GPI M-180S User manual

15-18 GPM (57-68 L/min)
12V & 24V (dc)
Fuel Transfer Pump
Models: M-150S M-180S, M240S
922123-01 Rev C11/2022
Product Owner’s Manual EN
SAVE THESE INSTRUCTIONS

SAVE FOR YOUR RECORDS
Model #: ___________________
Serial #: ___________________
Purchase Date: _____________
Thank you for choosing a Great Plains Industries product, and
congratulations on your purchase!
Headquartered in the heartland of the U.S., GPI strives
for integrity, innovation, continuous improvement, and
dependability—values you will immediately recognize when using
our products.
The maintenance policies and procedures outlined in this manual
emphasize our commitment to safety and our dedication to you
as a customer. By working together, we can ensure years of
reliable, quality service.
Please save these instructions for future reference. Read carefully before attempting
to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply
with instructions could result in personal injury and/or property damage.
Please refer to back cover for information regarding this product’s warranty and
other important information.
DO NOT RETURN THIS PRODUCT TO THE STORE!
Please contact Great Plains Industries, Inc. before returning any product. If you are
missing parts, or experience problems with your installation, contact our Customer
Support Department. We will be happy to assist you.
Call: 800-835-0113 or 316-686-7361
Email: [email protected]
Website: gpi.net

1-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
BEFORE YOU BEGIN
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Caution.eps
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Electrical_Caution.eps
Face_protection.eps
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Fall_protection.eps
GearHand_Hazard.eps
Head_protection.eps
Heavy_Hazard.eps
Hot_surface.eps
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Resp_protection1.eps
Resp_protection2.eps
Temp_Caution1.eps
body_protection.eps
chemical_Caution.eps
ear_protection1.eps
explosive_caution.eps
eye_protection1.eps
foot_protection.eps
hand_protection.eps
tools.eps
box.eps
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warning symbol.eps
measure.eps
plug.eps
oil.eps
megaphone.eps
biohaz.eps
Battery_Caution1.eps
Caution.eps
Crush_Caution1.eps
Electrical_Caution.eps
Face_protection.eps
Fall_Hazard.eps
Fall_protection.eps
GearHand_Hazard.eps
Head_protection.eps
Heavy_Hazard.eps
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Fueling Requirements:
• This fuel pump is designed, tested and approved for use with gasoline
blends (up to E15) diesel fuel blends (up to B20) and kerosene. Pump
only models sold without a hose/nozzle are compatible with aviation
gasoline AVGAS 100LL and kerosene grade Jet A. Please take all due
precautions when handling these flammable liquids.
• Do not use this pump for dispensing any fluids other than those for
which it was designed. To do so may damage the pumps components
and will void the warranty.
Power Source Requirements:
• This manual covers 12 and 24 volt DC electric gear pump
models M-150S, M-180S, and M-240S.
• Models M-150S and M-180S should be connected to a 12-volt DC
power source. Model M-240S should be connected to a 24-volt power
source only.
• Do not attempt connection of any pump to a 115-volt AC or
230-volt AC power source.
Tools Needed:
• Adjustable Wrench, Pipe Wrench, Pliers, Utility Knife,
Wire Crimper/Stripper, and Thread Tape
UNPACKING
Contents (See Figure 1):
• (1) 12-volt or 24-volt DC Fuel Transfer Pump with Spin Collar (Item A),
(1) Fiber Gasket (Item C) and (1) Tank Adapter (Item D); or 12-volt Fuel
Transfer Pump with Direct Mount (Item B) (M-150S-EM only)
• (1) 18 foot (5.5 m) Attached Power Cord with (1) Fuse Assembly (Item E),
(2) Ring Terminals (Item F) and (1) Wire Connector (Item G)
• (1) 12 foot (3.6 m) Dispensing Hose (Item H) (M-150S-AU & -MU,
M-180SAU & -ML, and M-240S-MU) or (1) 10 foot (3.0 m) Dispensing
Hose (M-150S-EM only)
• (1) 1 inch Female to 3/4 inch Reducer (Item K) - (M-180S-AU &
M-180S-ML)
• (1) 15 inch (38 cm) to 40 inch (101 cm) Adjustable Suction Pipe (Item L)
• (1) Automatic (Item M) - (M-150S-AU and M-180S-AU) or Manual Shutoff
Nozzle (Item N) - (M-150S-EM & -MU, M-180S-ML and M-240S-MU)
• (1) Lockable Nozzle Holder (Item P) - (M-150S-AU & -MU, M-180S-AU &
-ML, and M-240S-MU); or (1) Standard Nozzle Holder (Item Q) (M-150S-
EM only)
GETTING STARTED

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION GETTING STARTED
2-EN
UNPACKING (CONTINUED)
Contents (Continued):
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Caution.eps
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Fall_protection.eps
GearHand_Hazard.eps
Head_protection.eps
Heavy_Hazard.eps
Hot_surface.eps
Recycle.eps
Resp_protection1.eps
Resp_protection2.eps
Temp_Caution1.eps
body_protection.eps
chemical_Caution.eps
ear_protection1.eps
explosive_caution.eps
eye_protection1.eps
foot_protection.eps
hand_protection.eps
tools.eps
box.eps
magnify_2.eps
warning symbol.eps
measure.eps
plug.eps
oil.eps
megaphone.eps
biohaz.eps
Battery_Caution1.eps
Caution.eps
Crush_Caution1.eps
Electrical_Caution.eps
Face_protection.eps
Fall_Hazard.eps
Fall_protection.eps
GearHand_Hazard.eps
Head_protection.eps
Heavy_Hazard.eps
Hot_surface.eps
Recycle.eps
Resp_protection1.eps
Resp_protection2.eps
Temp_Caution1.eps
body_protection.eps
chemical_Caution.eps
ear_protection1.eps
explosive_caution.eps
eye_protection1.eps
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hand_protection.eps
Inspect:
• After unpacking the unit, inspect carefully for any damage that may
have occurred during transit. Check for loose, missing or damaged
parts. Shipping damage claims must be filed with carrier.
• See General Safety Instructions on page 3, and Cautions and
Warnings as shown.
15” - 25” Telescoping Suction Pipe
25” - 40” Extension Pipe
Figure 1
GETTING STARTED SAFETY /
SPECIFICATIONS
(A) Spin Collar
(B) Direct Mount
(H or J)
Dispensing
Hose
(F) Ring Terminals
(C) Fiber Gasket
(K) Reducer
(E) Fuse
Assembly
(D) Tank
Adapter
(L) Suction Pipe Assembly
(G) Wire
Connector
(M) Automatic
Shut-off Nozzle
(N) Manual
Shut-off Nozzle
(P) Lockable
Nozzle Holder
(Q) Standard
Nozzle Holder

3-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
GENERAL SAFETY INSTRUCTIONS
IMPORTANT: It is your responsibility to:
• Know and follow applicable national, state and local safety codes pertaining to
installing and operating electrical equipment for use with flammable liquids.
• Know and follow all safety precautions when handling petroleum fuels.
• Ensure that all equipment operators have access to adequate instructions
concerning safe operating and maintenance procedures.
Observe all safety precautions concerning safe handling of petroleum fuels
SYMBOLS
Description of imminent hazard and failure to avoid hazard will
result in death.
Description of hazard and possible resulting injures or death.
Description of hazard and possible resulting injuries.
Warning of general danger
Warning of electric shock
Warning of hot surface
Warning of automatic restart
Read the operating manual and safety instructions
Disconnect power for maintenance and inspection
Smoking, open flames, fires, and open ignition sources are
prohibited in the vicinity of this product.
gpi.net/my-pump
SEE OWNER’S MANUAL
FOR DETAILS
VOIR LE MANUEL DU PROPRIÉTAIRE
POUR PLUS DE DÉTAILS
VEA EL MANUAL DEL
PROPIETARIO PARA DETALLES
VEJA O MANUAL DO
PROPRIETÁRIO PARA DETALHES
This symbol indicates a general warning to the user. See additional specific
warnings.
This symbol indicates electrical shock hazard. Follow proper installation and
maintenance instructions in this manual.
This symbol indicates hot surface. Take care to avoid coming into contact with
hot surface.
This symbol indicates automatic restart. Pump contains thermal protection which
automatically shuts off motor before overheating. Pump will turn
back on automatically after cooling. Turn switch OFF and wait 30 minutes to
resume normal pumping. Disconnect power before any inspection or service.
Owner’s manual must be read before using, inspecting, or servicing this product.
Disconnect power when product is unattended or in the case of a malfunction.
Disconnect power before any inspection, servicing, or maintenance.
Smoking, open flames, fires, and open ignition sources are prohibited in the
vicinity of this product.
INTERNATIONAL ISO SAFETY SYMBOLS
AVIATION FUELING
“Pump Only” models sold without a hose or nozzle are approved for ground-based
refueling only. Do not use in or on aircraft. User must provide hose, suction pipe, nozzle,
and accessories that meet the appropriate NFPA 407 Standard for Aircraft Fuel
Servicing. Pumps have no actual or implied compliance with this standard. Please
consult NFPA 407 for recommended safety requirements during ground fuel servicing of
aircraft using petroleum fuels.
SAFETY /
SPECIFICATIONS

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
4-EN
SAFETY /
SPECIFICATIONS
4-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
GENERAL SAFETY INSTRUCTIONS
IMPORTANT: It is your responsibility to:
•Know and follow applicable national, state and local safety codes
pertaining to installing and operating electrical equipment for use with
flammable liquids.
•Know and follow all safety precautions when handling petroleum fuels.
•Ensure that all equipment operators have access to adequate
instructions concerning safe operating and maintenance procedures.
Observe all safety precautions concerning safe handling of petroleum fuels.
To ensure safe operation, all fuel transfer systems
must be properly grounded. Proper grounding
means a continuous metal-to-metal contact from one component
to the next, including tank, tank mount, pump, meter, filter, hose
and nozzle. Care should be taken to ensure proper grounding during
initial installation and after any service or repair procedures. For
your safety, please take a moment to review the warnings below.
To prevent physical injury or property damage,
observe precautions against fire or explosion
when dispensing fuel. Do not operate the system in the presence
of any source of ignition including running or hot engines, lighted
tobacco products, gas or electric heaters, or any type of electronic
device. A spark can ignite fuel vapors.
Observe precautions against electrical shock
when operating the system. Serious or fatal
shock can result from operating electrical equipment in damp
or wet locations.
Inspect external pump wiring regularly to make
sure it is correctly attached to the battery. To
avoid electrical shock, use extra care when connecting the pump
to power.
Avoid prolonged skin contact with petroleum
fuels. Use protective goggles, gloves and aprons
in case of splashing or spills. Change saturated clothing and wash
skin promptly with soap and water.
Observe precautions against electrical shock
when servicing the pump. Always disconnect
power before repairing or servicing. Never apply electrical power
to the system when any of the coverplates are removed.
If using solvent to clean pump components
or tank, observe the solvent manufacturer’s
recommendations for safe use and disposal.
Do not leave pump running unattended.

5-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
SPECIFICATIONS
M-150S-AU
M-150S-MU M-150S-EM M180S-ML M180S-AU M-240S-MU
Housing Material Lightweight, corrosion-resistant, cast aluminum body,
convenient union ring for easy installation.
Pump Rate Up to 15 GPM
(57 LPM)
Up to 18 GPM
(68 LPM)
Up to 15 GPM
(57 LPM)
Duty Cycle 30 minute ON, 30 minute OFF
Suction Lift Manual Nozzle: Up to 5.5 ft. (1.7 m)
Automatic Nozzle: Up to 4.8 ft. (1.5 m)
Operating
Temperature -20° F to 125° F (-29° C to 52° C)
Operating
Pressure 15 PSI (103.42 kPa)
Input 12-volt DC 24-volt DC
Current Draw 18 amps 20 amps 9 amps
Motor 1900 RPM, 1/5 hp (150
watts)
2000 RPM,
1/4 hp (187 watts)
1900 RPM,
1/5 hp (150 watts)
Motor Approval cULus Listed, Class I Div 2
Motor Protection 20 amp circuit breaker 25 amp circuit
breaker 15 amp fuse
Cord 18 ft. of 12 ga. (5.5 m)
Fuse 25 amp 30 amp 15 amp
Tank Adapter
(Item D) 2 inch NPT N/A 2 inch NPT
Inlet 1 inch NPT
Outlet 3/4 inch NPT 1 inch NPT 3/4 inch NPT
Hose Type Buna-N Electrically Conductive Discharge Hose
Hose Size 3/4 in. x 12 ft.
(3.6 m)
3/4 in. x 10
ft. (3.0 m)
1 in. x 12 ft.
(3.6 m)
3/4 in. x 12 ft.
(3.6 m)
Manual Nozzle 3/4 inch Unleaded 1 inch Leaded 3/4 inch Unleaded
Automatic Nozzle 3/4 inch Unleaded N/A
Weight:
Manual Nozzle 23 lbs. (10.5 kg) 26.5 lbs. (12.0 kg) 23 lbs. (10.5 kg)
Weight:
Automatic Nozzle 24 lbs. (10.8 kg) 27 lbs. (12.2 kg) N/A
SAFETY /
SPECIFICATIONS

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
6-EN
SPECIFICATIONS (CONTINUED)
M-150S-EM & -E-PO M-150S-AU & -MU & -PO
M-180S and M-240S
Dimensions Inches (cm)
A. Pump Ass’y Width 9.19 (23.34) 9.13 (23.20)
B. Pump Ass’y Height 5.42 (13.77) 4.95 (12.57)
C. Pump Ass’y Height
w/Nozzle Holder 7.00 (17.78) 6.74 (17.12)
D. Direct Mount (NPT
Male) Thread Height 1.00 (2.54) N/A
E. Pump Ass’y Depth 10.45 (26.54) 10.45 (26.54)
Figure 2
M-150S-AU & -MU & -PO
M-180S and M-240S
M-150S-EM & -E-PO
ALL
SAFETY /
SPECIFICATIONS
A
B
C
D
E
A
B
C

7-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
INSTALLATION INSTRUCTIONS
NOTE: This pump is designed to self-prime with dry gears. Expect suction
lift as follows:
Manual Nozzle: 5.5 feet (1.7 m) with diesel
6.7 feet (2.1 m) with gasoline
Automatic Nozzle: 4.8 feet (1.5 m) with diesel
5.8 feet (1.8 m) with gasoline
If you require a greater initial prime height, coat the gears with fluid by
removing the plug on the top of the pump and pour a small quantity of
motor oil into the gear cavity. Replace the plug and try again. A foot valve
with pressure relief may be needed to maintain prime.
Install Tank Adapter and Suction Pipe
(for all models except M-150S-EM & M-150S-E-PO)
1. Wrap both threaded ends of the tank adapter with three or four turns
of thread tape (see Figure 3). Using a pipe wrench, tighten the adapter
snugly into the fuel tank.
NOTE: For Aluminum Tank Installation - To prevent thread galling of
aluminum fittings, always prepare the threads for assembly using an
anti-seize compound such as Loctite®567™, Hernon®Dripstop®940 or
equivalent.
2. Using pliers, remove the plastic plug from inlet port on bottom of pump.
Place the spin collar gasket into the inlet fitting on the bottom of the
pump (see Figure 4).
3. Wrap the threaded end of suction pipe with three or four turns of thread
tape (see Figure 5). Thread the suction pipe into the inlet port on the
bottom of the pump and hand tighten until snug (see Figure 6).
NOTE: If your tank is 15” - 24” deep, do not use the included suction pipe
extension; if your tank is 24” - 40” deep, attach the suction pipe extension
(see Figure 7).
Figure 3
Figure 5
Figure 4
Figure 6
ASSEMBLY /
INSTALLATION

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
8-EN
INSTALLATION INSTRUCTIONS (CONTINUED)
Install Suction Pipe (for model M-150S-EM)
1. Wrap the threaded mount of the fuel pump with three or four turns of
thread tape.
NOTE: For Aluminum Tank Installation - To prevent thread galling of
aluminum fittings, always prepare the threads for assembly using an
anti-seize compound such as Loctite® 567™, Hernon®Dripstop®940
or equivalent.
2. Using pliers, remove the plastic plug from inlet port on bottom of pump.
3. Wrap the threaded end of suction pipe with three or four turns of thread
tape (see Figure 5). Thread the suction pipe into the inlet port on the
bottom of the pump and hand tighten until snug (see Figure 6).
NOTE: If your tank is 15 - 24 inches deep, do not use the included suction
pipe extension; if your tank is 24 - 40 inches deep, attach the suction pipe
extension (see Figure 7).
Figure 8
Figure 7
15” - 24” Telescoping Suction Pipe
24” - 40” Extension Pipe
Install Pump on Tank
(for all models except M-150S-EM & M-150S-E-PO)
1. Clean the tank interior of all dirt and foreign material.
2. Carefully lift pump / suction pipe assembly and insert suction pipe into
the tank opening.
While holding the spin collar gasket in place, position the pump spin collar
onto the tank adapter and tighten using a pipe wrench, making sure the
spin collar is not cross-threaded (see Figure 8). The spin collar measures
2.26 inches (5.74 cm) across flats.
NOTE: To prevent pressure buildup and possible fuel leaks through the
nozzle, make sure the fuel tank is properly vented. A vent cap rated at
3 psi (6.90 kPa) or less is recommended.
ASSEMBLY /
INSTALLATION

9-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
INSTALLATION INSTRUCTIONS (CONTINUED)
Install Pump on Tank (model M-150S-EM & M-150S-E-PO)
1. Clean the tank interior of all dirt and foreign material.
2. Carefully lift pump / suction pipe assembly and insert suction pipe into
the tank opening.
Position the pump mount and tighten securely, making sure the threads are
not cross-threaded; the pump mount exterior threads are 2 inches NPT.
NOTE: To prevent pressure buildup and possible fuel leaks through the
nozzle, make sure the fuel tank is properly vented. A vent cap rated at
3 psi (6.90 kPa) or less is recommended.
Install Hose and Nozzle
1. Using pliers, remove the plastic plug from outlet port on front of pump.
Wrap one end of the dispensing hose with three to four turns of thread
tape and thread into outlet port (see Figure 9). Tighten securely using
an adjustable wrench.
2. Wrap opposite end of hose with three or four turns of thread tape
and thread into nozzle. Tighten securely using an adjustable wrench
(see Figure 10).
3. Place the nozzle into the nozzle holder on the end of the pump motor
housing. Note that the nozzle cannot be placed in the holder unless
the pump switch is OFF (see Figure 11).
Figure 10
Figure 11 Figure 12
Figure 9
ASSEMBLY /
INSTALLATION

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
10-EN
INSTALLATION INSTRUCTIONS (CONTINUED)
Connect to a Power Source
NOTE: Please consult the Owner’s Manual for your vehicle before
proceeding.
IMPORTANT: The pump is designed for use with a 12 Volt (M-150S
and M-180S) or 24-Volt (M-240S) DC power source. Do not attempt
installation on a 115 or 230 Volt AC system.
Do not attempt to power the pump from vehicle wiring
smaller than 12 gauge, such as the cigarette lighter wire,
as these thin wires could overheat and
cause a fire.
NOTE: This pump is pre-wired for installation in CLASS I, DIVISION 2
locations such as portable fuel tanks, trailers, etc. Connection to a battery
will depend upon the application.
”Pump only” models (-PO) may be installed in a
CLASS I DIVISION I location with approved wiring.
IMPORTANT: Verify switch is in OFF position, then route the electrical
wires to the source of the vehicle power system. Be sure to support the
wires as necessary and protect them from sharp edges, heat or anything
that could damage the wires.
1. If the power cord provided is too long, disconnect from power and
cut to desired length. Using a utility knife, carefully strip 3 to 4 inches
(7.62 to 10.16 cm) of outer insulation from end of power cord. DO NOT
CUT INNER WIRES. Next, using wire strippers, remove 1/4 inch
(6.35 mm) of insulation from the black and red power cord wires.
2. For a negative ground system, first disconnect the vehicle’s
ground wire, and then connect as follows: Using a wire stripper,
carefully strip 1/4 inch (6.35 mm) of insulation from both ends of the
fuse assembly wire.
3. Insert one end of the fuse assembly wire into the wire connector and
crimp. Insert the red power cord wire into the other end of the wire
connector and crimp. Make sure the fuse assembly is positioned
outside of hazardous areas and as close to the battery as possible
(see Figure 12).
4. Using wire crimper, attach one ring terminal to the other end of the
fuse assembly and one ring terminal to the end of the black power
cord wire.
5. Connect the red wire/fuse assembly to the positive side of the battery
(see Figure 12).
6. Connect the black power cord wire to the negative side of the battery.
NOTE: Connecting directly to the battery terminal or the end of the battery
cable is recommended.
ASSEMBLY /
INSTALLATION

11-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
OPERATION
IMPORTANT: Always follow safety precautions when operating this
equipment. Review the Safety Instructions.
To prevent physical injury or property damage, observe
precautions against fire or explosion when dispensing
fuel. Do not operate the system in the presence
of any source of ignition including running or hot engines, lighted tobacco
products, gas or electric heaters, or any type of electronic device. A spark can
ignite fuel vapors.
Before each use, repair leaks around seals or
connections. Make sure hoses are in good condition and
connections are tight.
NOTE: Make sure the work area is dry.
Make sure the pump is properly grounded. Repair any
corroded or damaged wiring before use.
NOTE: Ensure the tank contains enough fuel.
IMPORTANT: Make sure the fuel is not contaminated with debris. Tighten
loose tank lids regularly.
Dispensing Fuel
1. Turn on the pump by removing the nozzle from the holder and pushing
up the switch lever. Insert the nozzle into the receiving tank and
squeeze the handle to start fuel flow. When done, release the nozzle
handle, turn the pump off and return the nozzle to its holder.
IMPORTANT: This pump is designed to be self-priming. If fuel is not
delivered within 15 to 20 seconds, turn the pump off and refer to priming
information in the Troubleshooting Section.
An automatic bypass valve prevents pressure build up
when the pump is on with the nozzle closed.
To avoid pump damage, do not run the pump more than 10 minutes with the
nozzle closed.
IMPORTANT: After running the pump for a maximum of 30 minutes,
allow it to cool for 30 minutes.
Motor Protector
NOTE: The M-150S and M-180S pumps have a motor protector that
provides added protection against motor damage. It must be reset
manually.
1. If the motor protector trips, reset by turning the switch OFF. Let the
pump cool then turn ON again. If the motor protector trips again, see
the Troubleshooting Section of this manual.
2. An inline fuse provides motor protection on the 24-volt M-240S model.
Replace fuse as needed.
OPERATION

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
12-EN
TROUBLESHOOTING GUIDE
Symptom Possible Cause(s) Corrective Action
Motor does not run 1. Fuse blown 1. Inspect fuse in fuse holder on
power cord. If blown, replace
2. Switch defective 2. Remove switch coverplate
and inspect switch. Replace,
if necessary
3. Switch or electrical
connections are faulty
(models M-150S and
M-180S)
3. Inspect for damaged motor
protector, defective wiring or
switch, or improper electrical
connections. Replace as
needed and reinstall
4. Circuit breaker tripped 4. Turn power off at source.
Inspect the pump thoroughly;
clean or repair. Reset circuit
breaker by turning the power
switch off then back on
5. Motor burned out 5. Replace motor
(see Maintenance /
Repair section)
Motor runs but
doesn’t pump
1. Gear coverplate or
O-ring damaged
1. Remove and inspect the
coverplate and O-ring.
Replace, as necessary.
(see Maintenance /
Repair section)
2. Strainer clogged
or defective
2. Remove strainer coverplate.
Remove and clean strainer.
Install again
3. Suction pipe clogged,
damaged or missing
3. Remove pump from tank.
Inspect suction pipe. Clean
or replace, as necessary
4. Bypass poppet O-ring
worn or missing
4. Inspect O-ring (see
Maintenance / 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. Remove the bypass poppet,
spring, and O-ring. Clean
cavity. Inspect and replace
components, if needed
TROUBLESHOOTING

13-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
TROUBLESHOOTING GUIDE (CONTINUED)
Symptom Possible Cause(s) Corrective Action
Motor runs but does
pump (continued)
7. System air leak 7. Tighten all pump fittings and
connections. Inspect suction
pipe for leaks or damage
8. System air lock 8. Occurs 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.
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 flowrate 1. Strainer partially
clogged
1. Remove the strainer
coverplate. Remove and
clean the strainer. Install
again
2. Poor connections
or low voltage
2. Make sure electrical
connections are secure.
Also check battery voltage
3. Suction pipe clogged
or damaged
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. Remove the bypass poppet
and inspect spring (see
Maintenance / Repair section.
Replace, if necessary
TROUBLESHOOTING

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
14-EN
TROUBLESHOOTING GUIDE (CONTINUED)
Symptom Possible Cause(s) Corrective Action
Motor stalls when
operating 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 coverplate
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
(model M-240S)
1. Inspect for a blown fuse,
defective wiring or switch,
or improper electrical
connections. Replace
or install again, as
necessary. Refer to Switch
Replacement instructions
in the Repair Section
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
4. Switch or electrical
connections faulty
(models M-150S and
M-180S)
4. Inspect for damaged motor
protector, blown fuse,
defective wiring or switch,
or improper electrical
connections. Replace as
needed and re-install
TROUBLESHOOTING

15-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
TROUBLESHOOTING GUIDE (CONTINUED)
Symptom Possible Cause(s) Corrective Action
Rapid overheating of motor 1. Duty cycle too long 1. Pump operation should
not exceed the standard
duty cycle of 30 minutes
ON, and 30 minutes
OFF. Allow the pump to
cool for 30 minutes
2. Strainer clogged 2. Remove strainer
coverplate. Remove
and clean strainer.
Install again
3. Suction pipe clogged
or damaged
3. Remove pump from
tank. Inspect suction
pipe. Clean or replace,
as necessary
4. Gears worn 4. Remove gear coverplate
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 10 minutes
TROUBLESHOOTING

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
16-EN
MAINTENANCE
NOTE: This pump is designed for minimum maintenance. The motor
bearings are sealed and require no lubrication. Inspect the pump and
components regularly for fuel leaks and make sure the hose and power
cord are in good condition. Keep the pump exterior clean to help
identify leaks.
IMPORTANT: Do not use this pump for water, chemicals or herbicides.
Dispensing any fluid other than those listed in this manual will damage the
pump. Use of the pump with unauthorized fluids will void the warranty.
Clean or Replace Strainer
1. Turn the pump off and disconnect from power. Remove the strainer
coverplate. Remove the inlet strainer and inspect for damage or clogs
(see Figure 13). Clean the strainer with a soft-bristled brush and
solvent (see Figure 14). If the strainer is very dirty, compressed air may
be used. If damaged, replace the strainer.
2. Place the strainer in the cavity. Clean the coverplate and O-ring. Coat
the O-ring lightly with grease. Ensure the coverplate O-ring is properly
seated (see Figure 15) and tighten the strainer coverplate.
MAINTENANCE /
REPAIR
Figure 13
Figure 15
Figure 14

17-EN
GETTING STARTED SAFETY /
SPECIFICATIONS
ASSEMBLY /
INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE /
REPAIR
REPAIR
IMPORTANT: Carefully inspect all parts for wear or damage. Replace
components, as necessary. The Illustrated Parts List gives information
on replacement parts and kits. Review the Safety Instructions before
proceeding.
Observe precautions against electrical shock when
servicing the pump. Always disconnect power before
repairing or servicing. Never apply electrical power
to the system when any of the coverplates are removed.
Avoid prolonged skin contact with petroleum fuels. Use
protective goggles, gloves and aprons in case of
splashing or spills. Change saturated clothing and wash skin promptly with
soap and water.
Remove Pump From Tank
1. Turn the pump OFF and disconnect from power.
2. Turn the spin collar counterclockwise to release the inlet fitting.
3. Lift the pump and suction pipe straight up from the tank adapter.
4. Elevate the nozzle and hose to allow excess fuel to drain into the tank.
5. Wipe the entire system with a clean cloth.
Service O-rings
NOTE: A Wet Seal Kit contains all seals for your pump and should be on
hand when performing repairs. Old seals may then be replaced with new
seals.
1. In general, when inspecting O-rings, look for breaks, wear and signs of
deterioration, such as swelling.
2. Replace, as necessary.
3. Before seating, coat O-rings with light grease.
Replace Gears and Drive Key
1. Turn the pump OFF and disconnect from power.
2. Remove the gear coverplate and O-ring from the pump housing
3. Inspect the gears and key for wear and damage. Replace, as
necessary.
4. Wipe the gear cavity with a clean cloth.
5. Replace the gears. Make sure they turn freely.
6. Replace the drive key.
7. Make sure the gear coverplate O-ring is securely in place. Tighten the
coverplate to the housing.
MAINTENANCE /
REPAIR

MAINTENANCE /
REPAIR TROUBLESHOOTING OPERATION ASSEMBLY /
INSTALLATION
SAFETY /
SPECIFICATIONS GETTING STARTED
18-EN
Figure 16
Figure 18
Figure 17
REPAIR (CONTINUED)
Clean Bypass Poppet
1. Turn the pump OFF and disconnect from power.
2. Using a 1/2” drive socket wrench, remove the pipe plug from the top
outlet port (see Figure 16).
3. Remove the gear coverplate and O-ring from the pump housing.
4. Pull the drive key and two gears from the pump (see Figure 17).
5. To clean the bypass poppet:
a. With a clean cloth, wipe the poppet cavity through the top
outlet port.
b. Push down on the poppet until the poppet O-ring is exposed inside
the housing (see Figure 18).
c. Using a clean cloth, rotate the poppet and clean it thoroughly.
MAINTENANCE /
REPAIR