INSTRUCTION MANUAL

ATD-50012

Electric Fuel Pump

(FPM-12)

S1590, Rev B

LISTED MOTOR

Congratulations on purchase of this World Class Electric Fuel Pump!

Elbow

Nozzle

Holder

Pad Lock

Lever

Fuel

Control

Nozzle

Pump

Outlet

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.

Swivel

Nut

OFF

ON

Motor

Switch

Suction Tube

Hose

12’ x 3/4” I.D.

1

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.

California Prop 65 WARNING:

Batteries contain lead and other chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling.

General Safety Warnings:

WARNING:

The instructions and warnings contained in this manual should be read and understood before using or operating this tool. Do not allow anyone to use or operate this tool until they have read this manual and have developed a thorough understanding of how this tool works. Failure to observe any of the following instructions 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 cautions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution 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 national 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 collection systems, and hearing protection when appropriate.

WARNING:

Keep bystanders and children out of the work area while operating this tool.

WARNING:

Always keep your work area clean, uncluttered, and well lit. Cluttered 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 tired or under the influence of alcohol, drugs, or medications 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 restrictive hair covering to contain long hair.

WARNING:

Do not reach over or across running machines. Keep proper footing and balance at all times. Nonskid footwear is recommended when working.

2

Lead Acid Battery Safety Warnings:

WARNING:

The instructions and warnings contained in this manual should be read and understood before using or operating this tool. Do not allow anyone to use or operate this tool until they have read this manual and have developed a thorough understanding of how this tool works. Failure to observe any of the following instructions 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:

Batteries contain lead and other chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling.

WARNING:

WORKING AROUND LEAD-ACID BATTERIES MAY BE DANGEROUS.

• Lead-acid batteries release explosive gases during normal operation, charging and jump starting.

• All lead-acid batteries (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 cigarette lighter while near batteries. Only work with lead-acid batteries in a well-ventilated area. Do not handle the battery while wearing vinyl clothing because static electricity sparks are generated when vinyl clothing is rubbed.

• To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary markings on these products and on engine.

EYE PROTECTION:

• User and bystanders should always wear eye protection, appropriate protective clothing and other safety equipment when working near lead-acid batteries. Do not touch eyes while working on or around lead-acid batteries.

• 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 caution while working within the engine compartment, because moving parts may cause severe injury. Read and follow all safety instructions published in the vehicle’s Owner’s Manual.

GENERAL PRECAUTIONS / PERSONAL PRECAUTIONS:

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

• Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.

• In case of battery 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 battery. A lead-acid battery can produce a short circuit current, which can melt metals and result in a severe burn.

• Do not drop tools or other metal objects on or near the battery as a spark may result, igniting explosive gases.

• Never attempt to jump start a frozen battery.

3

PUMP CONSTITUENTS

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)

7. Fuel Control Nozzle

8. Power Cord complete with Fuse & Clamps

9. PTFE Tape

4

1

2

5

3 5

6

9

5

8

7

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

M

RED

+

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 fits 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 / Off Switch.

Remove the bolts

& re-attach along with the nozzle holder

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

3. Now Fasten the

Elbow into the pump outlet & hand tighten. Once you can no longer hand tighten, take a wrench & tighten the elbow by about ½ a turn.

Elbow Pump Outlet

Pump Inlet

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

8. Take the Fuel being dispensed & pour it into the pump outlet, until completely filled. 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

5. In case the Bung Nut does not fit onto your drum/ tank, use a

Drum Bung Converter. Note that bung supplied with the pump has 2” Pipe threads

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

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

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 difficulty in priming. Follow the procedure below to initiate priming. Pumps installed at a suction height above 5’ (1.52m) may have difficulty 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 filled

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

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 off 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

3. Remove & clean strainer

1. Remove Nozzle from the Nozzle

Holder. The On\

Off switch can be

Switched ON only once the nozzle is removed from the nozzle holder

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

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

3. Pump On/Off

Switch Lever is located under the nozzle holder. Move switch lever ON & simultaneously open the Nozzle

OFF

ON

Pump in ON Position

6

Strainer

PARTS DRAWING FOR ATD-50012

(FPM-12)

PUMP ASSEMBLY

22

23

4

24

7 8 10 11

19

18

17

16

15A

20 21

15

12

13

14

1 2 3 4 5 6 9

29

32

34

36

37

27

31

28

30

33

35

25

26

38 39

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

40

41

42 43

7

PARTS LIST FOR ATD-50012

(FPM-12)

ITEM# ORDERING PART# MFG PART#

01

02

PRT50012-01

PRT50012-02

DESCRIPTION

TFB/M4/10/FPM/12 THREAD FORMING BOLT M4

CVR/STNR/FPM/12 COVER (STRAINER)

03

04

PRT50012-03-16

ATD-50005

FPM/KIT/SK

SVE/FPM/12

SEAL KIT (INCLUDED 3, 7, 15 & 16)

STRAINER

05

06

PRT50012-05

PRT50012-06

PRT50012-03-16

TFB/M8/FPM/12

CVR/HSG/FPM/12

FPM/KIT/SK

THREAD FORMING BOLT M8

HOUSING COVER

SEAL KIT (INCLUDES 3, 7, 15 & 16)

07

08

09

PRT50012-08-09

PRT50012-08-09

FPM/KIT/GK

FPM/KIT/GK

GEAR KIT (INCLUDES 8 & 9)

GEAR KIT (INCLUDES 8 & 9)

10

11

PRT50012-10

PRT50012-11

SFT/GEAR/FPM/12 SHAFT (GEAR)

HSG/FPM/12 HOUSING (MACHINED)

12

13

PRT50012-12

PRT50012-13

FTNG/BNG/FPM/12 FITTING (BUNG)

NUT/BNG/FPM/12 SWIVEL NUT

14

15

PRT50012-14

PRT50012-03-16

ADP/BNG/FPM/12

FPM/KIT/SK

BUNG ADAPTOR

SEAL KIT (INCLUDED 3, 7, 15 & 16)

15A

16

PRT50012-15

PRT50012-03-16

CCL/FPM

FPM/KIT/SK

CIRCLIP

SEAL KIT (INCLUDED 3, 7, 15 & 16)

17

18

PRT50012-17

PRT50012-18

PRT50012-19

VLV/FPM/12

SPR/VLV/FPM/12

EW/3-4/N/FPM/12

BYPASS VALVE

SPRING (BYPASS VALVE)

ELBOW

19

20

21

22

23

PRT50012-20

PRT50012-21

PRT50012-22

N/A

ASCR/M6/FPM/12

MOT/FPM/12

TFB/M8/FPM/12

N/A

THREAD FORMING BOLT M6

MOTOR, 12V DC

THREAD FORMING BOLT

ELECTRICAL COVER

M4

24

25

N/A

N/A

N/A

N/A

DRIVE SCREW U TYPE

LABEL

26

27

N/A

PRT50012-27-39

N/A

FPM/KIT/SA/DC

ELECTRICAL HOUSING (M/C)

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

28

29

PRT50012-27-39

PRT50012-27-39

FPM/KIT/SA/DC

FPM/KIT/SA/DC

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

30

31

PRT50012-27-39

PRT50012-27-39

FPM/KIT/SA/DC

FPM/KIT/SA/DC

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

32

33

PRT50012-27-39

PRT50012-27-39

PRT50012-34

FPM/KIT/SA/DC

FPM/KIT/SA/DC

SWITCH ASSEMBLY KIT FOR DC PUMPS

SWITCH ASSEMBLY KIT FOR DC PUMPS

TFB/M6/25/FPM/12 THREAD FORMING BOLT M6

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

34

35

36

PRT50012-27-39

PRT50012-27-39

FPM/KIT/SA/DC

FPM/KIT/SA/DC

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

37

38

PRT50012-27-39

PRT50012-27-39

FPM/KIT/SA/DC

FPM/KIT/SA/DC

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

39

40

PRT50012-27-39

PRT50012-40

FPM/KIT/SA/DC

FPM/2R/N

SWITCH ASSEMBLY KIT FOR DC PUMPS

( INC LUDES 27, 28, 29, 30, 31, 32, 33, 35, 36, 37, 38 & 39)

SUCTION TUBE

41

42

PRT50012-41

ATD-50007

SA/HOS/FPM/12

SA/FCN/S/3-4/FPM/N

HOSE ASSEMBLY

MANUAL FUEL CONTROL NOZZLE

43 PRT50012-43 FPM/KIT/PC POWER CABLE ASSY KIT

Optional Accessories Available (Not Shown On Parts List):

ATD-50002 - Fuel Tank Filter and Replacement Elements

ATD-50003 - 10 micron filter element for above

ATD-50004 - 10 micron water block filter element for above

ATD-50008 - Automatic Fuel Control Nozzle

8

1

1

1

1

1

1

1

4

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

9

1

1

1

1

1

1

1

1

1

2

1

1

2

1

4

QTY

4

1

1

ATD-50012

(FPM-12)

PUMP SPECIFICATION

Description

Flow Rate*

Explosion Proof

Motor

Amp draw from

Battery

Internal Bypass

Valve

Suction Pipe

Hose

ATD-50012 (FPM-12)

Heavy Duty 12V DC

Up to 15 GPM

(57 LPM)

1/7 HP

12V DC

12 Amp

Yes

2 pc threaded

¾” x 12’

Anti Static Hose

2” Threaded

Tank Adaptor

Inlet

Outlet

Dispensing Nozzle

1” NPT

¾” NPT

¾” Manual with Swivel

Battery Cable

(2 wire)

15’

* measured in lab conditions at pump outlet using Diesel with vehicle engine switched on

WETTED COMPONENTS

Aluminium, Steel, Cast Iron, Nylon, NBR, Zinc, Viton, Polypropylene

RECOMMENDED USE

Gasoline, Diesel, E15 Fuel, Kerosene, Bio Diesel (B20)

9

ATD-50012

(FPM-12)

TROUBLESHOOTING

PROBLEM CAUSE

Motor rotation wrong.

Motor runs but pump will not prime

Missing relief valve o-ring seal (16)

Sheared drive key (9)

Dirt under by-pass valve (17) or seal (16)

Strainer seal (3) leaking

Suction height too high to prime

Worn or damaged gears (8)

Fuel level low

Cover seal (7) damaged

Inlet strainer (4) clogged

Air leak in suction tube (40)

Air lock in system

SOLUTION

Check wiring instructions for possible problems

Remove gear cover (6), inspect seal, replace if missing or damaged

Remove cover (6) and inspect key, replace if worn or sheared

Remove cover (6) and inspect, clean or replace if damaged

Inspect and replace if damaged

See Priming Pump, page 5

Remove cover (6) and inspect gears. Replace if worn or damaged

R

Replace if worn or damaged

Remove and clean or replace

Inspect all joints in suction tube. Make sure all joints in suction tube are sealed and that there are no cracks from over-tightening

-

Unit pumps but

Motor stalls when nozzle is closed

Fuel leaking in motor mount

Motor overheating

Switch will not turn pump on

Motor does not run at proper speed

Curb Pump Auto Nozzle used

Clogged inlet strainer (4)

Check electric connections. Check supply voltage for proper voltage level

Change to Auto Nozzle for use with Electric Fuel Pumps

Clean or replace

Air leak in suction tube (40) Check to make sure all joints in suction tube are sealed and that there are no cracks

Suction tube (40) too close to tank bottom Suction tube must have a 2 in. (50 mm) minimum clearance

Tank empty R

Tank not vented

Worn or damaged gears (8)

Damaged motor (21)

Clogged suction tube (40), hose (41) or nozzle (42)

Curb Pump Auto Nozzle used

Bypass relief valve (17) stuck

Low supply voltage

Tank must be vented to atmosphere

Remove cover (6) and inspect gears. Replace if worn or damaged

Replace motor

Inspect and clean

Change to Auto Nozzle for use with Electric Fuel Pumps

Inspect relief valve, making sure poppet is free. Replace if damaged

Check supply voltage

Gears (8) damaged and binding

Faulty motor (21)

Faulty or damaged motor shaft seal (15)

Operating pump extended time with nozzle closed

Motor shaft worn

Gears (8) binding

Inspect gears. Gears should turn freely. Replace if damaged

Replace motor

Replace shaft seal

Do not exceed 5 minutes of operation with nozzle closed

Clogged inlet strainer (4)

Clogged suction tube (40), hose (41) or nozzle (42)

Replace motor if shaft has worn in seal area

Check to make sure gears turn freely on shaft

Operating pump extended time with nozzle closed

Do not exceed 5 minutes of operation with nozzle closed

Clean or replace, see Maintenance, page 5

Inspect and clean if required

Limit operation to 30 minutes per hour Operating pump more than 30 minutes continuous duty

Blown fuse

Electrical problem

Defective switch (27)

Mechanical problem

Damaged or defective motor (21)

Replace fuse. 30 amp automotive fuse

Check that supply voltage is proper and getting to pump

Check and replace if defective

Check switch actuator cam. Cam should be actuating the switch

Check motor, replace if damaged or defective

10