Roughneck 37889 User manual

Thank you very much for choosing a Roughneck™ Product! For future reference, please complete
the owner’s record below:
Model: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire manual
to become familiar with this product before you begin using it.
This machine is designed for certain applications only. The distributor cannot be responsible for
issues arising from modification. We strongly recommend this machine is not modified and/or
used for any application other than that for which it was designed. If you have any questions
relative to a particular application, DO NOT use the machine until you have first contacted
distributor to determine if it can or should be performed on the product.
For technical questions, please call 1-800-222-5381.
WARNING: Read carefully and understand all INSTRUCTIONS before operating.
Failure to follow the safety rules and other basic safety precautions may result in
serious personal injury.
Save these instructions in a safe place and on hand so that they can be read when required.
Keep these instructions to assist in future servicing.
INTRODUCTION
These products are positive displacement gear pumps. Depending on installation and viscosity,
these pumps can deliver up to 15 GPM (57 LPM). Their rugged design makes for a long life of
dependability.
TECHNICAL SPECIFICATIONS
• Inlet: 2in. male on tank adapter, 1in. female on pump
• Outlet: 3/4in. female
• Built-in bypass valve.
• Furnished with:
• 13ft. delivery rubber hose
• 1-pc. steel suction pipe
• 1-pc. aluminum manual nozzle.
• 2in. quick-change coupling
• Electrical Specifications
The above flow rate only indicates the flow rate for the outlet. Once connecting with the
hose and nozzle, the flow rate may change.
Fluid compatibility
If in doubt about compatibility of a specific fluid, contact supplier of fluid to check for any
adverse reactions to the wetted materials.
The pump is compatible with the following fluids:
• Diesel, Kerosene, Mineral spirits
Do not use the pump with the following fluids:
• Gasoline, Water, Sulfuric acid, Naphtha, Methanol, Methyl Ethyl ketone (MEK), Acetone,
Ammonia, Benzene, Bleach, Chlorine.
WARNING: This product should not be used for fluid transfer into aircraft. This
product is not suited for use with fluids for human consumption or fluids containing water.
12V FUEL TRANSFER PUMP
OWNER’S MANUAL
12V FUEL TRANSFER PUMP OWNER’S MANUAL
Item # 37889
1 of 6
Model Current
DC
Voltage
12
Maximum (Amp)
40
ELECTRICAL POWER CURRENT Flow Rate
(GPM)
15 GPM
37889
WARNING: Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other
basic safety precautions may result in serious personal injury.

12V FUEL TRANSFER PUMP OWNER’S MANUAL 12V FUEL TRANSFER PUMP OWNER’S MANUAL
OPERATING CONDITIONS
Temperature: Minimum -4°F (-20°C) / Maximum 140°F (60°C)
Relative Humidity: Maximum 90%
GENERAL SAFETY REGULATIONS
WARNING: Read and understand all instructions.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors that cannot be built
into this product, but must be supplied by the operator.
1. Keep the work area clean and dry. Damp or wet work areas can result in injury.
2. Keep children away from work area. Do not allow children to handle this product.
3.
Store idle equipment. When not in use, tools and equipment should be stored in a dry location
to inhibit rust. Always lock up tools and equipment, and keep out of reach of children.
4. Use the right tool for the job. Do not attempt to force small equipment to do the work of
larger industrial equipment. There are certain applications for which this equipment was
designed. It will do the job better and more safely at the capacity for which it was intended.
Do not modify this equipment, and do not use this equipment for a purpose for which it was
not intended.
5. Check for damaged parts. Before using this product, carefully check that it will operate
properly and perform its intended function. Check for damaged parts and any other condi-
tions that may affect the operation of this product. Replace damaged or worn parts immedi-
ately.
6. Do not overreach. Keep proper footing and balance at all times to prevent tripping, falling,
back injury, etc.
7. DO NOT use the equipment when tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating this equipment may result in serious
personal injury.
8. Industrial applications must follow OSHA requirements.
SPECIFIC OPERATION WARNINGS
To ensure safe and efficient operation, it is essential to read and follow each of these warnings
and precautions.
1. DO NOT smoke near pump or use pump near an open flame. Fire could result.
2. Disconnect power to pump before servicing pump.
3. Turn off the switch before connecting power.
4. Take motors needing service to an authorized repair shop or return to factory to maintain.
5. A filter should be used on pump outlet to ensure that no foreign material is transferred to fuel
tank.
6. Tank or barrel should be anchored to prevent tipping in both full and empty conditions.
WARNING:
1. Electrical wiring should be done by a licensed electrician in compliance with local codes.
Rigid conduit should be used and proper ground must be provided to avoid the possibility of
electrical shock. Failure to comply with this warning could result in serious injury and/or loss
of property.
2. This product should not be used for fluid transfer into aircraft. This product is not suited for
use with fluids for human consumption, or fluids containing water.
3. Extreme operating conditions with working cycles longer than 30 minutes can cause the
motor temperature to rise, thus damaging the motor itself. Each 30-minute working cycle
should always be followed by a 30-minute power-off cooling phase.
2 of 6
INSTALLATION
1. Tightly screw suction pipe into inlet coupling of pumping unit. Extend suction pipe into
truck tank or barrel to within 3in. of tank bottom.
2. Screw inlet coupling of pump into 2in. tank or barrel opening. Inlet coupling must be
completely and securely threaded into an undamaged tank or barrel bung.
3. During installation and maintenance, make sure that the electric supply lines are not live.
4. Always turn off the switch before supplying electrical power.
5. Check the correct rotation direction of the DC pump. If it is inverted, check the polarity of
the connection cable.
a) RED cable: positive pole (+)
b) BLACK cable: negative pole (-)
6. Systems should be designed to require a minimum amount of suction lift. Maximum
“equivalent feet of lift” is 8 feet for diesel fuel.
7. Tank or barrel must be properly vented. A water separator should be used for pumping
diesel fuel.
8. Power to the unit should be supplied from a dedicated 30 Amp circuit breaker. No other
equipment should be powered from this breaker. If two pumps are supplied from one
breaker, that breaker must be capable of handing the load of both motors.
9. Install bung adapter and suction pipe:
• Tighten the bung adapter snugly into the fuel tank
• Place the union ring gasket into the inlet fitting on the bottom of the pump
• Thread the suction pipe into the inlet fitting and tighten until snug. Install pump on tank
• Clean the tank interior of all dirt and foreign material
• Extend the suction pipe to its full length and insert into the tank opening
• Place the pump on the bung adapter and tighten the union ring securely with a pipe
wrench. Make sure the union ring is not cross-threaded
• To prevent pressure buildup and possible fuel leaks through the muzzle, make sure the tank
is vented a vent cap rated at 3 PSI or less is recommended
10. Replace gears and drive key:
• Turn the pump OFF and disconnect from power
• Remove the gear cover plate
• Lift the diver key and gears from the pump
• Inspect the gears and key for wear and damage. Replace as necessary
• Wipe the gear cavity with a clean cloth
• Replace the gears. Make sure they turn freely
• Replace the drive key
• Make sure the gear cover plate O-ring is securely in place. Tighten the cover plate to the
housing
11. To remove or replace the bypass poppet:
• As above, push down on the poppet until the O-ring is exposed
• Remove the O-ring with a small screwdriver or similar tool. Take care not to damage the
poppet or O-ring.
• From inside the housing, use a small screwdriver to push the poppet and spring through
the top outlet port
• Wipe the poppet and gear cavities with a clean cloth
• Replace the poppet, O-ring ,and spring as necessary
Note: Replace O-ring if damaged, swollen, or loose fitting
12. To clean or replace strainer:
• Turn the pump off and disconnect from power. Remove the strainer cover plate
• Remove the inlet strainer and inspect for damage or clogs
• Clean the strainer with a soft-bristled brush and solvent. If the strainer is very dirty,
compressed air may be used. If damaged, replace the strainer
13. Place the strainer in the cavity. Clean the cover plate and O-ring, coat the O-ring lightly
with grease. Ensure the cover plate O-ring is properly seated and tighten the strainer cover
plate.
3 of 6

12V FUEL TRANSFER PUMP OWNER’S MANUAL
TROUBLE SHOOTING
5 of 6
12V FUEL TRANSFER PUMP OWNER’S MANUAL
OPERATION INSTRUCTIONS
1. If using flexible tubing, attach the ends of the tubing to the tank(s). In the absence of an
appropriate slot, solidly grasp the delivery tube before beginning dispensing.
2. Before starting the pump, make sure that the delivery valve is closed (dispensing nozzle or
line valve).
3. Turn the ON/OFF switch to ON. The by-pass valve allows functioning with the delivery closed
for only brief periods.
4. Open the delivery valve, solidly grasping the end of the tubing.
5. Close the delivery valve to stop dispensing.
6. When dispensing is finished, turn off the pump.
MAINTAINANCE
Under normal working conditions, the noise emission from all models does not exceed the
value of 80dB at a distance of three feet from the electric pump.
Transportation
When the pump is in transit, do not expose the pump to direct sunlight and avoid rain, falling,
corrosive substances, etc.
Storage
①. Store the pump in a dry place with good ventilation. Do not expose it to excessive heat,
humidity or sunlight. Never let it touch any corrosive substances.
②. Store it out of the reach of children.
4 of 6
Problem Possible Cause Corrective Action
Motor does not
run
1. Fuse blown 1. Open the terminal box, check the fuse, if blown, replace
2. Switch defective 2. Remove switch cover plate and inspect switch. Replace if necessary
3. Motor burned out 3. Replace motor as described in the repair section
4. Switch or electrical connections
faulty
4. Inspect for damaged motor protector, defective wiring or switch, or
improper electrical connections. Replace as needed and reinstall
Motor runs but
does not pump
1. Suction pipe clogged, damaged,
or missing
1. Remove pump from tank, inspect suction pipe. Clean or replace as
necessary
2. Gear cover plate or o-ring
damaged
2. Remove and inspect the cover plate and o-ring, replace, as necessary,
refer to the repair section on servicing o-ring
3. Strainer clogged or defective 3. Remove strainer cover plate, remove and clean strainer, install again
4.
Bypass poppet o-ringworn or missing 4. Inspect o-ring using instructions in the repair section. Replace, if necessary
5. Bypass poppet o-ring dirty 5. Remove poppet assembly and clean poppet and cavity
6. Bypass poppet binding or
damaged
6.
Using instructions in the repair section. Remove the bypass poppet, spring
and o-ring. Clean cavity, inspect and replace components,as necessary
7. System air leak 7. Tighten all pump fitting and connections. Inspect suction pipe for leaks
or damage
8. System air lock 8. This can occur if external filter, meters, or an off-the-shelf automatic
nozzle is used. To correct, remove the pipe plug in the top outlet port
and fill the gear cavity with fuel. Use of a factory –supplied automatic
nozzle is recommended
9. Poor connections or low voltage 9. Make sure electrical connections are secure. Also check battery voltage
10. Fuel level low 10. Fill tank
11. Motor running backwards due to
incorrect polarity
11. Connect red wire to positive (+) ungrounded side of battery. Gear with
key should turn counterclockwise
Low flow rate 1. Poor connections or low voltage 1. Make sure electrical connections are secure, also check battery voltage
2. Strainer partially clogged 2.
Remove the strainer cover plate. Remove and clean the strainer. Install again
2. Strainer partially clogged 3. Remove pump from tank. Inspect suction pipe. Clean or replace, as
necessary
4. Fuel tank empty 4. Fill tank
5. Using off-the-shelf automatic
nozzle
5. Factory-supplied automatic nozzle is recommended
6. System air leak 6. Tighten all pump fittings and connections. Inspect suction pipe for leaks
or damage. Replace, as necessary
7. Bypass poppet spring weak 7. Using instructions in the Repair Section, remove the bypass poppet and
inspect spring, replace , if necessary
Motor stalls
when operation
in bypass mode
1. Motor protector activated 1. Turn off switch. Allow motor to cool, then turn on switch.
2. Gears locked 2. Remove gear cover plate and inspect gears and drive key. Make sure
gears turn freely with the key removed. Replace, if worn.
3. Wiring defective 3.
Use wiring instructions in the installation section to ensure proper connections
4. Bypass poppet binding or
damaged
4. Using instructions in the Repair section, remove the bypass poppet,
spring, and o-ring. Clean cavity. Inspect components and replace, as
necessary
5. Motor defective 5. Replace motor as described in the repair section
Switch fails to
operate motor
1. Switch or electrical connections
faulty
1.
Inspect for damaged motor protector, blown fuse, defective wiring or switch,
or improper electrical connections. Replace as needed and re-install
2. Motor burned out 2. Replace motor as described in the repair section
3. Motor protector activated 3. Turn off switch. Allow motor to cool , then turn on switch
Rapid
overheating of
motor
1. Duty cycle too long 1. Pump operation should notexceed the standard duty cycle of 30minutes
on, and 30minutes OFF. Allow the pump to cool for 30minutes.
2. Strainer clogged, 2. Remove strainer cover plate. Remove and clean strainer. Install again.
3. Suction pipe clogged or damaged 3.
Remove pump form tank. Inspect suction pipe. Clean or replace, as necessary.
4. Gears worn 4. Remove gear cover plate and inspect gears and drive key. Make sure
gears turn freely with key removed. Replace, if necessary.
5. Fuel level low 5. Fill tank
6. Running too long in bypass mode 6. Limit bypass operation to 5 minutes.

12V FUEL TRANSFER PUMP OWNER’S MANUAL
DIAGRAMS AND PARTS LIST
For replacement parts and technical questions, please call 1-800-222-5381.
6 of 6
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
Description
Screw M6×10
Strainer Cover
O-ring
Hexagon Flange Bolts M6x20
Strainer
Pump Cover
Seal
Key
Gear
Axle Bush
O-ring
Spring
Q’ty
4
1
1
4
1
1
1
1
1
1
1
1
Part No.
13
14
15
16
17
18
19
20
21
22
23
Description
Bypass Poppet
Elbows
Hoses
Nozzle Cover
1in. Manual Nozzle
Hex Bolts M6x10
Motor
Nut
Adapter
Tank Adapter
Suction Pipe
Q’ty
1
1
1
2
1
2
1
1
1
1
1
12V FUEL TRANSFER PUMP OWNER’S MANUAL
WARRANTY
One-year limited warranty
Distributed by
Northern Tool + Equipment Co., Inc.
Burnsville, MN 55306
NorthernTool.com
Made in China