TP91300

TP91300
INSTRUCTIONS FOR:
PORTABLE DIESEL / FLUID TRANSFER PUMP
AND FLOW METER
MODELS: TP91224 AND TP91300
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions
and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND CAUTIONS.
USE THIS PRODUCT CORRECTLY AND ONLY FOR ITS INTENDED PURPOSE. FAILURE TO DO SO MAY CAUSE DAMAGE
AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
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2.
SAFETY INSTRUCTIONS
Maintain the pump and meter in good condition (use an authorised service agent).
Replace or repair damaged parts. Use recommended parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
Keep the pump and meter clean for the safest and best performance.
Ensure the power supply (vehicle battery) corresponds with the requirements of the pump, 12V or 24V DC power supply.
Ensure that there is more liquid in the suction tank than will be pumped.
Ensure that the capacity of the receiving tank is sufficient to hold the pumped fuel.
Ensure that the fuel filter is securely attached to the pick up pipe at all times so that unfiltered fuel is not taken through the pump or meter.
Wear safety goggles and gloves, and protective clothing when working around fuel. A full range of personal safety equipment is available
from your local Sealey dealer.
Use the pump and meter in a suitable work area. Keep area clean and tidy and free from unrelated materials and ensure there is adequate lighting.
Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
Keep children and unauthorised persons away from the work area.
Disconnect from power source when not in use.
DO NOT ‘dry run’ the pump without fuel. This will damage internal components and will invalidate your warranty.
DO NOT operate the pump continuously for more than 30 minutes at 12 Volt or 10 minutes at 24 Volt. after which the motor must be left to cool down.
DO NOT run the pump for more than 2 minutes with the delivery nozzle closed.
DO NOT start or stop the pump by connecting or disconnecting the battery clamps.
DO NOT operate the pump with wet hands.
DO NOT use the pump where explosive or flammable vapours may be present.
DO NOT tamper with the pump connections.
DO NOT leave the unit working unsupervised as there is the potential for spillage.
WARNING! DO NOT use the unit to pump the following fluids:
Petrol, flammable liquids with Flashpoint <55°C, water, liquids with viscosity >20 cSt, corrosive chemicals and solvents.
TP91224 - INTRODUCTION AND CONTENTS
Electric, dual voltage, 12/24 Volt pump kit with battery clips. High flow pump unit with bypass valve, suitable for filling diesel vehicles on site. Includes
integrated On/Off switch, delivery hose with manual delivery nozzle, suction hose and filter.
A
B
C
D
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
TP91224 Accessories
Filling Nozzle
Meter Outlet Connector
Fuel Filter
Inlet/Outlet Connector (2)
Jubilee Clips (4)
3 Metre Hose (not shown)
PREPARATION & ASSEMBLY
Before using the pump, unpack all materials and inspect the pump unit for damage.
Connect the unit to appropriate voltage battery and ensure the motor will run up freely for a few seconds, this can be done before connecting hoses.
Attach the two C connectors supplied, to the inlet and outlet ports of the pump making sure that the O rings seat properly into each port (see fig.1 overleaf).
The hose is supplied in one 3 Metre length for both inlet and outlet purposes. Cut the hose to desired length, 1 Metre length for suction and 2 Metre
length for delivery is standard.
Fit suction hose to the C connector securing with jubilee clip supplied. Before the delivery hose can be attached to the outlet port, the pump must
be partially filled with diesel fuel to aid the priming process (see 4.3 overleaf).
Attach the filter to the other end of the suction hose and secure.
Attach the delivery nozzle to the other end of the delivery hose and secure.
TP91224 TP91300 - 1 - 281005
TP91300 accessories
A Meter Outlet Connector
E Convertor
F Pump Outlet Connector
If Flow Meter TP91300 (optional extra) is being used in conjunction with this pump it should be attached to the outlet port (see fig.2) using the supplied
connectors as follows.
3.8
3.9
3.10
3.11
Attach a C connector to the inlet port and connect suction hose using a jubilee clip.
Attach the F connector to the outlet port and then connect E connector onto the F connector.(see fig.3)
The flow meter screws directly onto the E connector.
Fit the A connector into the outlet port of the flow meter (not shown), and then the delivery hose should be attached to this, securing it with a jubilee
clip. Make sure all O rings have seated correctly and all joints are secure, but do not overtighten.
Fig.2
Fig.3
Fig.1
4.
USING THE APPLIANCE
4.1 Before each use, clean the inlet and outlet ports. Remove any dust or packing material that may have collected during transport or between uses.
4.2 PRIMING THE PUMP.
4.2.1 Lower the suction hose (with filter attached) into the fuel storage tank. Ensure the pump is no more than 2mtr higher than the end of the suction
hose during the priming phase. During normal running, this distance may be increased to a maximum of 3mtr.
4.2.2 Before first use partially fill the pump body with diesel fuel to aid the priming process, then connect the delivery hose.
4.2.3 If using an automatic delivery nozzle, it is recommended that you remove this while the pump is priming.
4.2.4 Connect the black clamp to the negative (-) terminal of battery, and the red battery clamp to the positive (+) terminal. Note that pump will run on
12 or 24 Volt battery supply without any adjustment.
4.2.5 The priming phase may last from several seconds to a few minutes, depending on conditions. Should this phase appear to be prolonged, stop the pump
and check the points listed in section 6.2.
Note:The foot valve incorporated in the suction filter ensures that the suction hose does not empty back into the tank and therefore
eliminates the need to repeat the priming of the pump each time it is used. However, should the suction hose be allowed to empty, it
will again be necessary to prime the pump before use. Failure to do so could cause damage to the pump.
4.3. NORMAL USE.
4.3.1 Place the delivery nozzle in the fuel tank of the vehicle.
4.3.2 Attach the black clamp to the negative (-) terminal of the vehicle’s battery, and the red battery clamp to the positive (+) terminal.
4.3.3 Before turning the pump on, be sure that the delivery nozzle is in the ‘OFF’ position.
4.3.4 Move the switch lever to the ‘ON’ position. The pump is capable of operating in bypass mode with the delivery nozzle closed for only 2-3 minutes
maximum.
p IMPORTANT: do not leave the pump in bypass mode longer than 2-3 minutes otherwise it will overheat and damage the pump.
4.3.5 Grip the nozzle firmly and squeeze the trigger to begin transferring fuel. The nozzle has a locking device so that the user can let go of the trigger
during pumping, but the unit should never be left to run unsupervised as there is the danger of fuel spillage.
4.3.6 Release the trigger to stop the fuel flow when the transfer is complete, (with an automatic delivery nozzle, simply turn the pump switch to ‘Off’).
4.3.7 Turn the pump switch ‘Off’.
The fuel pump may switch off automatically if there is insufficient voltage or a fault in the electrical connection. If this happens, release the
trigger handle, keeping the nozzle in place, and turn the pump switch ‘Off’. Investigate the cause of the interruption.
5.
PERFORMANCE
Model TP91224
Speed
Current
Power
Duty Cycle
Flow Rate
12V
1400rpm
15A
180W
30min/hr
40ltr/min
24V
2400rpm
17A
400W
10min/hr
60ltr/min
Environmental conditions:
Temperature: -20ºC / +40ºC Max Relative Humidity: 90%
TP91224 TP91300 - 1 - 281005
6.
6.1
TROUBLE SHOOTING
PROBLEM
The motor is not turning
The motor turns slowly
when starting
Low or no flow rate
POSSIBLE CAUSE
Lack of electrical power
Rotor jammed
Motor problems
Power supply is of insufficient voltage
Low level in source tank
Foot valve blocked
Filter clogged
Excessive suction pressure
High loss of head in the delivery circuit
(working with the bypass open)
Bypass valve blocked
Air entering the pump or the suction hose
A narrowing in the suction tubing
Low rotation speed
Increased pump noise
Leakage from the pump
body
The suction tubing is resting at the bottom
of the tank
Cavitation occurring
Irregular functioning of the bypass
Air present in the diesel fuel
Seal damaged
SOLUTION
Check all electrical connections and battery’s state of charge.
Check for possible damage or obstruction of the rotating
components
Contact your authorised Sealey dealer
Increase voltage
Refill the tank
Clean and or replace the valve
Clean the filter
Lower the pump with respect to the level of fluid in the tank, or
increase the bore of the tubing
Use shorter tubing or increase the bore.
Dismantle the valve and clean or replace it
Check seals and connections
Use tubing suited to the pressures involved
Check the voltage at the pump. Adjust voltage and/or use cable
of greater cross section
Raise the tubing
Reduce suction pressure
Dispense fuel until the air is purged from the bypass system
Verify the suction connections
Check and replace the offending seal
6.2. The priming phase may last from several seconds to a few minutes, dependant on conditions. Should this phase appear to be prolonged,
stop the pump and check the following:
That the pump is not running completely dry (see section 4.2 on priming the pump)
That the suction hose is not allowing air in
That the filter is not clogged
That the difference in height between the pump and the end of the suction hose is not more than 2 metres
That the delivery hose is allowing the evacuation of air
6.3. When priming has occurred, ensure that the pump is operating as anticipated.
7.
7.1
7.2
7.3
7.4
MAINTENANCE
Check the pump casing, suction and delivery hoses regularly for leaks.
Keep the pump clean for easy detection of leaks.
Remove and clean the filter every 10 hours of operation or sooner if the transfer flow begins to decrease.
Dispose of environmentally hazardous parts in the proper manner.
TP91224 TP91300 - 1 - 281005
8.
TP91300 DETAILS
Volumetric oscillating disc meter with three digit resettable display and six digit total display. Unique filter and flange assembly allows meter to be
positioned in four configurations. Suitable for use with TP91224 and TP955.
Specifications
Working pressure
Operating Temp.
Precision
Flow Rate
Partial Indicator
Total indicator
Resolution
Weight
0.1 - 3.5 Bar
-10 to +50ºC
+/- 1%
20 - 80 ltr/min
max 999 ltr
max 999999 ltr
0.1 ltr
1.5kg
8.1 INSTALLATION
See Section 3 for connecting directly to TP91224 pump.
The two directional arrows on the rear of the meter indicate the direction the flow of liquid must follow. If required the inlet/outlet can be rotated.
8.1.1 Slide the reset knob from its shaft.
8.1.2 Undo both small crosshead screws at the sides of the plastic body.
8.1.3 Undo the four allen headed bolts at the back of the meter (fig.1) - prise off the back of the meter and rotate through 180°.
8.1.4 Reassemble in the reverse order of the above.
The meter can be used in both gravitational systems and circuits with motor pumps or manual circuits equipped with a by-pass. Following installation and
setting, the meter is ready for use. To reset the partial counter to zero, rotate the reset knob clockwise.
Constructed for operation at a maximum pressure of 3.5 bar (50 PSI), the meter must be mounted in such way that no unfiltered liquid or air is pumped
through it. In the case of gravitational systems (without pumps), there must be a difference in height of at least 1 metre between the outlet of the tank and
the delivery gun to ensure optimum operation.
8.2 RESETTING
The meter has been set at the factory to a pressure of 1.5 bar (21 PSI) whilst transferring Diesel oil. As the operating pressure is a fundamental factor for
the measurement mechanism, it is recommended that the meter is reset every time different pressures and/or liquids are used. The meter must also be
reset every time it is disassembled for maintenance.
8.2.1 Unscrew the setting plug (screw A in fig. 2).
8.2.2 Start the pump by connecting to a battery then stop the flow of liquid by closing the delivery gun without stopping the pump.
8.2.3 Set the partial indicator to zero.
8.2.4 Perform the delivery at the flow rate for which the precision is required by transferring it into a container calibrated for no less than 20 litres.
8.2.5 Compare the value indicated on the partial/total counter with the volume in the container (the real value).
8.2.6 Turn the adjustment screw (B in fig.2) clockwise if the value is lower and counter-clockwise if the value is higher.
8.2.7 Repeat operation 4 until the measurement is satisfactory.
8.2.8 Screw the setting plug (screw A) back into place.
PROBLEM
Unsatisfactory precision
Low flow
POSSIBLE CAUSE
SOLUTION
Presence of air in liquid
Identify and eliminate leaks in
suction lines or add foot valve
Measurement chamber dirty or clogged
Clean measurement chamber
Filter dirty or clogged
Clean filter
Incorrect setting
Measurement chamber dirty or clogged
Reset (see above)
Clean measurement chamber
9 . DECLARATION OF CONFORMITY
Declaration of Conformity
We, the sole importer into the UK, declare that the products listed below are in conformity with the following standards and directives
Diesel/Fluid Transfer Pump - Model TP91224
73/23/EEC Low Voltage Directive
89/336/EEC EMC Directive
93/68/EEC CE Marking Directive
Flow Meter - Model TP91300
98/37/EC Machinery Directive 93/68/EEC CE Marking Directive
Signed by Mark Sweetman
28 October 2005
For Jack Sealey Ltd. Sole importer into the UK of Sealey Power Products.
The construction files for these products are held by the Manufacturer and may be inspected
on request by contacting Jack Sealey Ltd.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our catalogue and latest promotions call us on 01284 757525 and leave your full name, address and postcode.
Sole UK Distributor
Sealey Group,
Bury St. Edmunds, Suffolk.
01284 757500
01284 703534
Web
email
www.sealey.co.uk
[email protected]
TP91224 TP 91300 - 1 - 281005
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