Diesel dispenser pulser or gears worn out or broken
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The Totalizer gear drives the mechanical pulser, generating the pulses that FLEETWATCH records. If the Totalizer gear fails (a common issue where it stops turning), pulses will no longer be generated.
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The Totalizer numbers should rotate smoothly and increment in sync with the transaction counter dial beneath the "Gallons" label. If they do not increment correctly—for example, if the resettable display and the Totalizer are out of sync, the Totalizer increments erratically (in jumps or starts), or it does not increment at all—inspect the Totalizer gear for potential damage.
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If the Totalizer appears to function normally, and the gallons dispensed match the resettable display, but FLEETWATCH does not receive any counts, the issue likely lies with the mechanical pulser. In this case, inspect it and replace it if necessary.
- Inspect the lash in the gear at the main counter, ensure it's not too loose, and adjust as needed.
Image 1 is an overview of how the pulser works with the totalizer.
Image 2 is the inside of the dispenser showing the gears and mechanisms.
Image 3 shows the gears up close. Look for broken gears, missing teeth, worn out teeth, or other mechanical issues if you're seeing 0 fuel or low counting, missing fuel.
What is Backlash (Lash) in a Main Gear?
- Definition: The slight clearance or gap between the teeth of two interlocking gears.
- Purpose: A small amount of backlash is necessary to allow smooth operation, prevent binding, and accommodate thermal expansion.
- Too Much Lash: If excessive, it can cause delays in motion, inconsistent performance, excessive wear, and even gear failure.
- Too Little Lash: If too tight, it can lead to binding, increased friction, overheating, and premature wear.
Causes of Excessive Lash in a Main Gear:
- Wear and Tear – Over time, gear teeth wear down, increasing the gap.
- Misalignment – Improper installation or shifting can alter the gear mesh.
- Loose Bearings or Shafts – If the mounting components wear out, gears can move slightly out of position.
- Manufacturing Tolerances – Some backlash is built into gears based on design specifications.
How to Fix or Adjust Gear Lash:
- Inspect for Wear – Check for worn or damaged teeth.
- Adjust Spacing – Some systems allow backlash adjustment by repositioning the gears.
- Replace Worn Components – If excessive lash is due to worn gears, bearings, or shafts, replacement is the best option.
- Use Preload Mechanisms – Some systems use springs or adjustable mounts to reduce unwanted backlash.
