figure 7-2).
Figure 7-2: Vapor Pressure
10 PSI required to keep

product in liquid form
60º F (15º C)
Working Pressure
The difference between atmospheric pressure and vapor pressure is known as the working
pressure. The working pressure is all that the pump can create without the product turning to
vapor (see Figure 7-3).
14.7 PSI Atmospheric Pressure
- 10.0 PSI Vapor Pressure
4.7 PSI Working Pressure
Figure 7-3: Working Pressure
Atmospheric
Pressure 60º F (15º C) 14.7 PSI
Less
Vapor Pressure
10.0 PSI
equals
4.7 PSI
Working Pressure
Measuring Suction
To measure a pump’s suction, the working pressure must be converted to inches of vacuum. To
do this, multiply the working pressure by 2. The result is the number of inches of vacuum that
a pump can create before the product changes to a vapor (see Figure 7-4).
Figure 7-4: Converting Working Pressure to Inches of Vacuum
Atmospheric
Pressure (14.7 PSI)
equals 30 inches of
mercury
14.7 PSI of Atmospheric

Pressure pushes down
on the bowl of mercury
and causes it to rise to 30
inches.
4.7 PSI Working Pressure = 9.4 inches (23.88 cm) of vacuum (see Figure 7-5).
Figure 7-5: PSI and Vacuum Equivalents
4.7 PSI = 9.4 inches of Vacuum
PSI Vacuum
Reasons for Vapor Lock Vapor Lock Causes
Installation is the Key

The condition of installation dictates how much suction a pump must create to pump the
product.
It takes 1 inch (2.54 cm) of vacuum to lift gas 1.5 feet vertically.
To determine the inches of vacuum required to lift the gas in a system, proceed as follows:
1 Measure the distance from the top of the product in the tank to the center of the pumping unit
(see Figure 7-6). Divide the distance by 1.5 to obtain the inches of vacuum required by the
pump to lift the product.
For example, 9 feet (2.74 m) of lift requires 6 inches (15.24 cm) of vacuum by the pump
(see Figure 7-6).
Figure 7-6: Amount of Vacuum Required for Pump Suction
Amount of
Vacuum
Lift Required
60º F
(15º C)
It takes 1 inch (2.54 cm) of vacuum by the pump to overcome the restriction of an angle check
valve or foot valve (not part of the pump, but a necessary part of the installation),
(see Figure 7-7).
Figure 7-7: Compensating for Angle Check or Foot Valve
1” (2.54 cm) of vacuum to overcome the

restriction of an angle check valve or foot
valve
Angle Check Valve
Foot Valve
It takes 1 inch of vacuum by the pump to overcome the restriction of 60 feet (18.3 m) of
horizontal piping from the tank to the pump (see Figure 7-8).
Figure 7-8: Compensating for Horizontal Piping
60’ (18.3 m) of Horizontal Piping = 1” (2.54 cm)

of Vacuum
60º F (15º C)
2 To obtain the inches of vacuum required to deliver the product, simply add A, B, and C.
A. 9’ of lift = 6” (15.24 cm) of suction
B. Angle check or foot valve = 1” (2.54 cm) of suction
C. 60’ horizontal run = 1” (2.54 cm) of suction
TOTAL = 8” (20.3 cm) of suction
With 9.4 inches (23.88 cm) of suction to work with and only 8 inches (20.3 cm) of vacuum
required, conditions are normal and the pump delivers the product without vapor locking.
Note: This condition exists when the product is at 60° F (15° C).
Vapor Lock Conditions Vapor Lock Causes
Vapor Lock Conditions

Using the same example as above, 8 inches (20.3 cm) of vacuum is still required to deliver the
product.
With higher ambient temperatures, the vapor pressure of the product changes. As mentioned
above, the vapor pressure of today’s product is 10 PSI at 60° F (15° C). At temperatures of
90° F (32° C) or higher, it can go as high as 12 PSI.
Figure 7-9: Vapor Pressure at 95º F
95º F
(35º C)
Vapor Pressure of Product

may be as high as 12 PSI
Using the same formulae in “Working Pressure”, the working pressure equals atmospheric
pressure less the vapor pressure (see Figure 7-10).
14.7 PSI Atmospheric Pressure
- 12.0 PSI Vapor Pressure of the product
2.7 PSI Working Pressure
Figure 7-10: Working Pressure - Vapor Lock Conditions
Atmospheric
95º F (35º C)
Pressure
14.7 PSI
Less
Vapor Pressure
12.0 PSI
equals
2.7 PSI
Working Pressure
Vapor Lock Causes Vapor Lock Conditions
Multiplying the 2.7 working pressure by 2 equals 5.4 inches (13.7 cm) of vacuum that the
pump can create before the product turns to vapor (see Figure 7-11).
Figure 7-11: PSI and Vacuum Equivalents - Vapor Lock Conditions
2.7 PSI = 5.4 inches of Vacuum
PSI Vacuum
It still takes 8 inches (20.3 cm) of vacuum to deliver the product, but with higher temperatures,
there is only 5.4 inches (13.7 cm) of vacuum to lift the product. The result is vapor lock.
Figure 7-12: Vapor Lock Conditions
The pump plays a very small part in vapor lock situations. Following are the main reasons for
vapor lock:
• Installation
• Amount of product in the storage tank
• Vapor pressure of the product
Note: Vapor lock does not occur in diesel pumps because the vapor pressure of diesel is
approximately 8 PSI.
The only solution for vapor lock in hot climates is to keep the installation and pump cool.
Vapor Lock Conditions Vapor Lock Causes
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Index
Index
A P
Adjustable Bypass Parts Breakdown Parts List 4-2, 4-5
4-3, 4-6 Plug and Fitting Parts Breakdown 4-3
Air Eliminator Float Assembly Parts Pressure 6-1
Breakdown 4-7 Pump Pressure 6-3
Air Eliminator Parts Breakdown 4-6 Pump Vacuum 6-2
Air Separator Float Device 3-3 Pumping Unit - United States 4-1
atmospheric chamber 3-1 Pumping Unit, Euro and Heavy Duty
OIML Euro 4-4
Pumping Units 6-7
B
Bypass Valve 3-3
bypass valve assembly 3-3 R
Replacing Lip Seal 3-5
rotor assembly 4-2, 4-5
C
centrifugal air separator assembly 3-1
control valve 3-1, 3-4 T
throwout rings 3-6
F
float and valve assembly 3-1 V
float assembly 3-2 Vacuum 6-1
Flow Diagram 3-1 Vacuum Gauge Readings 6-2
G
Gauge Readings 6-4
Global Pumping Unit models 1-1
GPU M09593 functions 3-1
K
Kit Component Parts 4-9
Kits for M04920B003 and
M04920B015 4-8
L
lip seal 3-5
M
Model Breakdown 1-1
Model M04920B003 4-1, 4-2
Model M04920B015 4-4, 4-5
MDE-4447B Global Pumping Unit Operation and Service Manual · June 2016 Index-1
NEC® and NFPA 70® are registered trademarks of the National Fire Protection Association. Tokheim® is a registered trademark of
Tokheim Holding B.V. Corporation.
© 2016 Gilbarco Inc.

7300 West Friendly Avenue · Post Office Box 22087
Greensboro, North Carolina 27420
Phone (336) 547-5000 · http://www.gilbarco.com · Printed in the U.S.A.
MDE-4447B Global Pumping Unit Operation and Service Manual · June 2016

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Gilbarco® Global Pumping Unit

Operation and Service Manual

Federal Communications Commission (FCC) Warning

National Conference of Weights and Measures (NCWM) - Certificate of Conformance (CoC):

Non-registered trademarks Registered trademarks Service mark

Additional US and foreign trademarks pending.

This document is subject to change without notice.

2 – Important Safety Information 2-1

3 – Pumping Unit Operation and Maintenance 3-1

4 – Parts Lists and Kits 4-1

5 – Replacing Inlet Check Valve in GPU 5-1

7 – Vapor Lock Causes 7-1

This page is intentionally left blank.

Determining Model Number

Note: To ensure valid warranty, the servicing must be performed by a Gilbarco-trained

Abbreviations and Acronyms

2 – Important Safety Information

This safety alert symbol is used in this manual and on

Hazards and Actions

Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a

The following actions are recommended regarding these hazards:

Collision of a Vehicle with Unit Fire at Island Fuel Spill

• Do not go near a fuel spill or allow anyone else in the area.

This page is intentionally left blank.

3 – Pumping Unit Operation and Maintenance

Flow of Liquid Through Pumping Unit and Air Eliminator

2 The rotary vane pumping unit pressurizes the fluid.

Figure 3-1: Flow Diagram

Following table describes the parts in Figure 3-1 on page 3-1:

Float and Air Separator

Figure 3-2: Float Assembly

Enlarge Top Hole to

Flat Side Pointing

Adjustable Bypass Valve

Figure 3-3: Bypass Valve

Air Separator Float Device

Figure 3-4: Air Separator Float Device

Figure 3-5: Control Valve

The Control Valve Spring is

The Control Valve Assembly is

Replacing Lip Seal

1 Remove the belt, pulley, and shaft key.

3 Wipe the shaft clean.

5 Reinstall the seal retainer screws, key, pulley, and belt.

Figure 3-6: Replacing Lip Seal

Pumping Units with Throwout Rings

To replace blades in rotors with throwout rings, proceed as follows:

1 Install throwout rings in the recesses of the rotor.

2 Install the rotor in the stator assembly.

5 Repeat step 4 for the third blade.

Figure 3-7: Pumping Units with Throwout Rings

Blade Slot at 12:00 o’clock Position

Rotor and Shaft

4 – Parts Lists and Kits

Figure 4-1: Pumping Unit - United States

Model M04920B003 - Pumping Unit Parts List

5 Cover, Atmospheric Chamber 1 35 • Ring, Retaining 1

6 Cover, Bypass Valve 1 36 Screw (see note 1) 1

21 Nut 1 48 Tube, Vent Assembly-9024 2