FMT PREMA Series Instruction Manual

OPERATING INSTRUCTIONS
AND SAFETY NOTES
PREMAxx DEF axial gear pump
120 V~AC • 12 V-DC
87 952 006 A803 US

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US Operating instructions - PREMAxx DEF axial gear pump
FMT Swiss AG
This documentation is exclusively intended for the operating company and their sta.
Without our written consent, the content of this documentation (textes, gures, drawings,
charts, diagrams etc. ), must not be duplicated or distributed, neither in full or in part, utilized
for the purpose of competition or passed on/made availabe to third parties.
FMT Swiss AG
Fluid Management Technologies Swiss AG
Gewerbestraße 6
6330 Cham / Switzerland
Tel. [phone]
Fax [phone]
Email: [e-mail]
Internet: www.fmtag.com
Operating instructions translation
Date of issue: 10/2020
We reserve the right to make design and product modications, which serve to improve the product.

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Operating instructions - PREMAxx DEF axial gear pump
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Table of Contents
1. Introduction ________________________________________________________________________4
1.1. Preface ____________________________________________________________________________4
1.2. Obligations of the personnel ___________________________________________________________4
1.3. Symbols in this manual _______________________________________________________________4
1.3.1. Structure of the safety notes ___________________________________________________________4
1.3.2. Hazard warning symbols ______________________________________________________________5
1.3.3. General symbols _____________________________________________________________________5
2. Safety notes ________________________________________________________________________5
2.1. Authorized personnel_________________________________________________________________6
2.2. Notes for maintenance, cleaning and repair _______________________________________________6
2.3. Intended conditions of use ____________________________________________________________6
2.4. Risks when handling the DEF axial gear pump_____________________________________________7
2.5. Risks in handling DEF solutions _________________________________________________________7
3. Transport and temporary storage _______________________________________________________8
4. Design and functional description ______________________________________________________8
4.1. Area of application ___________________________________________________________________8
5. Technical data_______________________________________________________________________9
6. Installation _________________________________________________________________________9
7. Operation _________________________________________________________________________11
7.1. First and re-commissioning ___________________________________________________________11
8. Preventive maintenance _____________________________________________________________12
9. Maintenance_______________________________________________________________________12
10. Troubleshooting ____________________________________________________________________13
11. Repair/Service______________________________________________________________________14
12. Disposal___________________________________________________________________________14
13. Certicate of Compliance CSA _________________________________________________________15
14. Exploded view of the PREMAxx DEF axial gear pump 120 V _________________________________16
15. Exploded view of the PREMAxx DEF axial gear pump 12 V __________________________________18

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US Operating instructions - PREMAxx DEF axial gear pump
1. Introduction
1.1. Preface
Please carefully read these operating instructions and observe in particular all safety notes!
Our sta will be pleased to provide support if you have any questions about the product.
Yours sincerely, FMT Swiss AG
1.2. Obligations of the personnel
Before they start to work, all persons who are entrusted with work on the PREMAxx DEF axial gear
pump are obliged:
– to follow all applicable regulations on occupational safety and accident prevention.
– to read and to comply with all safety instructions and warning notes contained in these operating
instructions.
Please observe the following instructions in the interest of all concerned:
 Refrain from any unsafe working methods!
 Adhere to all hazard and warning notes contained in this manual!
 In addition to this documentation, keep to all generally accepted safety rules, legal provisions as
well as all other binding rules regarding occupational safety, accident prevention and environmental
protection!
 Wear appropriate protective clothing in accordance with the work to be done!
 Perform only work for which you have been suciently trained and instructed!
 Only genuine spare parts as well as original tools and auxiliaries of the manufacturer are allowed to be
used in order to ensure the functional safety and maintain the warranty coverage.
1.3. Symbols in this manual
1.3.1. Structure of the safety notes
The warning notes have the following structure:
SIGNAL WORD
Type and source of the hazard
 Consquences of non-compliance with the notes
 Measures to avoid that risk
Depending on the danger level, dierent signal words are used:
Signal word Danger level Consequences of non-compliance
DANGER Imminent threat of
danger
Death or serious bodily injury
WARNING Possible threat of
danger
Death or serious bodily injury
CAUTION Possibly dangerous
situation
Minor bodily injury
ATTENTION Possibly dangerous
situation
Damage to material property

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Operating instructions - PREMAxx DEF axial gear pump
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NOTE
Indicates further information or tips which facilitate work
1.3.2. Hazard symbols
Symbol Meaning
General hazard symbol. The warning note marked in this way contains
supplementary information on the type of hazard.
This symbol warns of dangerous electrical voltages
This symbol warns of a hazardous explosive atmosphere
1.3.3. General symbols
Symbol Meaning
A small black square indicates the work you have to perform
–The dash denotes lists
aThe arrow identies cross-references.
If cross-references to other chapters are required within the text, the
expression is shortened for reasons of clarity.
Example: aChapter 2 Safety instructions
This means: please refer to chapter 2 for the safety instructions
2. Safety instructions
Various dangers may occur if the PREMAxx DEF axial gear pump is improperly handled during installation,
commissioning and daily operation.
WARNING
Risk of injury and damage to material property because of improper
handling
 Hold the manual at the disposal of the operating sta at the usage site of the
unit.
 Country-specic safety measures and accident prevention regulations
must be observed.

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US Operating instructions - PREMAxx DEF axial gear pump
2.1. Authorized personnel
Only qualied and authorized persons are allowed to operate and to work on the PREMAxx DEF axial
gear pump.
Persons are qualied if they are, due to their training, experience, instruction and knowledge of the
relevant standards, able to assess assigned tasks and to identify potentially hazardous situations.
These persons must have been authorized by the person responsible for the safety of the unit and must
be able to identify and to avoid potential dangers.
All persons charged with installation, operation, maintenance and repair work, must have read and
understood this operation manual.
A copy of this operating manual must be stored permanently and ready at hand at the place of usage
of the unit.
2.2. Notes on maintenance/cleaning and repair
WARNING
Risk of injury and damage to material property because of improper
maintenance and repair
 Keep to the specied inspection and maintenance intervals
(aChapter Maintenance).
 Should unusual noises occur, immediately stop the pump. Immediately
identify and eliminate the cause in order to avoid consequential
damages.
 Observe the safety sheet for DEF.
2.3. Intended conditions of use
The PREMAxx DEF axial gear pump is an electrically driven pump for the delivery of DEF (AdBlue®).
The temperature of the conveying liquid must be between –5 °C and + 35 °C (23 °F to 95 °F).
The DEF electric diaphragm pump is only allowed to be connected to a suitable power source (see
nameplate).
To ensure that usage stipulations are met, read through the Operating Instructions completely before
using the pump and observe all stipulations.
Any departure from the usage stipulations (other uid media, use of force) or user modications
(changes, use of non-original parts) can be dangerous and are considered as non-intended usage.
The user is liable for any damage resulting from non-intended use.
During repairs to any electrical components, the appropriate safety and test requirements are to be
observed.
Only genuine replacement parts are to be used for any repairs, because otherwise the warranty will be
invalidated.
In order to prevent dirt from entering the pump chamber, it is absolutely necessary to install a strainer
with pre-cleaner in the suction line, because otherwise the warranty may be invalidated.
The use in explosive environment is prohibited.
Any application beyond the intended use can lead to hazardous situations and shall be regarded as non-
intended use.

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Operating instructions - PREMAxx DEF axial gear pump
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DANGER
Risk of injury and material damage from explosive vapors
 Never use the pump to deliver explosive uids such as petrol or other
uids with similar ashpoints!
 Since the motor and the switch are not explosion-protected, the pump
must not be operated in an explosion risk area.
 Pumping caustic or other hazardous chemical or biological substances is
forbidden.
2.4. Risks when handling the PREMAxx DEF axial gear pump
DANGER
Risk of injury and material damage because of improper installation,
electric current or contaminated media.
Never work on a pump that is running.
 Mount or remove attachments and accessories only when the pump is
switched o.
 For your own safety, disconnect the pump in addition from the power
supply.
 Never leave the pump unattended.
 Check to ensure that the pump does not work against the closed nozzle.
Do not pump contaminated uids
 Take special care to ensure that there are no contaminants in the uid to
be pumped.
 Install a strainer on the suction pipe.
Damaged attachments and accessories can lead to personal injury and
material damage
 Attachments and accessories must be checked for wear, splits or other
damage throughout their period of use.
 Damaged accessories and attachments must be replaced immediately.
 With reference to the period of use, please note the details in
ZH 1/A45.4.2 or DIN 20066 Part 5.3.2
Escaping liquids can cause environmental harm
Comply with the stipulations of the German Water Resources Act (WHG) and
of the Plant Regulations of the German federal states (VawS).
2.5. Risks in handling DEF solutions
The DEF concentrate is not inammable, not explosive and not oxidizing.
NOTE
For cleaning, ush equipment with water. Dispose of released contaminated
uid. As a non-hazardous liquid waste, it should be solidied with stabilizing
agents. Avoid release to the environment.
DEF is corrosive to non-ferrous metals.
Avoid skin and eye contact. In case of contact with the eyes, rinse the
eyes with plenty of drinking water and consult a physician.
Observe the safety sheet for DEF.

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US Operating instructions - PREMAxx DEF axial gear pump
3. Transport and temporary storage
Before transport, ensure that there is no liquid (DEF residues) in the pump.
Do not use the cable to transport the pump!
Storage and transport conditions:
– Weather-protected storage with temperature control, protection against frost, moisture and rain.
Maximum relative humidity: 80 %.
– Storage temperature range from -5 °C to + 55 °C
(23 °F to 131 °F)
4. Construction and functional description
The PREMAxx DEF axial gear pump is an electrically driven pump for the delivery of DEF (AdBlue®).
It is only designed for use as a barrel pump and can be screwed on storage barrels or containers.
The DEF axial gear pump is s a compact and handy pump, it‘ s not self-priming. It is quickly ready for use
thanks to its integrated priming stage, which allows to manually pump small quantities of uid before
commissioning or in case of a power failure.
The pump housing is made of high-quality, impact-resistant plastic.
Numerous accessories from FMT allow a simple and quick mounting on every installation.
The materials of the pump are compatible with slightly aggressive liquids like DEF.
The pump is electrically driven by an alternating current motor suitable for continuous operation. The
pump is directly ange-mounted to the motor. In case of overload, a thermal protection device auto-
matically switches o the electric motor.
When the motor has cooled down, the thermal protection device automatically restarts the motor.
Pump data aChapter Technical Data.
The PREMAxx DEF axial gear pump is available in the following versions:
– PREMAxx DEF, 48 l/min / 12.6 gpm, 120 V-1~AC-60 Hz
–PREMAxx DEF, 35 l/min / 9.2 gpm, 12 V-DC-battery terminal clips
The pump can be equipped with dierent nozzle valves:
–with a standard nozzle valve or
– with an automatically closing nozzle valve
The pump can be delivered in a set including:
– PREMAxx DEF in the above-mentioned motor variants
– Hose kits
– Nozzle valve in one of the above-mentioned versions
4.1. Area of application
The PREMAxx DEF axial gear pump is only suitable for the delivery of DEF (AdBlue®).
The temperature of the delivery uids must be between –5 °C and +35 °C (23 °F to 95 °F). The tempera-
tures must not be above or below these limit values.
Since the motor and the switch are not explosion-protected the PREMAxx Axial Gear Pump must not
be operated in an explosion risk area!

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Operating instructions - PREMAxx DEF axial gear pump
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5. Technical data
Description 120 V
23 739 006
12V
23 760 006
Connecting cable, length (m) / (ft) 2 / 6.6
Connection container G 2‘‘ male, drum adapter
Connection suction side G 1‘‘ male
Connection discharge side G 1‘‘ male
Hydraulic data
Pump design axial gear
Delivery rate under free discharge up to (l/min) / (gpm) 48 / 12.6 35 / 9.2
Suction height up to (m) / (ft) 2,5 / 8.2 2,5 / 8.2
Discharge height max. (m) / (ft) 15 / 49.2
Pumping media DEF
Motor data
Voltage (V) 120 12 DC
Frequency (Hz) 60
Power consumption (A) 3,5 14
Power (W) 420 180
Thermal protection self resetting
Duty cycle (min) 30
Rotation speed at 0,5 bar
counterpressure (rpm)
10000 7500
Sound pressure level dB(A) <70
Type of construction IMB 5
Protection class IP 34
Material of pump housing
and pump
PA6
Material motor shaft stainless steel 1.4021
Dimensions of pump L x W x H
(mm) / (inch)
130 x 130 x 350 /
5.1 x 5.1 x 13.7
Weight (kg) / (lb) 2,5 / 5.5
Tab. 5.-1: Technical data
6. Installation
The PREMAxx DEF axial gear pump is designed for installations in indoor and outdoor areas.
In case of outdoor installation, a housing is required as a protection against the eects of weather.
The installation must be carried out in the following sequences (see g. 6.-1):
 Click the lter (6) to the suction tube (5).
 Screw the suction tube (5) to the pump‘s suction port (4).
 At rst, screw the barrel adapter (3) into the storage container‘s connection thread.
Then put the pump in the desired position of the barrel adapter.
 The pump can be xed as desired in 12 dierent positions.
NOTE
Completely pull out the telescopic suction tube before mounting the pump
to the storage container.
The length automatically adapts to the height of the corresponding storage
container. Thus, each container can be almost completely emptied.

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US Operating instructions - PREMAxx DEF axial gear pump
CAUTION
Risk of minor personal injuries
 Mount and operate the pump only in vertical position on a storage
container.
 The pump is only allowed to be operated if it is rmly xed with the
dispensing container, so that it cannot carry out any uncontrolled
movements.
 The pump is only allowed to be operated if the dispensing container, to
which the pump is connected, stands on a rm and level surface.
 Screw the union nut (12) of the discharge hose to the discharge port (11) at the port.
 Screw the free end of the discharge hose with the male thread (14 or 15) into the thread of the nozzle
valve (9 or 19).
Fig. 6.-1 Overview of PREMAxx DEF axial gear pump with acessories

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Operating instructions - PREMAxx DEF axial gear pump
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1 Pump housing 11 Discharge port
2 Hand lever 12 Union nut, discharge hose
3 Barrel screw coupling 13 Discharge hose
4 Suction port 14 Connection standard nozzle valve
5 Telescopic suction tube 3-pieces 15 Connection automatic nozzle valve
6 Strainer 16 Automatic nozzle valve
7 Standard nozzle valve 17 Lock
8 Nozzle valve lever, standard nozzle valve 18 Nozzle valve lever, automatic nozzle valve
9 Thread, standard nozzle valve 19 Thread, automatic nozzle valve
10 On/o switch
 Connect the pump to a power source using the mains plug or the terminal clamps.
The pump is ready for commissioning.
CAUTION
Risk of injury from 12 V batteries
 When handling the 12 V battery (lead-acid battery), observe the
specications and the material data safety sheet of the battery manufacturer.
Carry out the following steps when connecting the pump to the battery:
 The switch of the pump must be in the OFF position.
 Remove the protection cap from the positive battery terminal (+).
 Connect the red terminal clamp to the positive battery terminal.
 Remove the protection cap from the negative battery terminal (-).
 Connect the black terminal clamp to the negative battery terminal.
Proceed in reverse order when disconnecting the pump from the battery:
At rst, disconnect the black clamp from the negative terminal and then the red clamp from the positive
terminal. Put the protection caps on the terminals again.
7. Operation
7.1. First and re-commissioning
Check the operativeness of the pump before use and after a failure-related or scheduled downtime.
Check the PREMAxx DEF axial gear pump and the installed accessories for completeness and damage.
Replace any damaged components immediately. Never use a pump if damaged.
ATTENTION
Danger of product damage
 Operate the pump by hand before putting the pump into operation for
the rst time or if the uid column has dropped down, because the radial
shaft seal may be destroyed by a dry run of the pump.
Preparing the pump for operation (see g. 6.-1):
 Hold the nozzle valve (7 or 16) into a container.
 Push the lever (8 or 18) or x it by the lock (17-if equipped with automatic nozzle valve). Hold the
nozzle valve into the container to be lled.
 Manually pump uid by means of the hand lever (2) until uid is pumped out of the nozzle
valve (7 or 16).
 Actuate the rocker switch to switch on the pump.

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US Operating instructions - PREMAxx DEF axial gear pump
ATTENTION
Danger of product damage
 Never operate the pump without liquid. The DEF pump may be damaged
by running dry.
 Mount and operate the pump only in vertical position on a storage
container.
 The DEF axial gear pump does not switch o automatically, therefore
never let the pump running without supervision during lling operations.
 For nishing the lling operation, release the nozzle valve control lever. Never operate the pump for
longer than 2 minutes with closed nozzle valve.
 Operate the rocker switch to switch o the pump.
 Position the nozzle valve so that no media can pollute the environment.
8. Preventive maintenance
In general, the PREMAxx DEF axial gear pump is very easy to maintain and to service.
DANGER
Risk of injury through contact with energized components
 When working on the electrical system of the pump, disconnect the pump in
addition from the power supply and protect it against restarting.
Due to the operator responsibilities according to § 19i WHG (German Water Resources Act) the fol-
lowing components must be regularly checked and replaced as necessary to minimise the risk of
environmental or equipment damage or personal injury:
 Pump housing
 Delivery hose
 Nozzle valve
9. Maintenance
Maintenance must be done by qualied technical personnel. External impact may cause a loss of per-
formance, constitute a risk of damage to persons and/or property and void the guarantee.
DANGER
Risk of injury through contact with energized components
 Before performing any maintenance work, disconnect the pump from all
electric and hydraulic supply sources
 When working on the electrical system of the pump, disconnect the pump in
addition from the power supply and protect it against restarting.

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Operating instructions - PREMAxx DEF axial gear pump
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Observe the following recommendations for operating the pump:
 Before performing any maintenance work, disconnect the pump from all electric and hydraulic supply
sources.
 Always wear personal protective equipment when carrying out maintenance work.
 If there is danger of freezing, the pump and the circuit must be emptied and stored at a location
with a temperature not lower than 0 °C/32 °F.
 Check to ensure that the labels and decals have not become illegible and have not come loose in the
course of time.
 Check at regular intervals that the line connections have not worked loose in order to avoid that liquid
escapes.
 Regularly check and clean the suction line lter.
 From time to time, check the pump housing and remove any dirt.
 Check to ensure that the power cables are in perfect working order.
 If the pump is planned to be put out of operation for more than 15 days, completely empty the pump
and the system in order to prevent the DEF from crystallizing inside the pump system.
Finally, thoroughly clean pump and system.
10. Troubleshooting
Malfunction Cause Solution
Motor does not run No power supply Check the electric connections
Discharge rate too low Discharge hose kinked or
clogged
Suction line
resistance too high
Filter resistance too high
Nozzle valve not completely
open
Check the discharge hose
Check the suction line, it may be
kinked or clogged
Check the suction lter
Check and clean the suction lter
Completely open the nozzle valve
Tab. 10.-1: Troubleshooting

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US Operating instructions - PREMAxx DEF axial gear pump
11. Repair/Service
The PREMAxx DEF pump was developed and produced according to the highest quality standards.
Should a problem develop, despite all quality controls, please contact our customer service:
FMT NA
Phone [phone]
12. Disposal
The operating company is responsible for the proper disposal of the pump.
Dispose of in accordance with all local, regional and federal regulations.
Only qualied personnel is authorized to disassemble and dispose of the PREMAxx DEF axial gear
pump.

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Operating instructions - PREMAxx DEF axial gear pump
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13. Certicate of Compliance
Manufacturer:
FMT Swiss AG
Fluid Management Technologies Swiss AG
Gewerbestraße 6
6330 Cham / Switzerland
Declares under his sole responsibility that the machine:
Model type PREMAxx DEF axial gear pump
23 739 006 (120 V)
23 760 006 (12 V-DC)
Motor voltage 120/12 V
Weight 2,5 kg
Power 23 739 006 (120 V) - 420 W
23 760 006 (12 V-DC) - 180 W
Function Conveying of DEF ( AdBlue® )
complies with all relevant provisions of the following directive:
Applicable standards CAN/CSA C22.2 No. 108-14–Fifth Edition–Liquid Pumps
UL 778–Sixth Edition; Revisions through and including October 20, 2017 -
Motor Operated Water Pumps
Authorized representative for the compilation of the technical documentation:
Name: Manuel Bredenbruch
Address: Fluid Management Technologies Swiss AG
Gewerbestraße 6
6330 Cham / Switzerland
Phone: [phone]
FMT Swiss AG
Cham, 17.12.2018
Dipl.-Ing. Rudolf Schlenker
(Managing Director)

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US Operating instructions - PREMAxx DEF axial gear pump
14. Exploded view of the PREMAxx DEF axial gear pump 120 V
Fig. 14. -1: Exploded view of the PREMAxx DEF axial gear pump 120 V

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Operating instructions - PREMAxx DEF axial gear pump
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Pos. Quantity Description
11 Rocker switch, illuminated in green
21 ELM-electric motor 110/120 V-50/60 Hz
31 Cable
41 Pump shaft PREMAxx
51 Housing cover, pump
61 Intermediate cover, pump
71 Fan propeller
81 Shaft seal ring - HNBR
91 Impeller for PREMAxx
10 1 Housing PREMAxx pump
11 1 Spacer
12 1 O-ring-FKM 70 - 32x2,2
13 1 Fitting PREMAxx pump
14 1 Threaded bolt PREMAxx pump
15 1 Con-rod for PREMAxx pump
16 1 Piston
17 1 Pump cylinder
18 1 Valve cone
19 1 Lever
20 4 Screw 4x20
21 2 Chipboard screw
22 2 Grooved taper pin DIN 1471
23 1 O-ring-FKM 70 - 35x2,0
24 4 Screw for plastic 3x16
25 1 Con-rod bolt PREMAxx pump
26 1 Piston seal
27 1 Ball D = 19,05 mm
28 1 Flat seal
29 1 Compression spring
30 1 Grooved taper pin DIN 1471
31 1 O-ring-FKM 70 - 7x3
32 1 Button-head rivet DIN 660
33 2 Safety washer
34 1 O-ring FKM 80
35 1 Cable sleeve support ID=6,5 mm
36 4 O-ring-FKM 70 - 4x1
37 1 Hexagon nut DIN 985
38 1 Blade terminal DIN 46247
39 1 Blade terminal 4.8 x 0,5 mm
40 1 Washer DIN 125
41 1 Barrel screw coupling-black, G 2‘‘ male
Tab. 14.-1: Overview of the components of g. 14.-1

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US Operating instructions - PREMAxx DEF axial gear pump
15. Exploded view of the PREMAxx DEF axial gear pump 12 V
Fig. 15. -1: Exploded view of the PREMAxx DEF axial gear pump 12 V

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Operating instructions - PREMAxx DEF axial gear pump
US
Pos. Quantity Description
11 Rocker switch, illuminated in green
21 ELM-electric motor 12 V
31 Cable H07 RN F2 G 1,5
41 Pump shaft
51 Housing cover, pump
61 Intermediate cover, pump
71 Fan propeller
81 Shaft seal ring - HNBR
91 Impeller for PREMAxx
10 1 Housing PREMAxx pump
11 1 Spacer
12 1 O-ring-FKM 70 - 32x2,2-FKM
13 1 Fitting PREMAxx pump
14 1 Threaded bolt PREMAxx pump
15 1 Con-rod for PREMAxx pump
16 1 Piston
17 1 Pump cylinder
18 1 Valve cone
19 1 Lever
20 4 Screw 4 x 20
21 2 Chipboard screw
22 2 Grooved taper pin DIN 1471
23 1 O-ring-FKM 70 - 35x2.0
24 4 Screw for plastic 3x16
25 1 Con-rod bolt PREMAxx pump
26 1 Piston seal
27 1 Ball D = 19,05 mm
28 1 Flat seal
29 1 Compression spring
30 1 Grooved taper pin DIN 1471
31 1 O-ring-FKM 70 - 7x3
32 1 Button-head rivet DIN 660
33 2 Safety washer
34 1 O-ring FKM 80
35 4 O-ring FKM 70
36 1 Hexagon nut DIN 985
37 1 Blade terminal DIN 46247
38 1 Blade terminal 4.8 x 0,5 mm
39 1 Washer DIN 125
40 1 Cable sleeve support ID=10 mm
41 1 Barrel screw coupling-black, G 2‘‘ male
Tab. 15.-1: Overview of the components of g. 15.-1

FMT Swiss AG
Fluid Management Technologies Swiss AG
Gewerbestraße 6
6330 Cham / Schweiz
Tel. [phone]
Fax [phone]
[e-mail]
www.fmtag.com