Aux Fuel Pump Continues to Fail

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Kigiin

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The second one just crapped out, virtually identical to how the first one failed:

- works for the first transfer of fuel from aux tank to main
- starts making a loud noise during the second transfer
- gallons per minute decreases significantly
- fuse (15 or 20 amp) blows as soon as pump is turned on

This is a Front Runner tank install, where Fernando at Campinglabs has sent me a replacement pump once already.

The electrical install seems pretty straightforward so don't know how that could be the problem, but given the pumps both failed almost exactly in the same way, makes me wonder. However, given that both pumps starting making very loud noises (compared to when new) shortly prior to the fuse blowing makes me wonder too.

How would you troubleshoot something like this?

I am going to buy a different type pump than FR supplies. I think the FR doesn't use a solenoid, if that matters.
 
Before the 2nd pump blew, were you ever able to do a complete fuel transfer on that second pump? (All forty something gallons)
 
Just asking the obvious: The aux tank is vented and the vent is functioning correct?
 
pegasis0066 said:
The second one just crapped out, virtually identical to how the first one failed:

- works for the first transfer of fuel from aux tank to main
- starts making a loud noise during the second transfer
- gallons per minute decreases significantly
- fuse (15 or 20 amp) blows as soon as pump is turned on

This is a Front Runner tank install, where Fernando at Campinglabs has sent me a replacement pump once already.

The electrical install seems pretty straightforward so don't know how that could be the problem, but given the pumps both failed almost exactly in the same way, makes me wonder. However, given that both pumps starting making very loud noises (compared to when new) shortly prior to the fuse blowing makes me wonder too.

How would you troubleshoot something like this?

I am going to buy a different type pump than FR supplies. I think the FR doesn't use a solenoid, if that matters.
Click to expand...

Replace the fuse, disconnect the wiring at the pump. If the circuit holds you have pump problems.
If you find its your pump again I would change brand immediately.

I run a Holley high volume vane pump on my FJ40 for fuel transfer. It was installed in 1991 and over the years has pump 1000's of gallon and pumped dry several time.
 
The tank is vented, but not sure how I could verify it is working correctly. I don't get any "vapor sound" when I open the cap.

I have never been able to pump all 45 gallons from aux to main. The pump always breaks on the second round of filling the 25 gallon main tank.

I will look into the restriction on the supply side and a vacuum, however I would think this would happen immediately and not after 20 or so gallons pumped.
 
pegasis0066 said:
I have never been able to pump all 45 gallons from aux to main. The pump always breaks on the second round of filling the 25 gallon main tank.
Click to expand...
It would do this if you didn't have the pump connected to the correct pick-up tube but rather a vent since the vent doesn't reach the bottom of the tank. Or if your pick-up tube had a crack in it somewhere. Didn't you lower the tank recently to troubleshoot a rub?
 
The vent tubes are significantly smaller than the supply lines, so definitely couldn't make that mistake. I am lowering the tank this Friday to put some type of mat between it and the cargo floor board so will look into things then.
 
I spoke to my independent mechanic who installed the tank/pump, and when he replaced the first failed pump he predicted the new pump would fail too... something about the type of pump and the application.

After talking to him yesterday, he thinks the lack of pressure between aux and main is causing the pump to overheat, blow the fuse, and eventually fail.

Thoughts?
 
Yeah, I know. I have emailed Fernando and Paul this link, but haven't received a response.

I think Christo is right that it can't be electrical, but something to do with pump input/output.
 
pegasis0066 said:
I spoke to my independent mechanic who installed the tank/pump, and when he replaced the first failed pump he predicted the new pump would fail too... something about the type of pump and the application.

After talking to him yesterday, he thinks the lack of pressure between aux and main is causing the pump to overheat, blow the fuse, and eventually fail.

Thoughts?
Click to expand...

Holley high volume vane pump:)
 
Installed a Carter rotary pump that is whisper quiet.

On another note, I think I may have caused this last pump failure. I thought I had over 25 gallons in the aux tank when I last tried to transfer, but as it turns out the tank was bone dry. So I burned out the pump by running it no fuel.

Not having a gauge for this tank is going to require more careful attention.
 
Operator error...that NEVER happens around here...damn, not sure I would have admitted it.

damn glad you figured it out and found a good quiet pump. This place is a wealth of info whether I get around to half the mods I want to or not. :)
 
I actually need one too. I have an aux fuel level gauge but no auto shut-off. I think I'll go another route though and utilize the fuel level signal for the shut-off.
 
Hi Robert,

Finally made it back to civilization to respond, but it sounds like you found out the issue. I have replaced the pump once on my tank too. The second pump is still working after a couple years of constant transferring. Running a pump dry for too long will do that. Pump 3 sounds like a nice one, and hopefully you use it for some time.

As for the vacume concern, there shouldn't be a change in any pressure under this system. The fuel is drawn from the bottom of the aux tank and poured into the top of the filler neck of the main tank. There are breather lined for both tanks up to the top of the filler neck too. Because it is all happening up at the filler neck level, air can make it to the aux tank, main tank, etc with relative ease.

cheers,
 
I thought I would report that lowering the pump closer to level with the aux tank's outlet has solved the problem. Maybe there are/were multiple problems, such as a vacuum issue too as Paul suggests above however by simply remounting the pump a little lower I now have no problems pumping all the gas out of the aux tank.
 
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