Groz D Series User manual

1
INSTRUCTION MANUAL S1590, Rev B
Electric Fuel Pump
FPM
Congratulations on purchase of this World Class Electric Fuel Pump!
D SERIES
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. In case of High Flow Model FPM/12/HF,
discharge is 20 GPM (75 LPM). The actual discharge varies
depending on fuel being used, temperature, Hose Length,
power supply etc.
Pump Comes in 4 Power Ratings
• 12V DC
• 24V DC
• 115V AC, 60 Hz.
• 220V AC , 50/ 60 Hz
Rating is marked on the pump motor.
Inside of
Pump
Elbow Nozzle
Holder
Pad Lock
Lever
Motor
Fuel
Control
Nozzle
Switch
ON
OFF
Swivel
Nut
Pump
Outlet
Hose
Suction Tube
FPM-12, FPM-12/HF, FPM-24, FPM-115, FPM-220

2
5
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. Gland Nut
9. Power Cord complete with Fuse &
Clamps*
10.PTFE Tape
*Only included on DC pumps. AC pumps
are supplied without power cord
1. Ensure pump switch
is OFF
2. Electrical cover
is located on the
opposite side of the
ON/OFF Switch.
Take a wrench &
open the 4 bolts to
open the Electrical
Cover
3. Take out the Power Cord supplied with the pump. It may be
cut to a shorter length as per requirement
4. Strip 3” (75 mm)
of outside black
coloured insulation
from power cord
from the end
opposite to the
fuse
5
4
7
3
9
10
8
6
6. Take out the Gland Nut from the package & open the 2 parts of
the Gland Nut
8. Insert power cable from the threaded opening on the Electrical
Housing
9. Connect wires
from power cord
to wires from the
motor using Wire
Nuts. Connect Red
to Red & Black to
Black
10. Screw Gland Nut into the Electrical Housing
11. Position power cord & tighten the Nut portion of the Gland
Nut ensuring that power cords connection with the motor is
not under any strain
7. Slide the Nut
portion of the
Gland Nut over the
end of power cord
on the end just
stripped. Now Slide
the other part of
the Gland Nut as
well ensuring that the male threaded portion of the gland
nut faces the stripped end of the power cord. Connect the 2
halves of the gland without tightening it much
male threaded
portion of
gland nut
5. You would see Black & Red Wires after the black insulation is
removed. Strip 3/8” (10 mm) from the Black & Red wires
ELECTRICAL INSTALLATION - 12V & 24V DC Pumps
Pump Switch
Electrical
Cover
1
2

3
12. Re-install
Electrical Cover
on the pump &
tighten using the
4 bolts
14. Attach battery
clamps with red
sleeve to red wire
& black sleeve to
black wire. Wire
must be crimped
to the battery
clamp firmly to get
a good electrical
connection
1. Ensure pump switch is OFF
2. Electrical cover is located on the opposite side of the ON/
OFF Switch. Take a wrench & open the 4 bolts to open the
Electrical Cover
3. AC Power Cord is not supplied with the pump & you must
purchase one separately
4. Strip 3” (75 mm) of outside insulation from power cord
5. You would see Black, White & Green Wires after the insulation
is removed. Strip 3/8” (10 mm) from all 3 wires
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
13. Remove ½” ( 13 mm) of insulation from wires on the fuse
holder end of the power cord
ELECTRICAL INSTALLATION - 115V AC & 220V AC Pumps
6. Take out the Gland Nut from the package & open the 2 parts of
the Gland Nut
7. Slide the Nut portion of the Gland Nut over the end of power
cord on the end just stripped. Now Slide the other part of the
Gland Nut as well ensuring that the male threaded portion
of the gland nut faces the stripped end of the power cord.
Connect the 2 halves of the gland without tightening it much
8. Insert power cord from the threaded opening on the Electrical
Housing
9. Connect wires from power cord to wires from the motor using
Wire Nuts. Connect Green to Green , White to White & Black
to Black
10. Screw Gland Nut into the Electrical Housing
11. Position power cord & tighten the Nut portion of the Gland
Nut ensuring that power cords connection with the motor is
not under any strain
12. Re-install Electrical Cover on the pump & tighten using the 4
bolts
On 115V AC & 220V AC pumps, electrical connections must be
made by a licensed electrician.
Only rigid conduit with threaded connections should be used.
Conduid opening in pump must be sealed with waterproof, fuel-
resistant sealant. Failure to comply with this warning could result
in injury from Electrical shock
ASSEMBLY & INSTALLATION

4
10. Connect the other end of the Hose to the Fuel Control Nozzle
11. Connect Power cord to source of power & switch it ON
12. The pump is now
ready for use
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
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
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 fit onto your drum/ tank, use a
Drum Bung Converter. Note that bung supplied with the pump
has 2” Pipe threads
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
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
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 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
PUMP OPERATION
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
2. Nozzle should be facing the container into which Fuel is to be
dispensed
Pump in ON Position
1. Clean Inlet Strainer after every 50 hours of operation
2. Inlet strainer is easily accessible without having to dis-
assemble 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
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
MAINTENANCE
Strainer
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
PRIMING
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
ON
OFF
3. Pump On/Off
Switch Lever is
located under the
nozzle holder. Move
switch lever ON &
simultaneously open
the Nozzle

6
4
EXPLODED VIEW FOR FPM-12, FPM-12/HF, FPM-24, FPM-115, FPM-220
PUMP ASSEMBLY
1
31
22
28
35
15
11
26
6
20
16
7
14
29
2
21
10
19
37
38 39
5
25
32
12
34
13
17
30
24
36
3
27
18
23
9
8
33
4
HOSE, SUCTION TUBE, POWER CABLE & FUEL CONTROL NOZZLE ASSEMBLY
40
41
42
43 44
15A

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PARTS LIST FOR FPM-12, FPM-12/HF, FPM-24, FPM-115, FPM-220
REFERENCE NUMBER DESCRIPTION QUANTITY
1 Thread Forming Bolt M4 4
2 Cover (Strainer) 1
3 O-Ring 1
4 Strainer 1
5 Thread Forming Bolt M8 4
6 Housing Cover 1
7 O-Ring 1
8 Gear 2
9 Key Gear 1
10 Shaft (Gear) 2
11 Housing (Machined) 1
12 Fitting (Bung) 1
13 Swivel Nut 1
14 Bung Adaptor 1
15 Seal (Metal Inserted) 1
15A Circlip 1
16 O-Ring (Viton) 1
17 Bypass Valve 1
18 Spring (Bypass Valve) 1
19 Elbow 1
20 Thread Forming Bolt M6 9
21A Motor, 12V DC 1
21B Motor, 12V DC HF 1
21C Motor, 24V DC 1
21D Motor, 115V AC, 60 HZ 1
21E Motor, 220V AC, 50 HZ 1
22 Thread Forming Bolt M4 4
23 Electrical Cover (M/C) 1
24 Drive Screw U Type 4
25 Label 1
26 Electrical Housing (M/C) 1
27 On Off Toggle Switch (SPST) with Spade Terminal (15 AMPS, 250V) 1
28 Bracket (Switch) 1
29 Screw (CAM) 2
30 Cam (Switch) 1
31 Thread Forming Bolt Screw M4 2
32 Shaft (Lever) 1
33 Switch Cover (M/C) 1
34 Thread Forming Bolt M6 4
35 Lever 1
36 Nylock Nut 1
37 Cover Nozzle 1
38 Lock 1
39 Rivet 1
HOSE, SUCTION TUBE, POWER CABLE & FUEL CONTROL NOZZLE ASSEMBLY
40 Suction Tube 1
41 Hose Assembly 1
42 Plastic Gland (Wiring) 1
43 Fuel Control Nozzle 1
44 Power Cable Assembly (Only for DC Pumps) 1
PUMP ASSEMBLY

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PUMP SPECIFICATION
WETTED COMPONENTS
Aluminium, Steel, Cast Iron, Nylon, NBR, Zinc, Viton, Polypropylene
RECOMMENDED USE
Gasoline, Diesel, E15 Fuel, Kerosene, Bio Diesel (B20)
FPM-12 FPM-12/HF FPM-24 FPM-115 FPM-220
Description Heavy Duty 12V DC High Flow 12V DC Heavy Duty 24V DC Heavy Duty 115V AC Heavy Duty 220V AC
Flow Rate* Up to 15 GPM
(57 LPM)
Up to 20 GPM
(76 LPM)
Up to 15 GPM
(57 LPM)
Up to 13 GPM
(49 LPM)
Up to 13 GPM
(49 LPM)
Explosion Proof
Motor
1/7 HP
12V DC
1/7 HP
12V DC
1/7 HP
24V DC
1/8 HP
115V AC, 60 Hz.
1/8 HP
220V AC, 50/60 Hz.
Amp draw from
Battery
12 Amp 15 amp 6 amp 1.7 Amp 1 Amp
Internal Bypass
Valve
Yes Yes Yes Yes Yes
Suction Pipe 2 pc threaded 2 pc threaded 2 pc threaded 2 pc threaded 2 pc threaded
Hose ¾” x 12’
Anti Static Hose
1” x 12’
Anti Static Hose
¾” x 12’
Anti Static Hose
¾” x 12’
Anti Static Hose
¾” x 12’
Anti Static Hose
Tank Adaptor 2” Threaded 2” Threaded 2” Threaded 2” Threaded 2” Threaded
Inlet 1” NPT 1” NPT 1” NPT 1” NPT 1” NPT
Outlet ¾” NPT 1” NPT ¾” NPT ¾” NPT ¾” NPT
Dispensing Nozzle ¾” Manual
with Swivel
1” Manual
with Swivel
¾” Manual
with Swivel
¾” Manual
with Swivel
¾” Manual
with Swivel
Battery Cable
(2 wire)
15’ 15’ 15’ NA NA
* measured in lab conditions at pump outlet using Diesel with vehicle engine switched on

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TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Motor runs but
pump will not prime
Motor rotation wrong. (12 VDC and 24 VDC
units only)
Check wiring instructions for possible problems
Missing relief valve o-ring seal (16) Remove gear cover (6), inspect seal, replace if missing or damaged
Sheared drive key (9) Remove cover (6) and inspect key, replace if worn or sheared
Dirt under by-pass valve (17) or seal (16) Remove cover (6) and inspect, clean or replace if damaged
Strainer seal (3) leaking Inspect and replace if damaged
Suction height too high to prime See Priming Pump, page 5
Worn or damaged gears (8) Remove cover (6) and inspect gears. Replace if worn or damaged
Fuel level low Refill tank
Cover seal (7) damaged Replace if worn or damaged
Inlet strainer (4) clogged Remove and clean or replace
Air leak in suction tube (40) Inspect all joints in suction tube. Make sure all joints in suction tube are sealed
and that there are no cracks from over-tightening
Air lock in system This may occur if filter or meter or automatic shut-off nozzle is used. If this
occurs, fill pump and meter with fuel through top of pump
Motor does not run at proper speed Check electric connections. Check supply voltage for proper voltage level
Curb Pump Auto Nozzle used Change to Auto Nozzle for use with Electric Fuel Pumps
Unit pumps but
output flow is low
Clogged inlet strainer (4) 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 Refill tank
Tank not vented Tank must be vented to atmosphere
Worn or damaged gears (8) Remove cover (6) and inspect gears. Replace if worn or damaged
Damaged motor (21) Replace motor
Clogged suction tube (40), hose (41) or nozzle
(43)
Inspect and clean
Curb Pump Auto Nozzle used Change to Auto Nozzle for use with Electric Fuel Pumps
Motor stalls when
nozzle is closed
Bypass relief valve (17) stuck Inspect relief valve, making sure poppet is free. Replace if damaged
Low supply voltage Check supply voltage
Gears (8) damaged and binding Inspect gears. Gears should turn freely. Replace if damaged
Faulty motor (21) Replace motor
Fuel leaking in
motor mount
Faulty or damaged motor shaft seal (15) Replace shaft seal
Operating pump extended time with nozzle
closed
Do not exceed 5 minutes of operation with nozzle closed
Motor shaft worn Replace motor if shaft has worn in seal area
Motor overheating
Gears (8) binding 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
Clogged inlet strainer (4) Clean or replace, see Maintenance, page 5
Clogged suction tube (40), hose (41) or nozzle
(43)
Inspect and clean if required
Operating pump more than 30 minutes
continuous duty
Limit operation to 30 minutes per hour
Switch will not turn
pump on
Blown fuse Replace fuse. 30 amp automotive fuse
Electrical problem Check that supply voltage is proper and getting to pump
Defective switch (27) Check and replace if defective
Mechanical problem Check switch actuator cam. Cam should be actuating the switch
Damaged or defective motor (21) Check motor, replace if damaged or defective

10
REPLACEMENT & SERVICE PARTS PROGRAM FOR ELECTRIC FUEL PUMPS
REFERENCE # FROM OIPM GROZ PART # DESCRIPTION
21A MOT/FPM/12 Motor, 12V DC
21B MOT/FPM/12/HF Motor, 12V DC HF
21C MOT/FPM/24 Motor, 24V DC
21D MOT/FPM/115 Motor, 115V AC, 60 Hz
21E MOT/FPM/220 Motor, 220V AC, 60 Hz
14 ADP/BNG/FPM/12 Bung Adaptor
40 FPM/2R/N Suction Tube
41A SA/HOS/FPM/12 Hose Assembly
41B SA/HOS/FPM/12/HF Hose Assembly, HF
42A SA/FCN/S/3-4/FPM/N Fuel Control Nozzle
42B SA/FCN/S/0-1/FPM/N Fuel Control Nozzle, HF
REPLACEMENT PARTS PROGRAM

11
SERVICE PARTS PROGRAM
KIT PART # KIT
DESCRIPTION
CONSTITUENT
PART # CONSTITUENT DESCRIPTION
CONSTITUENT
REFERENCE
FROM OIPM
QTY.
PER KIT
SUPPLY
CONDITION
FPM/KIT/SK Seal Kit
ORG/BS154 O Ring 7 1
SET
ORG/V/BS809 O Ring (Viton) 16 1
ORG/BS126 O Ring 3 1
SEL/FPM/12 Seal (Metal Inserted) 15 1
CCL/FPM Circlip 15A 1
FPM/KIT/GK Gear Kit GEAR/FPM/12 Gear 8 2 SET
KEY/GEAR/FPM/12 Key (Gear) 9 1
FPM/KIT/SA Switch
Assembly Kit
SWH/FPM On Off Toggle Switch 27 1
ASSEMBLED
BKT/SWH/FPM/12 Bracket (Switch) 28 1
SCR/CAM/FPM/12 Screw (CAM) 29 1
CAM/SWH/FPM/12 Cam (Switch) 30 1
TFS/M4/FPM/12 Thread Forming Bolt Screw M4 31 2
SFT/LVR/FPM/12 Shaft (Lever) 32 1
CVR/SWH/FPM/12 Switch Cover (M/C) 33 1
LVR/FPM/12 Lever 35 1 SET
NN/M6/RP-G Nylock Nut 36 1
CVR/NZL/FPM/12 Cover (Nozzle) 37 1
ASSEMBLED
LOC/FPM/12 Lock 38 1
RVT/FPM/12 Rivet 39 1
FPM/KIT/PC Power Cable
Assembly Kit
SA/PCLE/FPM/12/HF Power Cable 43 1 ASSEMBLED

Groz Engineering Tools (P) Ltd.
Groz Net Industries
Village Kherki Daula, National Highway-8
Gurgaon-122001, Haryana, INDIA
TEL [phone]
FAX [phone]
FAX (USA) +1.509.271.7848
FAX (UK) +44.870.121.1854
E-MAIL [email protected]
URL www.groz-tools.com
The Groz name, Groz logo and the mark are
trademarks of Groz Engineering Tools (P) Ltd. India