Ironton 1040R User manual

1
M157101A
Owner’s Manual
Instructions for Installation, Testing, Operation, Servicing, and Storage
12V Freshwater Pump: For use in transferring potable water, indoor use only.
WARNING
•READ and UNDERSTAND the Owner’s Manual completely before using this
potable water pump. Install, test, and use only in accordance with the Owner’s Manual
instructions.
•WEAR personal protective gear when filling, using, cleaning, and servicing the
water pump.
•DO NOT START water pump until ready to use to avoid unintentional spray release.
•FOR INDOOR USE ONLY.
•ALWAYS keep a fire extinguisher rated “ABC” nearby.
•Improper use of the water pump could result in serious injury to the operator or
nearby persons/animals or could cause damage.
Any Questions, Comments or Problems
Call Ironton Product Support 1-877-234-6869.
ITEM NUMBER: 157101
SERIAL NUMBER: _______________

Hazard Signal Word Definitions
2

Table of Contents
3
Intended Use .................................................................................................................................... 4
Summary of Important Safety Information....................................................................................5
Before Installation
During Installation
General Safety
Operation
Accident Procedures
Warning Label Location ..................................................................................................................6
Installation
Step One: Prepare for Installation................................................................................................7
Step Two: Mounting....................................................................................................................7
Step Three: Plumbing ..................................................................................................................7
Step Four: Connect pump to 12 Vdc power supply......................................................................7
Step Five: Check and test the installation of the pump.................................................................9
Operation
Preparing the Pump for Use....................................................................................................10
Using the Pump
Step One: Operate the pump...............................................................................................11
Step Two: Clean pump after each use.................................................................................11
Storage.............................................................................................................................................12
Preparing for storage
Removing from storage
Troubleshooting..............................................................................................................................14
Specifications...................................................................................................................................16
Limited Warranty...........................................................................................................................17

Intended Use
4
The pump is intended for use in transferring potable/drinking water, for indoor use only.
The pump is intended for intermittent or continuous duty when the proper operating criteria is met.
The technical specifications for your pump are provided in the Specifications section of this manual.
Follow all safety precautions presented throughout the manual. A summary of important information
can be found at the beginning of this manual.
Contact Ironton Product Support at 1-877-234-6869 for any questions about the appropriate
use of the pump.

Summary of Important Information
5
WARNING
Read and understand this owner’s manual completely before using the pump.
Improper use of the pump could result in serious injury or illness for the operator or
nearby persons/animals, or cause damage to the environment.
LISTED BELOW is a summary of safety information of particular importance. See individual
sections of this owner’s manual for more details.
--------------------------------BEFORE INSTALLATION---------------------------
•CHECK for properly sized wiring and correct electrical protection.
•CONFIRM the mounting location will allow adequate ventilation to prevent overheating.
•TURN power OFF to the existing pump(s).
•RELIEVE system pressure.
•DISCONNECT the main power to the pump.
------------------------------DURING INSTALLATION---------------------------
•EXERCISE CAUTION when attaching pump to 12 Vdc power supply. Follow the steps
listed in the Installation section of this manual when connecting the pump to the power supply.
•CHECK and TEST installed pump as directed in this manual.
•DO NOT MODIFY pump design.
-------------------------------GENERAL SAFETY---------------------------------
•READ and FOLLOW instructions and warnings in this manual.
•DO NOT USE flammable or corrosive chemicals in this pump.
-----------------------------------OPERATION--------------------------------------
Before Use
•INSPECT and PREPARE pump before each use as directed in this manual.
•SANITIZE the pump before each use and prior to storage.
•DO NOT TURN ON POWER to pump until ready to USE to avoid unintentional flow.
During Use
•TURN OFF power to pump and RELIEVE system pressure before leaving pump
unattended.
•SEE the Troubleshooting section of this manual before attempting any repairs. Wear
personal protective equipment and follow safety instructions.
After Use
•SANITIZE pump immediately after use according to the directions provided in this manual.
Accident Procedures
Immediate response is necessary in the event of a pump leak. See instructions below:
Pump leak
If the pump develops a leak, immediately stop using. Turn off power to the
pump and refer to the troubleshooting section of this manual, as applicable.

Warning Label Location
6
Always make sure warning labels are in place and in good condition. If a warning label is missing
or not legible, order new labels or unsafe operation could result. To order replacement warning
labels, call Ironton Product Support at 1-877-234-6869.
Part#
Description
Model
799654
Decal, 1.0 GPM Potable Water Pump
1040R

Installation
7
Step One: Prepare for Installation
•This Ironton pump is self-priming.
•The pump is for indoor use only and should be mounted on a solid surface in a location that
is dry and provides adequate ventilation.
•Prior to installation, ensure properly sized wiring, proper electrical protection, and
adequately sized plumbing lines and connections.
Step Two: Mounting
•The pump may be mounted in any horizontal position. If mounting the pump vertically, the
pump head should be in the down position so that in the unlikely event of a leak, fluid will
not enter the motor.
•Secure the rubber feet with #10 fasteners. DO NOT compress the feet, doing so will reduce
their ability to isolate vibration/noise. (Note: fasteners are not included.)
•Mount pump within 6 feet of the tank for best pump performance and longer pump life.
Step Three: Plumbing
•See table below for port size and recommended hose sizes.
oRemove shipping plugs from pump ports.
NOTE: Ironton does not recommend the use of rigid pipe to plumb the inlet/outlet ports.
•Tubing/hose should be flexible, compatible with potable water, and rated for the pump’s
maximum pressure. At least 18" [450mm] length is suggested to minimize stress on the
fitting/ports and reduce noise. Allow for the shortest possible tubing/hose route and avoid
sharp bends that may kink over time.
•The tubing/hose should be anchored where it meets rigid pipe/hard plumbing to reduce
vibration.
•Installation of a potable water approved 50-mesh strainer is recommended to prevent
foreign debris from entering the system. Failures due to foreign debris are not covered
under the warranty.
NOTE: Restrictions on the inlet may cause a loss in performance. Additionally, inlet pressure must
not exceed 30 psi [2.1 bar].
•If a check valve is installed in the plumbing, it must have a cracking pressure of no more
than 2 psi [.14 bar].
Step Four: Connect Pump to 12 Vdc Power Supply
WARNING
•Caution must be exercised when making connections to a 12 Vdc power supply to avoid
shock.
•ALWAYS follow the safety instructions and steps listed below in exact sequence when
connecting the pump to a 12 Vdc power supply.
1. Preparatory
safety
Preparatory safety steps:
•ALWAYS use eye protection.
•NEVER smoke or work near sparks or other sources of ignition.
CAUTION
DO NOT locate the motor near plastics that could melt or combustible material. The surface
temperature of the motor may exceed 200°F [93°C].
Model
Ports
Minimum inlet hose size
Minimum outlet hose size
1040R
3/8" Hose Barb
3/8" (9.5mm) Inside Diameter
3/8" (9.5mm) Inside Diameter

Installation (continued)
8
2. Electrical
requirements
•The pump should be on a dedicated (individual) circuit, controlled
with a double pole switch (UL/CSA certified) rated at or above the
fuse ampere indicated by the pump motor label. Depending on
distance of the power source from the pump and ampere load on the
circuit, wire may need to be heavier than indicated by the chart.
•Use an approved wire of the size specified below or heavier.
Voltage
Model
Fuse
(amp)
Wire Leads
Wire Size
(Stranded MTW)
12 Vdc
1040R
5.0
RED (positive +)
BLACK (negative -)
#16 AWG (1.3mm2)
(or heavier)
3. Connect pump
to 12 Vdc
power supply
Connect the pump to a 12 Vdc power supply using the following procedure:
a) Strip off about 1 inch of insulation from the end of each power supply
wire.
b) Position the pump’s red wire parallel with the positive (+) wire from
power supply. Secure using a twist-on wire nut.
c) Position the pump’s black wire parallel to the negative (-) wire from
the power supply. Secure using a twist-on wire nut.
WARNING: Always connect in this sequence to avoid possible shock.
2687061, 2687062
FIG.06680
Negative (black)
Positive (red)

Installation (continued)
9
Step Five: Check and Test the Installation of the Pump.
WARNING
Serious injury could result from leaks if pump is improperly assembled, installed or the design
of the pump is modified. Follow the steps below to ensure the pump is properly installed.
Never modify the pump design.
1. Check
installation
Check installation to ensure the pump is properly mounted, wired, plumbed, and
in safe working condition.
2. Test with
potable water
Test the system for leaks with potable water:
a) Fill the tank with potable water.
b) The pump is an on-demand pump. When turned on, the pump will prime
itself, then turn off once reaching pressure. When the demand for flow
continues, the pump will automatically re-start.
c) Check for leaks throughout the system. If a leak is detected, fix the leak
and re-test the system with potable water.

Operation –Preparing the Pump for Use
10
Inspect and prepare pump before each use.
Important safety rules:
•Power off. Make sure all power is OFF before cleaning, inspecting, or servicing the pump.
•Guards / shields. Make sure all guards and shields are replaced after servicing the pump.
•Replacement parts. If a part needs replacement, only use parts that meet the manufacturer’s
specifications. Replacement parts that do not meet specifications may result in a safety
hazard or poor operation of the sprayer.
1. Ensure clean
system
Ensure the pump has been thoroughly flushed, drained and sanitized.
2. Inspect &
repair
Inspect and test the system thoroughly with potable water:
a) Inspect hoses/ lines for exposed mesh and holes. Replace all worn
or damaged hoses/ lines.
b) Inspect fittings for cracks and leaks. Replace Ironton pump if
needed.
c) Partially fill system with potable water and turn on to test for
leaks. Repair as needed.
IMPORTANT: After any repair work has been done, ALWAYS test for
leaks with potable water one final time before using.
WARNING
Read instructions below carefully for inspecting and preparing the pump.
Damaged or clogged equipment could result in leaks or uncontrolled spray.
Leaks could result in injury to the operator or bystanders.

Operation –Using the Pump
11
Step One: Operate the Pump.
WARNING
ALWAYS wear personal protective equipment when operating or servicing the pump.
1. Review
safety
information
Review the Summary of Important Information provided in this manual.
2. Wear
personal
protective
equipment
Wear personal protective equipment as needed.
3. Turn on
power
Turn on the power to the pump.
Note: The pump will start automatically when power is turned on. The
pump will cycle on and off as needed to retain pressure in the hose.
4. Pressure
switch
operation
The pressure switch reacts to outlet pressure and interrupts power at the preset
shut-off pressure indicated on the pump label. When outlet pressure drops
below a predetermined limit the switch will close and the pump operates until
the shut-off pressure is achieved. The shut-off pressure is set to factory
calibrated standards.
NOTE: If the plumbing is restrictive or the flow rate is very low, the pump
may re-pressurize the outlet faster than the fluid is being released, causing
rapid cycling (*ON/OFF within 2 seconds). If the pump is subjected to rapid
cycling during normal operation, or for infrequent periods, damage may
occur. Applications which exhibit rapid cycling should have restrictions in the
outlet minimized.
5. Leaving
unattended
If the pump must be left unattended at any time:
a) Disconnect power to the pump.
b) Relieve system pressure.
6. Discontinue
use if
clogged or
inoperative
If the pump becomes clogged or inoperative during use, discontinue use
immediately.
- Do not attempt to service while water is in the pump and power is
connected.
- Return to the troubleshooting section of this manual before attempting to
service.
CAUTION
DO NOT operate the pump at pressures which cause the motor to exceed the amperes rating
indicated on the name plate.
Improper adjustment of the pressure switch setting may cause severe overload or premature
failure. Failures due to improper adjustment of the pressure switch setting will not be covered
under the warranty.

Storage
12
Step Two: Clean Pump After each Use.
Pump should always be stored indoors.
For long term or winter storage, prepare the pump by running RV antifreeze through the system. This
will keep internal parts lubricated, protect against corrosion, and keep the unit from freezing.
CAUTION
The pump will be damaged if it freezes.
Protect the pump from freezing during storage by following the instructions below.
Preparing for storage:
1. Add antifreeze
Pour RV antifreeze into the pump system.
Note: RV antifreeze is non-toxic and biodegradable and generally safer for
the environment than automotive antifreeze.
2. Spray briefly
Turn on the pump and run the pump system briefly until fluid sprays.
Removing from storage:
1. Drain
Drain the antifreeze left in the pump system into a suitable container.
2. Flush with
water
Fill the pump system with potable water and run through the system.
Operate the pump system until the system is completely flushed. Be sure to
set up containers to capture the antifreeze flush water.
3. Disposal
Dispose of the antifreeze and flush properly with potable water.
4. Sanitize
To ensure clean, safe drinking water it is important for your health to
sanitize the potable water system if the pump has been sitting in storage or
has not been used for a while. The potable water holding tank, hot water
tank and the water lines are a great place for bacteria to grow.
Before you start, read all of the instructions in this manual on how to
properly sanitize the pump system.
Before you get started, consider the following.
•You will need at least 5 to 10 hours of time to complete this task.
•Do you have internal and external water filters? Remove the water
filters while sanitizing the water system and consider replacing the
water filter when you have completed the sanitation.
•Do you have a hot water tank? If you do, this is an ideal time to
flush out your hot water tank.
•Determine the size of your water system, the potable water holding
tank, plus the hot water tank and two to three gallons for your
water lines depending on your set up. Refer to your owner’s
manual.

Storage
13
Now you are ready to sanitize your potable water system.
1. Prepare a 5% sodium-hypocaloric solution using chlorine bleach
(non-scented and non-gel) and water. Use the chart below for
mix concentrations.
Fresh Water Tank
Size
Amount of
Bleach
Mix Including
Water
40 gallons (152 liters)
1 cup (240 ml)
4 gallons (16 liters)
50 gallons (190 liters)
1 1/4 cup (300 ml)
5 gallons (20 liters)
60 gallons (227 liters)
1 1/2 cup (360 ml)
6 gallons (24 liters)
80 gallons (302 liters)
1 3/4 cup (420 ml)
7 gallons (28 liters)
100 gallons (380 liters)
2 cups (480 ml)
8 gallons (32 liters)
2. Add bleach mixture to the water tank. NEVER POUR
STRAIGHT BLEACH INTO THE FRESH WATER TANK!
3. If you have a bypass for your hot water tank, make sure that is
set for normal use so that the bleach mixture will be pumped
thought the hot water tank.
4. Top off the potable water tank with potable water.
5. Run the chlorinated water through all lines (hot and cold one at a
time) for one to two minutes; You should be able to smell the
chlorine.
6. Top off the potable water tank again.
7. Let it sit for 4 hours minimum, but overnight is best. The most
important step is to wait the appropriate amount of time for the
tank to be properly sanitized.
NOTE: Doubling the bleach will not cut the time in half! Drain and rinse
the potable water tank and water lines several times with fresh potable
water.
The water should now be safe to drink but if the chlorine odor is too
strong, add a mixture of 1/2 cup baking soda and a gallon of fresh water to
the potable water tank and repeat the potable water flush.

Troubleshooting
14
WARNING
Before troubleshooting or attempting to service, read the following safety rules to avoid risk of
electric shock.
Before attempting to service the pump:
1. Personal
protective
equipment
Wear personal protective equipment while servicing your pump.
2. Review
troubleshoot-
ing table
Review the Troubleshooting Table below for the type of problem you are
experiencing. However, DO NOT attempt to repair until the steps listed
below are followed.
3. Empty and
flush
Empty the pump system and flush the pump system with potable water as
directed in the Storage section: Removing from Storage.
4. Disconnect
power/relieve
pressure
Disconnect power to the pump and be sure all system pressure is relieved.
5. Perform
repairs
Follow the directions provided in the troubleshooting table to repair the
pump.
6. Test after
servicing
After servicing, ALWAYS test the pump for leaks with potable water before
using.

Troubleshooting (Continued)
15
PROBLEM
CAUSE
SOLUTION
Pump will not turn on
Bad electrical connection
Check battery connections
Short in wires
Check condition of wires
Fuse blown (if applicable)
Replace fuse
Locked drive
Replace pump
Faulty pressure switch
Replace pump
Incorrect voltage
Check voltage (±10%)
Pump will not prime
Out of potable water
Refill potable water tank
Inlet air leak
Tighten hose clamps/Replace pump
Inlet/Outlet tube restriction
Remove restriction
Incorrect voltage
Check voltage (±10%)
Clogged intake valves
Remove obstruction
Clogged intake tube
Remove obstruction
Low pressure/flow
Inlet air leak
Tighten hose clamps/Replace pump
Worn diaphragm
Replace pump
Worn valves
Replace pump
Inlet/Outlet tube restriction
Remove restriction
Incorrect voltage
Check voltage (±10%)
Clogged intake valves
Remove obstruction
Clogged intake tube
Remove obstruction
Pump leaks
Loose fasteners
Tighten fasteners
Pump seals degraded
Replace pump
Leak in diaphragm
Replace pump
Pump starts with
faucets closed
Leak in the system
Tighten leaking hose clamps/ fittings
Faulty pressure switch
Replace pump
Incorrect voltage
Check voltage (±10%)
Air trapped in system
Purge the air from the system
Rough operation
Flexible mounting surface
Mount pump on rigid surface
Loose pump head
Tighten fasteners
Compressed base feet
Decompress base feet
Rigid plumbing
Plumb pump with flexible plumbing

Specifications
16
The noise emissions from this product do not exceed 70 dB(A).
The manufacturer reserves the right to make improvements in design and/or changes in specifications at
any time without incurring any obligation to install them on units previously sold.
Model
number
Electrical
connection
Maximum
amp draw
Maximum
flow
Maximum
pressure
Ports
Overall dimensions
Weight
1040R
12 Vdc
3 Amps
1.0 GPM
[3.8 LPM]
40 PSI
[2.8 bar]
3/8" Hose
Barb
6.87"x 3.93"x 2.39"
[174.7mm x 99.9mm x
60.75mm]
1.3 lbs.
[0.6 kg]

Limited Warranty
17
Dear Valued Customer:
Use this product properly and enjoy the benefits from its high performance. By purchasing an Ironton
product, you show a desire for quality and durability. Like all mechanical equipment this unit requires
a due amount of care. Treat this unit like the high-quality piece of machinery it is. Neglect and
improper handling may impair its performance. Please thoroughly read the instructions and understand
the operation before using your product. Always contact Ironton Product Support at 1-877-234-6869
prior to having any service or warranty work performed, as some services performed by parties other
than Ironton approved service centers may void this warranty. This warranty is in lieu of any other
warranty expressed or implied and Ironton assumes no other responsibility or liability outside that
expressed within this warranty.
Limited Warranty
Ironton shall warranty any piece of equipment manufactured, or parts of equipment manufactured, to
be free from defects in material or workmanship for a period of 90 days for noncommercial/nonrental
use from date of purchase by user. There is no commercial warranty on this product.
This warranty applies to the original purchaser of the equipment (verification of purchase, in the form
of a receipt, is the responsibility of the buyer), is non-transferable, and covers some parts and no labor.
Parts will be replaced or repaired at no charge, except when the equipment has failed due to lack of
proper maintenance. If a part is no longer available, the part may be replaced with a similar part of
equal function. Any misuse, abuse, alteration or improper installation or operations will void warranty.
Determining whether a part is to be replaced or repaired is the sole decision of Ironton. Ironton will
not provide for replacement of complete products due to defective parts. Any costs incurred due to
replacement or repair of items outside of an Ironton approved facility is the responsibility of the buyer
and not covered under warranty. Transportation costs to and from service center is the responsibility of
the customer.
In addition to the normal warranty, Ironton shall warrant any normal wear item from defects in material
or workmanship for a period of 90 days from the date of purchase by user. Normal wear items include,
but are not limited to, diaphragm, valves, seals, motor, switch, decals, wiring, barbs, fittings and
hardware.
This warranty specifically excludes the following; failure of parts due to damage caused by accident,
fire, flood, windstorm, acts of God, applications not approved by Ironton in writing, corrosion caused
by chemicals, use of replacement parts which do not conform to manufacturer’s specifications, damage
related to rodent and/or insect infestation and damage caused by vandalism. Additional exclusions:
loss of running time, inconvenience, loss of income, or loss of use, including any implied warranty of
merchantability of fitness for a specific use. Also, outdoor equipment needs periodic parts and service
to perform well, and this warranty does not cover instances when normal use has exhausted the life of a
component.
This warranty does not cover any personal injury or damage to surrounding property caused by failure
of any part. Repair or replacement of parts does not extend the warranty period.
Customer Number: ____________________________________________________________
Date of Purchase: _____________________________________________________________
Ironton Serial Number: ________________________________________________________
Item Number: _______________________________________________________________

18
Northern Tool + Equipment Co., Inc.
Burnsville, MN 55306
www.northerntool.com
Made in China