Harbor Freight Tools 98135 User's Manual
Contents
1. have replaced or repaired by qualified technician Pump may need to rest 5 minutes after every 5 minutes of pumping Remove and clean Screen 25 Remove and clean Suction Pipe 58 and or Suction Pipe Extension 59 Replace Armature 3 Have Motor repaired by a qualified technician Check incoming power source Check Line Switch 17 Have repaired by qualified technician Check Thermal Protector 8 and fuse and replace if needed with identical part by qualified technician Check all O Rings and Gaskets See Parts List on page 12 of this manual 2 Clean seal and seal cavity Replace seal with identical part 4 Refer to Specification Chart on page 3 of this manual Follow all safety precautions whenever diagnosing or servicing the pump Disconnect power supply before service by qualified technician only PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYE2. qualified technician TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn OFF the power to the Fuel Transfer Pump before any inspection or maintenance is performed TO PREVENT SERIOUS INJURY FROM PUMP FAILURE Do not use damaged equipment If abnormal noise vibration or leakage occurs have the problem corrected before further use A Cleaning Maintenance and Lubrication BEFORE EACH USE inspect the general condition of the Pump Check for loose screws loose or bro ken electrical wiring and any other condition that may affect its safe operation Maintain labels and nameplates on the pump These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement AFTER USE clean external surfaces of the Pump with clean cloth 4 For technical questions please call 1 800 444 3353 To keep Fuel Transfer Pump running at its best flush with diesel fuel if it is to be stored for long periods of time Remove and clean Screen 25 after every 20 hours of continuous opera tion Cleaning frequency depends on the type and cleanliness of fluids being pumped For safety reasons service and main tenance should be performed regu larly by a qualified technician Page 9 Pump will not prime Pump hums but will not operate Low Capacity Pump runs slowly Troubleshooting Possible Causes Likely Solutions Suction Pipe 58 leak Bypass Val
3. 800 444 3353 Page 13 LIMITED 1 YEAR 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that for a period of one year from date of purchase that the tank is free of defects in materials and work manship 90 days if used by a professional contractor or if used as rental equipment Harbor Freight Tools also warrants to the original purchaser for a period of ninety days from date of purchase that all other parts and components of the product are free from defects in materials and workmanship This warranty does not apply to damage due di rectly or indirectly to misuse abuse negligence or accidents repairs or alterations out side our facilities normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limita tion of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the com plaint
4. the end of this manual Assembly Note Use a gasoline and oil proof pipe compound not supplied on all joints Thread male end of Steel Elbow 39 into the Pump Housing 1 Tighten securely at this point Thread end of Hose 55 into female end of Steel Elbow 39 DO NOT tighten securely Thread Nozzle 54 to Hose 55 DO NOT tighten securely After making sure connections will fit remove parts attached in step two and three until after Fuel Transfer Pump has been installed on tank barrel or drum When installed at tach parts as in steps two and three Wrench tighten all connections Functions This Fuel Transfer Pump is com patible and may be used with the following fluids Diesel Kerosene light weight oils water and anti freeze This Pump IS NOT compat ible with and should NEVER be used to pump Acetone Gasoline Ammonia Lacquer Thinner Ben zene Bleach Hydrochloric Acid Ink or Toluene NOTE No other fluids should be used but the incom patible fluids listed above can be especially dangerous Not for use with fluids that have a flashpoint below 100 F 38 C Once used with a specific type of fluid continue to use ONLY that fluid with this Pump except for diesel flushing for storage Using another fluid may lead to contamination or reaction between the fluids General Installation and Connection Instructions Keep work area clean and well lit Cluttered or dark areas in
5. the outer insulation cover 10 ing the Cable 60 being careful not to damage the wire insulation Pass the stripped end of the Cable 60 through the Cable Connector 53 until 2 of the unstripped wire is within the Motor Casing Assembly 6 Strip 1 2 of the insulation from the ends of the Cable 60 Connect these wires to the matching colored Pump Wires using wire nuts not sup plied T Fold all wires into the Motor Casing assembly 6 and replace the Junc tion Box Cover 18 Make sure all screws are seated so there is no space between the Junction Box Cover 18 and the Motor Casing As sembly 6 Run the Cable 60 to the 12 Volt DC battery or similar power source Support the Cable 60 as necessary and protect it from heat sharp edges or any other obstacle that could dam age it Strip the outer Cable 60 covering as necessary Make a secure con nection to the tank barrel drum or vehicle with the Ground Wire 51 NOTE To determine if a vehicle system is negative or positive check the battery marking of the terminal that is wired to the vehicles frame or motor block For vehicles with negative ground connect the negative black wire to the vehicle frame For vehicles with positive ground connect the positive red wire to the ve hicle frame For technical questions please call 1 800 444 3353 If attaching to a vehicle attach one end of a 30 amp fuse holder to th
6. R THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 98135 For technical questions please call 1 800 444 3353 Page 11 PARTS LIST Q ty 1 Pump Housing 2 Ball Bearing 3 Armature Assembly 4 Motor Frame Magnet Assembly 3 2 2 EE 5 1420x6 Tin Bot 7 Swich Plate with Bushing 7 Brush Holder Assembly 2 4832 X16 Star Screw 2 Bypass Spring 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 3 0 1 3 4 5 6 7 8 9 0 2 3 4 5 6 7 8 9 0 SKU 98135 For technical questions please call 1 800 444 3353 PARTS LIST Q Bypass Cap 1 4 20 X 3 4 HHCS Rotor Key D 0 gt O 5 Rotor Cover Gasket Seal Assembly Steel Elbow 5 16 18 X 3 4 HHCS f 2 10 24 X 50 Star Screw 4 4 2 f ty 1 5 1 1 1 1 2 1 1 1 1 1 1 1 1 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 49 51 52 53 54 55 56 57 58 59 Page 12 ASSEMBLY DIAGRAM Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98135 For technical questions please call 1
7. e end of the remaining wire Connect the other end of the fuse holder to the ungrounded side of the power source The battery terminal or the end of the battery cable is recom mended Check all connections to make sure they are correct Install the 30 amp fuse in the fuse holder Page 7 OPERATION AWARNING This Fuel Transfer Pump must be set up according to all Installation and Connection information on pages 6 thru 8 of this manual To reduce build up of static electricity and possible fire and or explosion do not wear synthetic fibers while using this Fuel Transfer Pump 1 Maintain nozzle contact with neck of container being filled to reduce static electricity buildup 2 On initial start up it may be necessary to hold the Nozzle 54 open a few seconds to allow pump to prime 3 Remove Nozzle 54 from Pump and insert into neck of tank barrel drum or fuel cell 4 Begin fueling by squeezing lever on nozzle 54 5 WARNING The Pump Motor is equipped with thermal overload protection If overheated it will shut itself off without any damage to the electrical system Be sure to turn off the Pump power if this occurs As the Motor cools it will start without warning if the power is left on SKU 98135 For technical questions please call 1 800 444 3353 Page 8 AWARNING SKU 98135 MAINTENANCE AND SERVICING Procedures not specifically explained in this manual must be performed only by a
8. for wear Check for loose or broken wiring and replace if damage is found Motor frame must be installed with punch mark in line with notch in Motor Casting Assembly 6 Check Brushes for excessive wear and adequate spring tension Have repaired or replaced by qualified technician Inspect armature and commutator and repair or replace if necessary Have work done by a qualified technician Motor bearing s 2 failing Have repaired by qualified technician Follow all safety precautions whenever diagnosing or servicing the pump Disconnect power supply before service by qualified technician only SKU 98135 For technical questions please call 1 800 444 3353 Page 10 Troubleshooting Possible Causes Likely Solutions Motor Stalls Bypass Valve 28 sticking 1 Remove and inspect Bypass Valve 28 Low voltage 2 Check incoming line voltage Excessive Rotor 34 or Vane 3 Inspect Rotor 34 and Vanes 33 for Motor overheats Motor will not turn on Fluid leakage 33 wear Pumping high viscosity fluids Clogged Screen 25 Restricted Suction Pipe 58 or Suction Pipe Extension 59 Damaged or worn Armature 3 Motor failure No Power Switch failure Motor failure Thermal Protector 8 or fuse failure Bad O Ring or Gasket Dirty shaft seal Bad shaft seal Incompatible fluid excessive wear or damage and if necessary
9. ible injury or death DANGER indicates 4 DANGER a hazardous situation which if not avoided will result in death or serious injury AWARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury ACAUTION CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury SKU 98135 For technical questions please call 1 800 444 3353 NOTICE is used to NOTICE address practices not related to personal injury CAUTION without CAUTION the safety alert symbol is used to address practices not related to personal injury WARNING Read all instructions Failure to follow all instructions listed below may result in fire explosion and or serious injury SAVE THESE INSTRUCTIONS Installation safety 1 When connecting this Fuel Trans fer Pump to a 12 Volt DC battery or power source connect the nega tive wire the positive wire and the ground wire All three need to be connected securely before using this Pump 2 Install the Fuel Pump according to the instructions in this manual A risk of explosion may be created if some instructions are not fol lowed 3 This Fuel Transfer Pump has a built in Check Valve Assembly 27 with pressure relief to prevent fluid ther mal expansion from causing unsafe system pressure DO NOT install additional check valves or foot valves during
10. installation without proper relief valves built into them Product damage may result 4 Keep work area clean and well lit Cluttered or dark areas invite acci dents Page 2 SKU 98135 Use safety equipment Wear ANSI approved safety goggles a dust mask respirator for fumes and non skid safety shoes during installation General Operation Safety DO NOT SMOKE while using this Fuel Transfer Pump DO NOT use this pump near pilot lights open flame or sparks Keep multiple class ABC fire extin guishers nearby Before use make sure to ground the Nozzle 54 to the neck of the tank container being filled with fuel at all times This will help prevent buildup of static electricity which can spark causing fire and or ex plosion and serious bodily injury or death Keep children and bystanders away while installing operating or main taining this Fuel Transfer Pump Stay alert watch what you are doing and use common sense when operat ing Do not use while you are tired or under the influence of drugs alcohol or medication A moment of inat tention while operating may result in serious personal injury Do not leave this Fuel Transfer Pump unattended while it is operating Do not lock the Fuel Nozzle in open posi tion This Fuel Transfer Pump is not a toy DO NOT allow children to operate it Do not wear clothing made from synthetic fibers There is danger from static electricity build up causing Fo
11. must accompany the merchandise If our inspection verifies the defect we will ei ther repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return re paired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 SKU 98135 For technical questions please call 1 800 444 3353 Page 14
12. person using only identical replacement parts This will ensure that the safety of the equipment is maintained 2 Maintain labels and nameplates on the pump These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement SAVE THESE INSTRUCTIONS SPECIFICATIONS Permanent Magnetic Motor pumps diesel Application Kerosene Light weight oils water and anti freeze Up to 10 Gallons Per Flow i Minute Duty Cycle Voltage Required 12 VDC 23 5A Not for use with fluids that have a flashpoint below 100 F 38 C UNPACKING When unpacking check to make sure that the item is intact and undamaged If any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible REV 08h SKU 98135 For technical questions please call 1 800 444 3353 Page 4 SKU 98135 INITIAL SET UP INSTRUCTIONS Read the ENTIRE IMPORTANT A SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product TO PREVENT AWARNING serious INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch of the pump to its OFF position and disconnect from power source before assembling or making any adjustments to the pump Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near
13. r drum opening 4 Install the Hose 55 and Nozzle 54 See Assembly Instructions on page 6 of this manual 5 Connect the Cable 60 that extends from the Cable Connector 53 Make sure to connect the Ground Wire 51 The tank barrel or drum should be securely anchored to prevent acci dental movement or tipping Attaching Fuel Transfer Pump to a Vehicle DO NOT attempt to connect and power this pump to thin wiring from cigarette lighter NOTE The Ground Wire 51 must always be independently connect ed to the frame or chassis of vehi cle and or container being fueled or filled For example DO NOT connect green and black wires together Unless the Fuel Transfer Pump and the fuel tank barrel or drum are grounded to one another sparking due to a static charge or wiring faults could possibly ignite fumes resulting in an explosion If this Fuel Transfer Pump is to be powered from a vehicle power sys tem it is recommended that perma nent wiring and connections be made to the vehicle power system and include a 30 amp slow blow fuse Connecting Fuel Transfer Pump 1 Remove the Junction Box Cover 18 from the Motor Casing Assembly 6 and straighten wires to make the stripped wire ends accessible Screw the furnished Cable Connector 53 into the Conduit Opening of the Motor Casing Assembly 6 SKU 98135 For technical questions please call 1 800 444 3353 Page 6 SKU 98135 Strip 6 of
14. r technical questions please call 1 800 444 3353 sparks that could lead to fire or explo sion Place empty containers on flat level ground before filling Use this Fuel Transfer Pump out doors only DO NOT pump from or into a vehicle that is running Turn off engine of fueled vehicle and fueling vehicle before hooking up nozzle or starting to pump Follow all local and state laws gov erning use of Fuel Pumps This Fuel Transfer Pump should only be used for one fluid This will ensure that different fluids will not contami nate one another and help to prevent unexpected reactions WARNING This product contains or when used produces a chemi cal known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq WARNING The brass components of this product contain lead a chemi cal known to the State of California to cause birth defects or other repro ductive harm California Health amp Safety Code 25249 5 et seq The warnings precautions and in structions discussed in this instruction manual cannot cover all possible con ditions 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 Page 3 product but must be supplied by the operator Maintenance Safety 1 Have your equipment serviced by a qualified repair
15. ve 28 open Vanes 33 sticking Inlet Gasket 26 leakage Excessive Rotor 34 or Vane 33 wear Motor not operating Motor is running backwards Dirt in Pump cavity Motor failure Excessive dirt in Screen 25 Suction Pipe 58 Problem Bypass Valve 28 sticking Vanes 33 sticking Excessive Rotor 34 or Vane 33 wear Hose 55 damage Incorrect voltage Vanes 33 sticking Wiring problem Motor Casting Assembly 6 out of line Brush problem Motor problem Motor failure Check for leaks in Suction Pipe 58 Remove and inspect Bypass Valve 28 Check Vanes 33 and slots for nicks burrs wear and accumulation Check and tighten all covers and joints Check Rotor 34 and Vanes 33 for excessive wear or possible damage Motor Rotor 34 should turn clockwise at Pump end if not have it repaired by a qualified technician Check all wiring for correct polarity Clean out Pump cavity Motor bearing s 2 possibly frozen Have Motor repaired by qualified technician Remove and clean Screen 25 Check Suction Pipe 58 for leaks or restrictions Remove and inspect Bypass Valve 28 4 Check Vanes 33 and slots for wear or deposits Check Rotor 34 and Vanes 33 for excessive wear or damage Replace Hose 55 DO NOT REPAIR Check incoming line voltage Check Vanes 33 and slots
16. vite acci dents Use safety equipment Always wear ANSl approved safety gog gles Safety equipment such as dust mask respirator for fumes and non skid safety shoes This Fuel Transfer Pump has a built in Check Valve Assembly 27 with pressure relief to prevent fluid ther mal expansion from causing unsafe REV 08h For technical questions please call 1 800 444 3353 Page 5 system pressure DO NOT install additional check valves or foot valves during installation without proper relief valves built into them 4 Systems should be set up requiring a minimum amount of suction lift The maximum vertical distance from the surface of the fuel inside the tank to the inlet of the Pump is 9 feet for gas and 10 feet for diesel 5 A water separator not supplied should be used if you are going to pump diesel fuel 6 A filter not supplied should be used at Pump outlet to insure that no foreign material is transferred to fuel tanks Attaching Fuel Transfer Pump to Tank or Barrel 1 Tightly thread Suction Pipe 58 into the inlet flange 24 at the base of the Pump Housing 1 Thread the Suc tion Pipe Extension 59 to Suction Pipe 58 2 Using a hack saw not supplied cut the Suction Pipe Extension 59 to a length within 3 of the bottom of the tank barrel or drum DO NOT rest the Suction Pipe Extension 59 on the bottom 3 Screw the Inlet Flange 24 complete ly and securely into the tank barrel o
17. yS GENERA FUEL TRANSFER PUMP 12VDC SET UP AND OPERATING INSTRUCTIONS Distributed exclusively by Harbor Freight Tools 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2008 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein For technical questions or replacement parts please call 1 800 444 3353 SAVE THIS MANUAL Keep this manual for the safety warn ings and precautions assembly operat ing inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference IMPORTANT SAFETY INFORMATION In this manual on the labeling and all other information provided with this product This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid poss
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