Lincoln 1550 Product manual

Fuel transfer pump
Model 1550, 12 V DC 15 gal./min.
Installation and maintenance guide
Read manual prior to installation or use
of this product. Keep manual nearby for
future reference. Failure to follow
instructions and safety precautions may
result in death or serious injury.
DANGER
Date of issue July 2014
Form number 404605A
Section B5
Page 51A

Overview
The Lincoln model 1550 fuel transfer pump
features a rotary vane pump design utilizing
a 12 V DC motor. The 12 V DC input is ideal
for vehicle auxiliary tanks since most vehicle
electrical systems are 12 V DC.
The pump comes with a tank adapter to
mount the pump to a 2 in. NPT tank
opening.
This pump is compatible with diesel,
kerosene, and mineral spirits. The pump kit
includes:
a two piece telescopic pickup tube de-
signed to fit a wide range of tank depths
up to 36 in. (0,91 m)
a
3
/ 4 in. ID anti-static delivery hose, and
control nozzle.
Specifications
Power input 12 V DC
Flow rate1) 15 gal./min. (57 l/min.)
Fluid compatibility Diesel, kerosene, mineral spirits
Maximum current draw 35 A
Delivery hose 13 ft. (3,9 m) antistatic 3/4 in. ID
Tank pickup 2 piece telescopic steel tube
Pump inlet 1 in. NPT internal
Pump outlet 1 in. NPT internal
Weight 14 lbs. (6,4 kg)
1 Flow rate is dependent on the fluid being used and the voltage of the power supply. Using a power supply voltage of less than 12 V
reduces the performance of the pump. This flow rate has been determined in a lab using diesel calibration fluid under ambient
conditions of 75 °F (24 °C).
Power source
requirements
A 12 V DC power supply is required to
operate this pump. Pump performance is
dependent on proper supply voltage.
Under extreme working conditions this
pump can draw up to 35 A.
Ensure the vehicle’s alternator is rated
high enough to supply the pump current or
the vehicle’s battery may be depleted during
pump operation.
Optional accessories
Spin On 30um Filter 25100
Filter Head, Spin-On 25113
Fuel Filter Kit 25114
2

Work area safety
Keep work area clean and well lit. Cluttered
and dark areas invite accidents.
Do not operate the pump in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust.
Keep children and bystanders away while
operating the pump. Distractions can cause
user to lose control. Do not allow children to
operate the pump.
Electrical safety
All electrical work must be performed by a
licensed electrician.
Avoid body contact with earthed or
grounded surfaces such as pipes, radiators,
ranges and refrigerators. There is an
increased risk of shock if one’s body is
earthed or grounded.
Do not abuse the cord. Never use the cord
for carrying, pulling or unplugging the tool.
Keep the cord away from heat, oil, sharp
edges or moving parts. Damaged or entan-
gled cords increase the risk of electric shock.
Do not operate the pump with a damaged
cord, alligator clips, or terminals. Replace
immediately.
Read all safety warnings and all instruc-
tions. Failure to follow the warnings and
instructions may result in electric shock,
fire, property damage, serious injury
and/or death. Save all warnings and
instructions for future reference.
WARNING
Do not operate pump without 40 A fuse.
Failure to comply may result in elec-
tric shock or damage to vehicles electri-
cal system.
WARNING
The pump must be properly grounded.
Always use the supplied fuse holder and
40 A fuse.
Only use the power cord that was sup-
plied with the pump.
Personal safety
Stay alert, watch what you are doing, and
use common sense when operating the
product. Do not use the product while you
are tired or under the influence of drugs,
alcohol or medication. A moment of
inattention while operating the product may
result in serious personal injury.
Never smoke near the pump. Fire or
explosion may result.
Use personal protective equipment.
Always wear eye protection. Safety
equipment such as dust mask, respirator,
non-skid safety shoes, hard hat, gloves, and
hearing protection used for appropriate
conditions will reduce personal injuries.
Prevent unintentional starting. Always
ensure the switch is in the off position
before connecting power source.
Remove any adjusting key or wrench
before turning the tool on. A wrench or key
left attached to the tool may cause personal
injury.
Dress properly. Do not wear loose clothing
or jewelry. Keep your hair, clothing and
gloves away from moving parts. Loose
clothes, jewelry or long hair can be caught in
moving parts.
If devices are provided for the connection
of dust and/or fume extraction and collection
facilities, ensure these are connected and
properly used. Use of these devices can
reduce dust or fume related hazards.
Always keep proper footing and balance.
This product is made from raw materials
known to the State of California to cause
developmental harm and/or cancer.
Do not adjust alligator clips when the
pump is operating. Always ensure alliga-
tor clips are securely fastened before
operating the pump.
Risk of electric shock or explosion.
WARNING
!
Notice
Pump does not exceed a noise of
80 db at a 3.2 ft. (1,0 m) distance from
the pump during normal operation.
3

Product use and care
Do not use pump to transfer gasoline.
Risk of explosion.
Do not use this pump for liquids or
materials intended for human consump-
tion. Personal injury may occur.
Do not use the pump to fill aircraft.
Never use this pump as source of
building pressure.
Use correct tool for application. The
correct tool will perform job in better
and safer manner when used for intend-
ed application.
Do not modify this equipment or use
for other than its intended purpose.
Store transfer pump out of reach of
children and in dry location to reduce
opportunity for rust.
Do not allow persons unfamiliar with
transfer pump or these instructions and
warnings to operate or handle tools.
Fuel transfer pumps are dangerous in
hands of untrained users.
Maintain all components of this prod-
uct. If any components are worn or
damaged, replace immediately.
Many accidents are caused by poor
maintenance.
WARNING !Notice
Do not use pump to transfer
water. Damage to pump will occur.
Always use filter on pump outlet to
avoid foreign material from contaminat-
ing and/or damaging equipment’s fuel
system.
Do not operate pump outside an en-
vironment temperature range of –4 °F
and 140 °F (–20 and 60 °C).
Do not allow motor temperature to
exceed 140 °F (60 °C); damage to motor
will occur. Use fan to cool motor under
high temperatures.
!Notice
Always disconnect the tool
from its power source before making
adjustments, changing accessories,
storing the tool, or repairing parts. Fol-
low appropriate company lockout/tag
out procedures. Such preventive safety
measures reduce the risk of starting the
power tool accidently.
Industrial applications must follow
OSHA requirements.
Do not allow metal components to
come in contact with alligator clips which
could cross the positive and negative
terminals. This can cause spark or dam-
age to vehicle’s electrical system and/or
pump.
Always ensure tank is properly bolted
and supported to avoid shifting or tip-
ping before attaching pump.
Extreme operating conditions with
working cycles of more than 30 minutes
can cause motor temperature to rise
and cause damage to motor. Each
30 minute working cycle must be fol-
lowed by 30 minutes of power off.
Use only anti-static hose supplied
with pump to reduce static electricity
buildup. Always keep control nozzle in
contact with tank being filled.
4

Fig. 1
Service
Separate collection.
This product must not be
disposed of with normal
household waste.
Assembly and
installation
Remove all components from packaging and
ensure all components are present. Refer to
fig IPB1, fig IBP2, and fig IPB3, pages 3–5
for reference to components.
1 Assemble the tank adapter (26)
(2 in. NPT thread) to the tank opening
(† fig. 1).
2 Insert adapter (27) into the nut and hold
in place with (25) as shown in Fig. 2.
3 Apply provided thread sealant tape to
threads of the 1 in. NPT adaptor (27).
Fig. 2
4 Tighten the 1 in. (25,4 mm) NPT internal
thread of the adapter (27) into the pump
inlet (1 in. NPT).
5 Measure the depth of the tank from top
of the adapter (26) to bottom of the
tank.
6 Assemble the rigid tube and/or
telescopic tube in order to reach desired
depth († table 1).
26
Fig. 3
Table 1
Tank depth Tube configuration
Less than 14 in.
(356 mm)
Use rigid tube and cut
to correct length.
14 in. (356 mm) to
27.5. in. (699 mm)
Use only telescopic
tube and extend to
correct depth.
27.5 in. (699 mm)
to 39 in. (991 mm)
Use rigid and
telescopic tubes.
Extend to correct
depth.
More than 39 in.
(991 mm)
Order an additional
rigid tube.
27
25
!Notice
Have this product serviced by a
qualified repair person using only identi-
cal replacement parts. This will ensure
that safety of the product is maintained
!Notice
To reduce risk of injury,
the user must read the
instruction manual. 26
7 Assemble the rigid extension tube (28)
and/or telescopic tube (29) into adapter
(27).
8 Use the provided thread sealant tape for
this connection point.
9 Insert the pump with tube assembled
into the tank.
10 Orient the pump to the desired position
with respect to the tank.
5

Fig. 8
Fig. 6
Fig. 4
14 Apply provided thread sealant tape to
threads of the 1 in. NPT street elbow (9).
!Notice
Keeping hose straight will make
tightening coupler easier.
Fig. 5
15 Insert and tighten the 1 in. NPT street
elbow (9) into the outlet of the pump
body.
16
Fig. 7
16 Connect and tighten the delivery
hose (27) to the street elbow (9).
17 Apply provided thread sealant tape for
this connection point.
!Notice
Over torque of bolts († step 9)
can result in damage to casting.
.
18 Connect and tighten the nozzle (28)
to the delivery hose (27).
19 Apply provided thread sealant tape for
this connection point.
20 Hang the nozzle (28) on the nozzle
hanger (16).
!Notice
Installing 30 micron or finer filter
between pump and control nozzle is
recommended. Failure to use filter can
allow debris to damage to vehicle’s fuel
tank, fuel line, fuel pump, injectors, and
similar components.
!Notice
Insure On/Off lever (19) is in Off
(down) position prior to proceeding to
electrical wiring instructions.
!Notice
If tank is less than 12.5 in.
(3,8 mm) deep, cut the rigid extension
tube to desired length allowing at least
0.5 in. (0,500 mm) between tube and
tank bottom when assembled.
!Notice
If telescopic tube is used with rigid
extension tube, use provided thread
sealant tape at this connection point.
11 Tighten the nut (25) to the tank adapter
(26).
12 Assemble the nozzle hanger (16) to the
pump using the two bolts provided.
13 Torque to 22 in.lbf (2,8 Nm).
6

Electrical wiring
Grounding the pump
This pump requires electrical grounding to
the vehicle’s chassis.
1 Strip one end of a green 12 AWG wire
and fasten a ring terminal to fit a 0.20 in
(5 mm) diameter screw.
2 Insert screw with lock washer (17) into
the ring terminal and tighten to the pump
casting.
!Notice
Avoid orienting ring terminal and
wire in direction of actuator lever (19)
and control nozzle (31) when stored on
hanger (16).
3 Route the new wire to a proper grounding
location on a steel or metal chassis
component.
4 Install a ring terminal on end of wire and
fasten the terminal with a screw.
!Notice
Do not ground to a fuel tank. This
may jeopardize the integrity of the fuel
tank and/or cause the tank to leak.
!Notice
Do not ground to a suspension
member or crash structure of a vehicle.
This may cause damage to the vehicle
and/or effect performance/safety.
Connect with alligator clips
1 Only use the insulated power cable (24)
supplied with the pump kit.
2 Inspect the cable for any damage that
may have occurred during shipment.
3 Observe the markings on the vehicle’s
battery to determine the positive (+) and
negative (–) posts.
4 Use the red colored (handle) alligator clip
to connect to the positive (+) battery
terminal.
5 Use the black colored (handle) alligator
clip to connect to the negative (–) battery
terminal.
Hard wire to vehicle’s battery
Never wire into vehicle’s accessories
outlet.
Wires can overheat, cause fire, or
damage wires of vehicle’s electrical
system.
Length of wire from pump to power
source should never exceed 18 ft.
(5,5 m) with 12 AWG wire.
Voltage drop due to use of incorrect
wire size and length may result in poor
pump performance and/or damage to
the pump.
Refer to the national, international,
or local electrical codes to determine
correct wiring for application.
CAUTION
1 Use only the insulated power cable (24)
that is supplied with the pump kit.
2 Inspect the cable for any damage that
may have occurred during shipment.
3 Cut the two wires nearest the alligator
clips.
4 Strip approximately 0.5 in. (12,7 mm)
insulation from the wire ends and add
ring terminals.
5 Remove the 40 A fuse from the fuse
holder.
6 Route the insulated power cable from
the pump junction box through the vehi-
cle to the main battery.
!Notice
Do not cut fuse holder out of
power cable.
!Notice
Use ring wire terminals that fit
battery lug size.
!Notice
This pump is designed for
12 V DC power supply. Using power
source other than 12 V DC can cause
damage to pump.
Always use 40 A fuse and fuse holder.
Mount fuse holder as close to positive (+)
side of power source as possible.
Always ground pump to vehicle’s
chassis before dispensing fuel.
Do not wire the pump using wire size
smaller than 12 AWG.
Do not connect pump wiring to vehi-
cle’s wiring system that uses wire small-
er than 12 AWG.
Failure to comply will result in damage
to vehicle’s electrical system and risk of
fire.
WARNING
7

7 Observe the markings on the vehicle’s
battery to determine the positive (+) and
negative (–) posts.
8 Connect the pump’s power cable (24)
white wire to the positive (+) terminal of
the battery.
9 Connect the pump’s power cable (24)
black wire to the negative (–) terminal of
the battery.
10 Ensure all wiring connections to the
pump, including the ground wire, are
correct.
11 Reinstall the 40 A fuse into the fuse
holder.
!Notice
Avoid routing wires near areas of
high temperature, sharp edges, or any
environment that may cause damage to
wires.
!Notice
Secure power cable by using
cable glands, cord clips, nylon ties, etc.
Fig. 9
Operation
1 Remove the fuel control nozzle from the
nozzle hanger.
2 Place the fuel control nozzle into the
desired tank.
3 Rotate the pump switch lever to the “on”
(up) position.
4 Engage the control nozzle handle to
dispense fuel.
5 When the tank is full or at the desired
level, release the handle to close the
nozzle’s valve and stop dispensing fuel.
6 Rotate the pump switch lever to the “off”
(down) position to turn off the pump
motor.
7 Remove the fuel control nozzle from the
tank and return it to the nozzle hanger.
8 If alligator clips are used for power
connection, disconnect the alligator clips
from the power source.
!Notice
Do not operate pump in bypass
mode for more than 30 minutes.
In bypass mode pump motor is on but
control nozzle is not open (is not dis-
pensing fuel).
Operating in bypass mode for more
than 30 minutes can cause motor
failure.
Control nozzle must stay in contact with
tank being filled.
Contact between control nozzle and
tank grounds system.
Failure to comply involves risk of fire
or explosion that may result in death or
serious injury.
WARNING
Do not rig control nozzle handle to stay
open.
Do not leave pump unattended when
dispensing fuel.
Fuel control nozzle is not equipped
with automatic shut off device that turns
off nozzle when tank is full. Always watch
tank fuel level closely and disengage
nozzle so tank does not overflow.
If fuel overflows and comes in contact
with user it can result in injury such as
skin irritations and burns.
CAUTION
8

!Notice
Do not over-torque screws. This
can result in damage to the casting and
wear of rotor.
Service
Rotor and vane replacement
1. Remove the three screws from
the cover plate.
2. Remove the cover plate. Note
the direction of the vanes and
rotor as shown.
3. Replace any worn or damaged
components.
4. The rotor is designed to allow it
to only be assembled one way.
Do not force the rotor onto the
motor shaft.
5. Align the O-ring and cover
plate.
6. Torque the (3) M6-1mm screws
to 22 in-lb
(2.5 N-m).
Switch repair
1 Remove the (6) M5-0.8mm screws from
the casting.
2 Loosen and remove the M8 lock nut
from the lever shaft.
3 Slide the wave washer, lever arm, and
washer from the shaft.
4 Flip the casting over and remove the nut
securing the switch to the plastic mount
bracket, then pull the switch from the
mount bracket.
5 If replacement of the mount bracket is
required, loosen and remove the (2)
Phillips head screws from the plastic
mount bracket. Replace bracket and
torque the (2) Phillips head screws to 20
in-lb (2.2 N-m).
11 Adjusting the toggle switch nuts changes
how soon the toggle switch is engaged.
Slight twisting of the shaft forks may be
necessary to get proper alignment.
12 Ensure the wire leads are correctly as-
sembled to the switch, if the wires are
backwards then the vane pump will
pump in the wrong direction.
13 Reinstall the (6) M5-0.8mm screws into
the casting and tighten to 22 in-lb (2.5
N-m).
Brush replacement
1 Loosen and remove the plastic plug se-
curing the brush.
2 Pull the brush from the brush holder.
3 Insert new brush.
4 Reinstall the plastic plug. Use a screw
driver to tighten. Do not over-torque the
plastic plug, the plastic plug will break.
!Notice
Do not over-torque screws. This
can cause in damage to the casting or
screw.
6 If required, slide the shaft assembly from
the casting and replace any damaged or
worn parts.
7 Prior to reassembly of the shaft assem-
bly into the casting, lubricate the shaft
and O-ring with a light grease. This will
reduce wear on parts during use and
make assembly easier.
8 Fit the toggle switch to the plastic mount
bracket and tighten the nut to secure the
toggle switch.
9 Reassemble the washer, lever arm, wave
washer, and M8 lock nut to the shaft
assembly.
10 Manually actuate the lever arm between
the On (up) and Off (down) positions to
ensure the alignment of the shaft as-
sembly fork and switch work correctly.
9

Troubleshooting
Condition Possible cause Remedy
Motor not operating. Blown fuse. Locate fuse holder and replace fuse.
Power supply voltage is too low. Check battery electrical connections
Recharge battery
Jammed rotor. Remove pump access plate and remove any
debris stuck between vane, rotor, and/or inlet/
outlet ports.
Brushes worn. Replace brushes and clean communtator
Brushes welded to communtator.
Reduced or no flow. Pickup tube drawing air. Disassemble all connections of pickup tube
before pump casting. Clean threads and apply
new thread sealant. Reassembly according to
assembly instructions.
Blockage. Disassemble pump and inspect the system for
any debris that is blocking fluid path. Inspect the
vanes and rotor for signs of damage.
Low voltage of power supply. Recharge vehicle’s battery.
Head loss too high. Reduce distance from pump to bottom of pickup
tube or raise fluid level of supply tank.
Bypass valve stuck open. Remove bypass valve plug and bypass valve from
pump. Clean bypass valve and sealing surface of
pump housing.
Water/moisture in motor. Damaged/worn seal. Replace two seals between motor and both
casting parts.
Pump body leakage. Damaged/worn seal. Replace pump seal kit.
Control nozzle leakage Damaged/worn seal. Using control nozzle seal kit, replace all seals.
Probable location for leakage is o-ring seal used
in swivel.
On/off lever difficult to rotate. Locknut too tight. Reduce amount of torque on locknut.
On/off lever will not turn pump on. Blown fuse. Replace fuse.
Incorrect voltage. Check power supply voltage.
Damaged/worn shaft assembly. Check and replace if defective.
Damages/worn lever switch.
Defective toggle switch.
Lever switch locknut is loose. Ensure that D-shaped hole on the lever switch is
aligned with slot on the shaft assembly. Tighten
the locknut with correct torque.
Motor stalls when control nozzle is closed. Bypass valve not opening. Remove the bypass valve plug and bypass valve
from pump. Clean bypass valve and sealing
surface of pump housing. Inspect bypass valve,
spring and sealing surface for damage/wear.
10