ATD Tools fpm-12 User Manual

INSTRUCTION MANUAL S1590, Rev B

ATD-50012 Electric Fuel Pump

(FPM-12)

Congratulations on purchase of this World Class Electric Fuel Pump!

Swivel Nut

Pump Outlet

Elbow

Nozzle Holder

Motor

Pad Lock Lever

OFF

ON

Switch

Fuel Control Nozzle

This is an Electric Fuel Pump. Pump uses 2 Sintered Powder Metal gears for suction & is designed for use with Gasoline, Diesel, E15 Fuel, Kerosene, Bio Diesel (B20) etc. In ideal laboratory conditions, pump dispenses up to 15 GPM (57 LPM) at the pump outlet. The actual discharge varies depending on fuel being used, temperature, Hose Length, power supply etc.

LISTED MOTOR

Suction Tube

Hose

12’ x 3/4” I.D.

Inside of Pump

ATD-50012 is a 12V DC Pump

Rating is marked on the pump motor.

Pump uses an Explosion Proof motor & the motor is UL , cUL, ATEX & IECEx listed.

1

California Prop 65 WARNING:

Baeries contain lead and other chemicals known to the State of California to cause cancer, birth defects and other reproducve harm. Wash hands aer handling.

General Safety Warnings:

WARNING: The instrucons and warnings contained in this manual should be read and understood before using

or operang this tool. Do not allow anyone to use or operate this tool unl they have read this manual and have developed a thorough understanding of how this tool works. Failure to observe any of the following instrucons could result in severe personal injury to tool user and bystanders, or cause damage to the tool and property. Keep this manual for future reference.

Note: The warnings and cauons discussed in this instrucon manual cannot cover all possible condions and

situaons that may occur. It must be understood by the operator that common sense and cauon are factors which cannot be built into this product, but must be supplied by the operator.

WARNING: Use safety equipment. Users and bystanders should use safety goggles or safety glasses with side

shields which comply with current naonal standards, or when needed, a face shield. Use an ANSI approved dust mask or respirator when working around metal, wood, and chemical dusts and mists. This applies to all persons in the work area. Also use non-skid safety shoes, hardhat, gloves, dust collecon systems, and hearing protecon when appropriate.

WARNING: Keep bystanders and children out of the work area while operang this tool.

WARNING: Always keep your work area clean, uncluered, and well lit. Cluered or dark areas invite accidents

and injuries. DO NOT work on ﬂoor surfaces that are slippery.

WARNING: Do not operate this tool if you are red or under the inﬂuence of alcohol, drugs, or medicaons that

could aﬀect your ability to use the tool properly.

WARNING: Dress properly. Do not wear loose clothing or jewelery as they can be caught in moving parts. Wear

restricve hair covering to contain long hair.

WARNING: Do not reach over or across running machines. Keep proper foong and balance at all mes. Non-

skid footwear is recommended when working.

2

Lead Acid Baery Safety Warnings:

WARNING: The instrucons and warnings contained in this manual should be read and understood before using

or operang this tool. Do not allow anyone to use or operate this tool unl they have read this manual and have developed a thorough understanding of how this tool works. Failure to observe any of the following instrucons could result in severe personal injury to tool user and bystanders, or cause damage to the tool and property. Keep this manual for future reference.

CA Prop 65 WARNING:

Baeries contain lead and other chemicals known to the State of California to cause cancer, birth defects and other reproducve harm. Wash hands aer handling.

WARNING: WORKING AROUND LEAD-ACID BATTERIES MAY BE DANGEROUS.

• Lead-acid baeries release explosive gases during normal operaon, charging and jump starng.

• All lead-acid baeries (car, truck and boat) produce hydrogen gas which may violently explode in the presence of

ﬁre or sparks. Do not smoke, use matches or a cigaree lighter while near baeries. Only work with lead-acid baeries in a well-venlated area. Do not handle the baery while wearing vinyl clothing because stac

electricity sparks are generated when vinyl clothing is rubbed.

• To reduce risk of baery explosion, follow these instrucons and those published by the baery manufacturer and manufacturer of any equip on these products and on engine.

EYE PROTECTION:

• User and bystanders should always wear eye protecon, appropriate protecve clothing and other safety equipment when working near lead-acid baeries. Do not touch eyes while working on or around lead-acid baeries.

• IF SPLASHED WITH BATTERY ACID, IMMEDIATELY FLUSH AFFECTED AREA SUCH AS FACE AND PARTICULARLY THE EYES WITH CLEAN WATER. SEEK MEDICAL ATTENTION AND CONTINUE FLUSHING FACE AND EYES UNTIL MEDICAL HELP ARRIVES.

WORKING IN ENGINE COMPARTMENT:

• Use extreme cauon while working within the engine compartment, because moving parts may cause severe

Read and follow all safety instrucons published in the vehicle’s Owner’s Manual.

injury.

GENERAL PRECAUTIONS / PERSONAL PRECAUTIONS:

• Never work alone with lead-acid baeries. Make sure that someone is around to give assistance if you need help.

• Wear complete eye protecon and clothing protecon. Avoid touching eyes while working near baery.

• In case of baery acid contact with eyes, skin or clothing, always have soap and water near your work area.

• Remove jewelery such as rings, bracelets, necklaces and watches when working around a baery. A lead-acid

baery can produce a short circuit current, which can melt metals and result in a severe burn.

• Do not drop

• Never aempt to jump start a frozen baery.

tools or other metal objects on or near the baery as a spark may result, igning explosive gases.

ment you intend to use in the vicinity of the baery. Review cauonary markings

3

5

PUMP CONSTITUENTS

1

3

5

1. Pump & Motor Assembly

2. Nozzle Holder

3. Elbow

4. Suction Tube (2 parts)

5. Bung Nut

6. Hose Assembly (12’ Long x ¾” ID Anti Static Hose)

4

2

6

7. Fuel Control Nozzle

8. Power Cord complete with Fuse & Clamps

9. PTFE Tape

8

7

9

ELECTRICAL INSTALLATION - DC MOTORS

Cable systems and accessories should be installed in positions that prevent them from being subject to mechanical damage, corrosion, chemical attack, heat and other detrimental environmental conditions. Selection of the wiring system and cable type must consider these and where exposure to such conditions are avoidable, protective measures such as minimizing the risk of mechanical damage by the use of appropriate armoured cable types should be considered. Motor must be connected using a cable incorporating an earthing or equipotential bonding conductor. Filed wiring shall comply with requirement stated article 501 in National Electrical Code (NEC) for Class I, Division 1 Location.

ELECTRICAL DIAGRAM FOR DC MOTOR

RED

BLACK

+

-

MOTOR

RED

M

+

ON / OFF

TOGGLE SWITCH

BLACK

-

+

-

4

ASSEMBLY & INSTALLATION

Ensure tank / drum being used is clean & free of welding slag. Ensure the tank is vented to allow air into the tank as fuel is being pumped out. Failure to provide a vent will cause priming problems

1. Wrap around PTFE tape on the following male threaded joints. This will ensure a leak-proof connection

• Male Threads on the Elbow

• Male Threads on the Fitting ends of the Hose

• Male threads between the 2 Suction Tube parts

• Male threads on the Suction tube end that ts into the

pump inlet

2. Assemble the Nozzle Holder with the pump. In order to do so, open the 2 bolts on top of the On / O Switch. Remove the bolts & re-attach along with the nozzle holder

3. Now Fasten the Elbow into the

Elbow

Pump Outlet

pump outlet & hand tighten. Once you can no longer hand tighten, take a wrench & tighten the elbow by

about ½ a turn.

Pump Inlet

6. Connect the two halves of the Suction Tube. Suction tube is designed for use with tanks / drums which are 36” (914 mm) deep & has a total connected length of 34” (865 mm). In case you are installing the pump on a tank that is deeper, you would have to get a standard 1” dia. tube with 1” NPT threads on one end. Suction tubes longer than 5’ (1.52 m) require a foot valve (not provided) at the bottom of the tube to prevent loss of prime. For shallower drums, cut the suction tube to the desired length. Ensure that there is about 2” (50 mm) gap between the bottom of the tank/drum & inlet of the suction tube allowing for easy entry of fuel into the tube. Now connect the Suction Tube to the pump inlet. Hand tighten

7. Lift the Pump from the motor. Be careful as the assembly is heavy. Insert suction tube into the drum through the 2” opening on the drum. Use the Swivel Nut mounted at the pump inlet to fasten onto the Bung Nut. Hand tighten

4. Take the Bung Nut & fasten it onto the 2” opening on the Drum/ Tank. Bung Nut has a large 2” thread & a small 1-1/2” thread. 2” thread goes into the drum/ tank, whereas the 1-1/2” thread is for connecting bung to the pump

5. In case the Bung Nut does not t onto your drum/ tank, use a Drum Bung Converter. Note that bung supplied with the pump has 2” Pipe threads

8. Take the Fuel being dispensed & pour it into the pump outlet, until completely lled. This will ensure that the gear chamber stays lubricated & makes it easier for the pump to prime

9. Take the Hose Assembly & connect the threaded end onto the Elbow at the pump outlet. Hose has a hex nut at the threaded end which can be tightened to the elbow using a wrench

10. Connect the other end of the Hose to the Fuel Control Nozzle

11. Connect Power cord to source of power & switch it ON

5

12. The pump is now ready for use

PRIMING

All pump models using the supplied 34” (865mm) suction tube should prime within 10 seconds after pump is turned on. Pumps installed at a height upto 5’ (1.52 m) may have diculty in priming. Follow the procedure below to initiate priming. Pumps installed at a suction height above 5’ (1.52m) may have diculty in holding prime. It is recommended that a foot valve with ball check (not supplied with the pump) be added to the bottom of the suction tube to maintain prime

1. Remove the Elbow from the pump outlet

2. Pour fuel being pumped into the pump outlet until completely

lled

3. Re-assemble the Elbow back into the pump outlet & turn the

pump on. Pump should get primed in less than 10 seconds

4. If pump still does not gain prime, check for any major leaks

in the system. If no leaks are found , then the pump is mechanically defective & should be reported back to your Distributor

PUMP OPERATION

4. In less than 10 seconds, the pump will be primed & fuel will start dispensing from the Nozzle

5. Dispensing Action can be stopped by closing the Nozzle, with the pump still ON. This however must not be done for more than 5 minutes. DO NOT operate the pump for more than 30

minutes continuously in 1 hour

6. It is best practice to Switch Lever in the OFF position to stop dispensing

7. The pump must never be run dry (no media in the drum) as

that can possibly cause irreparable damage to the motor

8. Once Dispensing is completed, switch o the Lever & disconnect power supply to the pump

9. Store the Nozzle Back into the Nozzle Holder

WARNING

Do not use curb pump auto nozzle with this pump. Contact your distributor for auto nozzles for use with electric fuel pumps

MAINTENANCE

1. Clean Inlet Strainer after every 50 hours of operation

2. Inlet strainer is easily accessible without having to disassemble the pump. Strainer is installed just above the pump inlet & can be accessed by removing the 4 bolts on the side of the pump holding the Strainer cover

1. Remove Nozzle from the Nozzle Holder. The On\ O switch can be Switched ON only once the nozzle is removed from the nozzle holder

2. Nozzle should be facing the container into which Fuel is to be dispensed

3. Pump On/O Switch Lever is located under the nozzle holder. Move switch lever ON & simultaneously open the Nozzle

OFF

ON

Pump in ON Position

3. Remove & clean strainer

4. If strainer is excessively dirty, clean tank to protect pump and the equipment being fuelled

5. After cleaning strainer, replace strainer & cover. Make sure cover seal is in place

Strainer

6

PARTS DRAWING FOR ATD-50012 (FPM-12)

PUMP ASSEMBLY

22

23

4

19

18

20

17

7

8

10

11

16

15A

21

15

12

13

14

24

29

32

34

36

27

31

25

26

28

30

33

35

1

2

3

4

6

5

9

HOSE, SUCTION TUBE, POWER CABLE & FUEL CONTROL NOZZLE ASSEMBLY

37

38 39

40

41

42 43

7

PARTS LIST FOR ATD-50012 (FPM-12)

1

ITEM# ORDERING PART# MFG PART# DESCRIPTION QTY

PRT50012-01 TFB/M4/10/FPM/12 THREAD FORMING BOLT M4

01

PRT50012-02 CVR/STNR/FPM/12 COVER (STRAINER)

02

PRT50012-03-16 FPM/KIT/SK SEAL KIT (INCLUDED 3, 7, 15 & 16)

03

ATD-50005 SVE/FPM/12 STRAINER

04

PRT50012-05 TFB/M8/FPM/12 THREAD FORMING BOLT M8

05

PRT50012-06 CVR/HSG/FPM/12 HOUSING COVER

06

PRT50012-03-16 FPM/KIT/SK SEAL KIT (INCLUDES 3, 7, 15 & 16)

07

PRT50012-08-09 FPM/KIT/GK

08

PRT50012-08-09 FPM/KIT/GK GEAR KIT (INCLUDES 8 & 9)

09

PRT50012-10 SFT/GEAR/FPM/12 SHAFT (GEAR)

10

PRT50012-11 HSG/FPM/12 HOUSING (MACHINED)

11

PRT50012-12 FTNG/BNG/FPM/12 FITTING (BUNG)

12

PRT50012-13 NUT/BNG/FPM/12 SWIVEL NUT

13

PRT50012-14 ADP/BNG/FPM/12 BUNG ADAPTOR

14

PRT50012-03-16 FPM/KIT/SK SEAL KIT (INCLUDED 3, 7, 15 & 16)

15

15A

PRT50012-15 CCL/FPM CIRCLIP

PRT50012-03-16 FPM/KIT/SK S

16

PRT50012-17 VLV/FPM/12 BYPASS VALVE

17

PRT50012-18 SPR/VLV/FPM/12 SPRING (BYPASS VALVE)

18

PRT50012-19 EW/3-4/N/FPM/12 ELBOW

19

PRT50012-20 ASCR/M6/FPM/12 THREAD FORMING BOLT M6

20

PRT50012-21 MOT/FPM/12 MOTOR, 12V DC

21

PRT50012-22 TFB/M8/FPM/12

22

N/A N/A ELECTRICAL COVER

23

N/A N/A DRIVE SCREW U TYPE

24

N/A N/A LABEL

25

N/A N/A ELECTRICAL HOUSING (M/C)

26

PRT50012-27

27