GREAT PLAINS PA-120DEF User manual

PA-120DEF 115-Volt
Plastic Utility Pump
Owner’s Manual
General Information ..................................................... 2
Safety Instructions ....................................................... 2
Installation ................................................................... 3
Operation .....................................................................3
Maintenance ................................................................ 4
Repair:
PA-120DEF ............................................................. 5
P-120DEF ............................................................... 6
Troubleshooting :
PA-120DEF ............................................................. 8
P-120DEF ............................................................... 9
Illustrated Parts List:
PA-120DEF ...........................................................10
P-120DEF ............................................................. 11
Specications ............................................................ 12
Service.......................................................................13
5252 East 36th Street North
Wichita, KS USA 67220-3205
TEL: [phone]
FAX: [phone]
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PA-120DEF P-120DEF
To the owner...
Congratulations on receiving your GPI pump. We are
pleased to provide you with a system designed to give
you maximum reliability and efciency.
Your pump is designed, tested, and approved for use
with Diesel Exhaust Fluid (DEF). Please take all due
precautions when handling DEF. Your safety is important
to us.
Also, to assure the longest possible service life, it is
important that you follow the operation and maintenance
procedures outlined in this manual. We are proud to
provide you with a quality product and dedicated
support. Together with your conscientious use, we are
sure that you will obtain years of safe, dependable service.
President
Great Plains Industries, Inc.
P-120DEF 12-Volt
Plastic Utility Pump
TABLE OF CONTENTS
Rev. A 92176201
1
11/11

To ensure safe operation, all transfer systems
must be properly grounded. Proper grounding
means a continuous metal-to-metal contact from
one component to the next, including tank, bung,
pump, meter, lter, 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.
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 power supply. To avoid electrical
shock, use extra care when connecting the pump to power.
Avoid prolonged skin contact with DEF. 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.
PA-120DEF:
• This pump is designed for use with GFCI protected,
115-volt power. Do not attempt installation or operation
with 12-volt, 24-volt or 230-volt power sources. Use
only three-pronged, grounded connectors. Do not use
two-prong adapters. Inspect power cords regularly
and replace if signs of wear are evident.
• To avoid personal injury, use a ground fault circuit
interrupter (GFCI) approved by Underwriters
Laboratories Standard 943 with this pump.
To protect against overload, this pump is equipped with
a thermal protector, that resets automatically, and a
circuit breaker, that resets manually. If your pump stops
unexpectedly, please reference further information about
the thermal protector and circuit breaker in the Operation
or Troubleshooting Sections.
P-120DEF:
This pump is designed for use with a 12-volt DC battery.
• Inspect wiring regularly. Make sure the power cord is
correctly attached to the battery. To avoid electrical
shock, use extra care when connecting the pump to
the battery.
PA-120DEF & P-120DEF:
• Do not exceed standard duty cycle of 30 minutes ON
and 30 minutes OFF. Allow the pump to cool for 30
minutes.
• Some uid may spill from the pump during pump
removal. Follow DEF label directions for cleanup
and disposal.
The purpose of this manual is to assist you in
installing, operating and maintaining your GPI pump. It
provides information which will help you achieve years
of dependable performance and trouble-free operation.
The system is approved for DEF (Diesel Exhaust Fluid)
only. Do not use with gasoline, diesel, other ammable
uids, or micro-encapsulated uids. Using uids, other
than those for which the pump was designed, could lead
to serious personal injury and void the warranty.
Before operating your pump, read this manual thoroughly.
If you have problems with your pump in the future, please
refer to the Maintenance and Troubleshooting Sections.
For assistance, contact your dealer or the GPI Customer
Service Department.
The following safety alert symbols are
used in this manual.
DANGER indicates a
hazardous situation
which, if not avoided,
will result in death or
serious injury.
WARNING indicates
a hazardous situation
which, if not avoided,
could result in death or
serious injury.
CAUTION indicates a
hazardous situation
which, if not avoided,
may result in minor or
moderate injury.
It is your responsibility to:
• know and follow applicable national, state, and local
safety codes pertaining to installing and operating
electrical equipment.
• ensure that all equipment operators have access to
adequate instructions concerning safe operating and
maintenance procedures.
Observe all safety precautions concerning safe handling
of DEF.
2
DANGER
WARNING
CAUTION
GENERAL INFORMATION
SAFETY INSTRUCTIONS

Using uids other than those for which the pump was
designed could lead to serious personal injury and void
the warranty.
The pump is approved for Diesel Exhaust Fluid only.
Do not use with gasoline, diesel, other ammable
uids, or micro-encapsulated uids.
When handling uids, always wear protective
clothing such as goggles, gloves and respirators,
as instructed by the uid manufacturer.
Clean any spills from the system exterior as they occur,
following uid manufacturer’s instructions.
Before Each Use
1. Keep pump exterior clean to help identify leaks.
Before each use, inspect for leaks around seals or
connections.
2. Check for leaks under the pump housing. A small
drain hole relieves any uid which bypasses the
motor shaft seal. (Figure 2) If any leakage is found
here, replace the motor shaft seal using instructions
in the Repair Section.
3
Figure 1
WARNING
WARNING
Figure 2
CAUTION
• Do not run the pump more than necessary without
ow. “Dry running” can cause overheating and pump
damage.
• To avoid personal injury, turn the pump off and
disconnect from power before repair or service.
• For your protection, thoroughly ush the pump before
cleaning or repair.
When you receive your pump, examine it for visible
damage. If any items are damaged or missing, please
contact your distributor.
For proper installation, your pump requires a hose, nozzle
and suction pipe. Kits are available from the factory and
are listed as accessories on the Illustrated Parts List.
Used pumps must be ushed and cleaned before
installation as outlined in the Maintenance Section.
To prevent leaks, seal all connecting threads with 3 to 4
turns of thread tape during installation.
Before installing the pump, install the suction pipe into
bung adapter on the pump. Tighten the suction pipe into
the bottom of the bung adapter until only three threads
are visible.
Installing Pump
The pump has a 2-inch NPS bung adapter with gaskets
installed at the inlet end.
After installing the suction pipe into the bung adapter,
insert the suction pipe into the tank opening and tighten
the pump securely. Make sure the bung adapter threads
are not cross-threaded. (Figure 1)
INSTALLATION
Install Hose and Nozzle
If installing accessories such as meters or lters, do
so before installing the hose and nozzle. Follow the
manufacturer’s instructions.
Make sure any hose and nozzle used are compatible
with DEF.
After sealing threads, hand-tighten the hose into the
outlet until snug. Hand-tighten the nozzle to the hose.
OPERATION
3. Make sure hoses are in good condition and
connections are tight.
4. Make sure the work area is dry.
Electrical Connections
PA-120DEF:
This pump is designed for use with GFCI protected, 115-
volt power. Do not attempt to install or operate the pump
with 12-volt, 24-volt or 230-volt power.
Use only three-prong, grounded connectors. Do not use
two-prong connectors or adapters. Inspect power cords
regularly and replace if signs of wear are evident.

Circuit Breaker
PA-120DEF:
The magnetic circuit breaker trips automatically when the
motor draws more than 3 amps. This feature provides
added protection against motor damage and must be
reset manually.
When the circuit breaker trips, turn the power off and
disconnect from power before attempting any repairs.
Inspect the pump thoroughly and clean or repair it as
necessary.
Make sure the pump switch is in the OFF position
before restoring power.
Reset the circuit breaker after repairs are complete. To
reset, press in on the circuit breaker reset button at the
end of the cover assembly.
Proper cleaning and maintenance is vital to prolong pump
life and promote trouble-free operation.
NOTE: Failure to follow recommended cleaning and
storage procedures increases the chance of pump
failure and may void the warranty.
Remove Pump from Tank
Some uid may spill from the pump during
removal. Follow DEF label directions for cleanup
and disposal.
1. Disconnect pump from power.
2. Loosen the pump from the tank.
3. Lift the pump from the tank.
4. Place the nozzle in the tank.
5. Reconnect the pump to the appropriate power supply
(PA-120DEF to grounded GFCI protected, 115-volt
power) (P-120DEF to a 12-volt DC battery). Open
the nozzle to remove uids from the system and turn
on. Turn pump off and disconnect from power.
6. Remove the suction pipe, as necessary.
7. Clean uid from bung adapter or tank nipple and
tank. Cover the bung adapter or tank nipple.
8. If the pump will not be used for more than 2 weeks,
ush to prevent drying of uids in the pump.
4
To avoid personal injury, use a ground fault circuit
interrupter (GFCI) approved by Underwriters Laboratories
Standard 943 with this pump. If your electrical service
already had GFCI outlets, you are protected. If not, a
portable GFCI is available through electrical equipment
distributors or from GPI. Contact your distributor or GPI
Customer Service for more information.
P-120DEF:
This pump is designed for use with a 12-volt DC battery.
1. Inspect wiring for corrosion or damage. Replace, as
necessary.
2. Connect the pump to a 12-volt DC battery with the
red wire attached to positive (+) and the black to
negative (–).
PA-120DEF & P-120DEF:
For best results, immediately before use, purge the
system of air.
Follow these steps to purge the system of air.
1. Connect the pump to the appropriate power supply
(PA-120DEF to grounded GFCI protected, 115-volt
power) (P-120DEF to a 12-volt DC battery).
2. Place the nozzle in the ll hole of the tank. Turn the
pump on.
3. Open the nozzle and pump at full ow until the system
is full of DEF.
4. Close the nozzle and turn the pump off.
NOTE: The PA-120DEF and P-120DEF pumps include
an automatic bypass that will open automatically if
internal pump pressure builds up.
Dispense Fluid
The PA-120DEF and P-120DEF pumps are intended for
use with Diesel Exhaust Fluid (DEF) only.
1. Turn power ON.
2. Insert the nozzle into the receiving tank.
3. Open the nozzle. Always dispense at full ow.
Do not exceed the standard duty cycle of 30 minutes
ON and 30 minutes OFF. Allow the pump to cool
for 30 minutes.
4. Dispense the desired amount.
5. Close the nozzle and turn the pump off.
Thermal Protector
PA-120DEF:
This pump’s motor contains an automatic thermal
protector. Excessive motor heat can trip the protector.
It resets automatically after the motor has cooled
approximately 30 minutes.
WARNING
CAUTION
CAUTION
MAINTENANCE

Clean Pump
If uid dries inside pump, remove the residue before
further use.
1. Disconnect from power, remove the pump from the
tank, and ush.
2. Disassemble the pump as outlined in the Repair
Section.
3. Thoroughly clean dried uid from the interior of the
pump. Take care not to scratch parts.
4. Wash the bypass poppet in distilled water.
5. Assemble the pump.
When handling DEF, always wear protective
clothing such as goggles, gloves, and respirators,
as instructed by the uid manufacturer.
For your protection, ush system before dis-
assembling.
During repair, carefully inspect all parts for wear or
damage and replace, as necessary. Check O-rings and
seals for breakage, wear, and signs of deterioration,
such as swelling.
Clean or Replace Strainer
1. Disconnect pump from power and ush.
2. Remove the coverplate and O-ring from the housing.
3. Remove the strainer.
4. Clean or replace the strainer. Install again.
5. Install the coverplate and O-ring. Torque screws to
25 to 35 in-lbs.
Clean or Replace Inlet Fitting
1. Disconnect pump from power and ush.
2. Remove the inlet tting from the pump housing.
NOTE: Ensure proper seating of the O-ring between
the inlet tting and the housing.
3. Clean or replace the inlet tting. Install again. Torque
screws to 45 to 50 in-lbs.
Clean or Replace Bypass Poppet
1. Disconnect pump from power and ush.
2. Remove the bypass poppet plug.
3. Remove the bypass poppet. Gently rock it back and
forth as necessary to remove.
5
Figure 3
WARNING
WARNING
WARNING
CAUTION
Flush Pump
When the pump will not be used for more than 2 weeks,
it must be ushed to prevent internal drying of uid.
It is strongly recommended, for protection from personal
injury, that a simple ush tank be created. Use a container
with a tight tting lid with a minimum volume of 5 gallons
(19 litres). Cut two holes in the lid of this container; one
which is approximately 1 inch (2.5 cm) larger than the
largest diameter of the pump inlet tting and a second
hole slightly larger than the nozzle tip. Fill the container
with distilled water. Secure the lid tightly on the top of
the container.
1. Disconnect from power. Remove the pump from the
tank and drain using the instructions above.
2. Connect the pump to the appropriate power supply
(PA-120DEF to grounded GFCI protected, 115-volt
power) (P-120DEF to a 12-volt DC battery)
3. Place the pump inlet and nozzle through the holes
in the top of the ush tank. (Figure 3)
4. Open the nozzle and turn the pump on. Circulate
distilled water through the pump for 10 to 15 minutes.
Open and close the nozzle several times to ush the
bypass poppet.
5. Lift the pump from the water. Allow the pump to run
briey until only air passes through the system. Turn
the pump off.
Do not run the pump any longer than necessary
without ow. “Dry running” can cause overheating
and pump damage.
6. Drain the hose and nozzle. Wipe entire system with
a clean damp cloth.
To avoid uid exposure, follow uid manufacturer’s
instructions for the disposal of contaminated water.
REPAIR – PA-120DEF

6
4. Wipe the cavity clean and wash the bypass poppet
in distilled water.
5. Examine all components and replace as necessary.
6. To replace the poppet O-ring, carefully remove the
O-ring using a small screwdriver or similar tool. Seat
new O-ring on the poppet head.
7. Assemble by placing the bypass poppet assembly
in the cavity. Tighten the plug rmly.
Replace Motor
1. Disconnect pump from power and ush.
2. Remove the four screws holding the motor and handle
to the housing.
3. Lift the motor from the housing and drive shaft.
4. Remove the motor shaft adapter from the drive shaft.
5. Assemble by reversing the steps above. Make sure
the motor is properly seated against the motor adapter
seal. Torque the four screws to 75 to 100 in-lbs.
Replace Switch
1. Disconnect pump from power and ush.
2. Remove the cover assembly on the side of the motor.
3. Press in on the sides of the switch. Push the switch
from the switch box.
NOTE: Before disconnecting wires, note their positions
on the switch. Connect to the new switch in the same
positions.
4. Disconnect the terminal wires from the back of the
old switch.
5. Install the new switch by reversing steps above.
Carefully position wires in switch box before replacing
cover.
6. Install cover assembly and tighten screws until snug.
Do not overtighten.
Replace the Drive Shaft or Motor Shaft Seal
Follow these steps to remove the drive shaft and
motor shaft seal.
1. Disconnect pump from power and ush.
2. Remove the motor as described above.
3. Carefully slide the drive shaft from the motor and the
housing. Note the position of the motor shaft washer.
4. Carefully pry the motor shaft seal from the housing
with a at-bladed screwdriver.
NOTE: While removing the motor shaft seal, note carefully
the orientation and which side of the seal faces the
motor. The new seal must be installed with the same
orientation.
5. Inspect the drive shaft, motor shaft washer, motor shaft
seal, and bearings for wear. Replace, as necessary.
Follow these steps to install the drive shaft and
motor shaft seal.
1. Press the new motor shaft seal into the housing with
the same orientation as the old seal.
2. Position the motor shaft washer on the seal. Slide
the notched end of the drive shaft into place in the
housing.
3. Align the drive shaft with the motor adapter. When
properly aligned, the drive shaft will slip into place
with the motor against the housing.
4. During assembly, make sure the motor is properly
seated against the motor adapter seal and the
housing.
5. Replace the screws to fasten the motor and handle
to the housing. Use the two longer screws to secure
the handle. Torque to 75 to 100 in-lbs.
Replace Gears or Drive Key
Follow these steps to remove the gears and drive key.
1. Disconnect pump from power and ush thoroughly.
2. Remove the coverplate and O-ring from the housing.
3. Remove the drive key and gears from the housing.
4. Inspect gears and key for wear or damage. Replace,
as necessary. Clean cavity.
Follow the steps below to install gears and drive key.
1. Place a gear over the drive shaft.
2. Align the slotted drive shaft end with the gear.
3. Place the other gear in the housing. Turn the gears
to make sure they do not bind. Carefully place the
key in the slot.
4. Replace the O-ring and coverplate. Torque screws
to 25 to 35 in-lbs.
Read, understand and follow all safety instructions given
at the front of this manual.
During repair, carefully inspect all parts for wear or
damage and replace, as necessary. Check O-rings and
seals for breakage, wear, and signs of deterioration,
such as swelling.
Replace Fuse
1. Locate the fuse holder on the power cord.
2. To remove fuse, push the ends together and twist.
Replace the blown fuse.
REPAIR – P-120DEF

7
Clean or Replace Strainer
1. Disconnect pump from power and ush.
2. Remove the coverplate and O-ring from the housing.
3. Remove the inlet strainer.
4. Clean or replace the strainer. Install again.
5. Install the coverplate and O-ring. Torque screws to
25 to 35 in-lbs.
Clean or Replace Inlet Fitting
1. Disconnect pump from power and ush.
2. Remove the inlet tting from the pump housing.
3. Clean or replace the inlet tting. Install again. Torque
screws to 45 to 50 in-lbs.
Clean or Replace Bypass Poppet
1. Disconnect pump from power and ush.
2. Remove the bypass poppet plug.
3. Remove the bypass poppet. Gently rock it back and
forth as necessary to remove.
4. Wipe the cavity clean and wash the bypass poppet
in very pure deionized water.
5. Examine all components and replace as necessary.
6. To replace the poppet O-ring, carefully remove the
O-ring using a small screwdriver or similar tool. Seat
O-ring on the poppet head.
7. Assemble by placing the bypass poppet assembly
in the cavity. Tighten the plug rmly.
Replace Motor
1. Disconnect pump from power and ush.
2. Remove the screws holding the motor and handle
to the housing.
3. Lift the motor from the housing and drive shaft.
4. Remove the motor shaft adapter from the drive shaft.
5. If replacing the motor only, remove the power cord
using instructions below.
6. Assemble by reversing the steps above. Make sure
the motor is properly seated against the motor adapter
seal. Torque the four screws to 75 to 100 in-lbs.
Replace Switch
1. Disconnect pump from power and ush.
2. Remove the switch coverplate on the side of the
motor.
3. Press in on the sides of the switch. Push the switch
from the switch box.
NOTE: Before disconnecting wires, note their positions
on the switch. Connect to the new switch in the same
positions.
4. Disconnect the terminal wires from the back of the
old switch.
5. Install the new switch by reversing steps above.
Carefully position wires in switch box before replacing
coverplate.
6. Install coverplate and tighten screws until snug. Do
not overtighten.
Replace Power Cord
1. Disconnect pump from power and ush.
2. Remove the switch coverplate on the side of the
motor.
3. Remove electrical tape and unscrew the wire nut.
Remove wire from terminal on back of the switch.
4. Remove the old power cord.
5. Install new power cord by reversing steps above.
6. Secure wire nut with two wraps of electrical tape.
7. Install coverplate and tighten screws until snug. Do
not overtighten.
Replace the Drive Shaft or Motor Shaft Seal
Follow these steps to remove the drive shaft and
motor shaft seal.
1. Disconnect pump from power and ush.
2. Remove the motor as described above.
3. Carefully slide the drive shaft from the motor and the
housing. Note the position of the motor shaft washer.
4. Carefully pry the motor shaft seal from the housing
with a at-bladed screwdriver.
5. Inspect the drive shaft, motor shaft washer, motor shaft
seal, and bearings for wear. Replace, as necessary.
Follow these steps to install the drive shaft and
motor shaft seal.
1. Press the new motor shaft seal into the housing with
the same orientation as the old seal.
2. Position the motor shaft washer on the seal. Slide
the notched end of the drive shaft into place in the
housing.
3. Align the drive shaft with the motor adapter or the
planetary gear module. When properly aligned, the
drive shaft will slip into place with the motor against
the housing.
4. During assembly, make sure the motor is properly
seated against the motor adapter seal and the
housing.
5. Replace the screws fastening the motor and handle
to the housing. Use the two longer screws to secure
the handle. Torque to 75 to 100 in-lbs.

8
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
A. MOTOR DOES NOT 1. Circuit breaker tripped Manually reset circuit breaker located in cover assembly. See Operation
RUN Section.
2. Switch defective Remove cover assembly and inspect switch. Replace, if necessary.
3. Motor burned out Remove motor and test by making grounded connection to GFCI protected
115-volt power. Replace, if necessary.
4. Thermal protector tripped Turn switch off. Allow motor to cool. Protector resets automatically after
approximately 30 minutes. See Operations Section.
5. GFCI tripped Manually reset GFCI. If motor does not run, disconnect power and check
for wet or damaged pump or power cord. Correct problem before resuming
operation. Operate pump only in dry locations.
B. MOTOR RUNS BUT 1. System air leak Make sure all ttings and connections are tight. Inspect suction pipe, bung
DOES NOT PUMP adapter and pump inlet seals for leaks or damage.
FLUID
2. Drive key broken Replace key.
3. Strainer clogged Remove coverplate. Clean strainer. Install again.
4. Gear coverplate O-ring worn Remove coverplate. Inspect O-ring and replace if worn or damaged.
5. Bypass poppet stuck open Remove poppet and clean. Install again.
6. Suction pipe clogged, Remove pump. Inspect suction pipe and clean or replace, as necessary.
damaged or missing
7. Gear drive shaft broken Remove coverplate, gears, and motor. Remove and inspect drive shaft.
Replace, if necessary.
8. Gear wear Remove the coverplate and inspect gears, and drive key. Gears must turn
freely with the drive key removed. Replace any worn or damaged parts.
C. LOW FLOWRATE 1. Low voltage Check for adequate power supply voltage.
2. Strainer partially clogged Remove coverplate. Clean strainer. Install again.
3. Suction pipe clogged or Remove pump from tank. Inspect suction pipe and clean or replace, as
damaged necessary.
4. Bypass poppet stuck open Remove poppet and clean. Install again.
5. Gear wear Remove the coverplate and inspect gears, and drive key. Gears must turn
freely with the drive key removed. Replace any worn or damaged parts.
6. Discharge hose too long Long hoses reduce owrate. Shorten hose.
7. Extension cord too long Long cords reduce voltage at pump. Reduce cord length or use larger gauge
cord.
D. RAPID OVERHEATING 1. Duty cycle too long Do not exceed the standard duty cycle of 30 minutes ON and 30 minutes
OF MOTOR OFF. Allow the pump to cool for 30 minutes.
2. Strainer clogged Remove coverplate. Clean strainer. Install again.
3. Thermal protector tripped Turn switch off. Allow motor to cool. Protector resets automatically after
approximately 30 minutes. See Operation Section.
Replace Gears or Drive Key
Follow these steps to remove the gears and drive key.
1. Disconnect pump from power and ush thoroughly.
2. Remove the coverplate and O-ring from the housing.
3. Remove the drive key and gears from the housing.
4. Inspect gears and key for wear or damage. Replace,
as necessary. Clean cavity.
Follow the steps below to install gears and drive key.
1. Place a gear over the drive shaft.
2. Align the slotted drive shaft end with the gear.
3. Place the other gear in the housing. Turn the gears
to make sure they do not bind. Carefully place the
key in the slot.
4. Replace the O-ring and coverplate. Torque screws
to 25 to 35 in-lbs.
TROUBLESHOOTING – PA-120DEF

9
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
A. MOTOR DOES NOT 1. Fuse blown Inspect fuse. If blown, replace.
2. Switch defective Remove switch coverplate and inspect switch. Replace, if necessary.
3. Motor burned out Remove motor from pump and test by connecting to 12-volt DC power
supply. Replace if necessary.
B. MOTOR RUNS BUT 1. System air leak Make sure all ttings and connections are tight. Inspect suction pipe, bung
DOES NOT PUMP adapter and pump inlet seals for leaks or damage.
FLUID
2. Drive key broken Replace key.
3. Strainer clogged Remove coverplate. Clean strainer. Install again.
4. Gear coverplate O-ring worn Remove coverplate. Inspect O-ring and replace if worn or damaged.
5. Bypass poppet stuck Remove poppet and clean. Install again.
6. Suction pipe clogged, Remove pump. Inspect suction pipe and clean or replace, as necessary.
damaged or missing
7. Gear drive shaft broken Remove coverplate, gears, and motor. Remove and inspect drive shaft.
Replace, if necessary.
8. Gear wear Remove the coverplate and inspect gears, and drive key. Gears must turn
freely with the drive key removed. Replace any worn or damaged parts.
C. LOW FLOWRATE 1. Low voltage or poor Check for adequate battery voltage and good terminal connections.
connections
2. Strainer partially clogged Remove coverplate. Clean strainer. Install again.
3. Suction pipe clogged or Remove pump from tank. Inspect suction pipe and clean or replace, as
damaged necessary.
4. Bypass poppet stuck Remove poppet and clean. Install again.
5. Gear wear Remove the coverplate and inspect gears, and drive key. Gears must turn
freely with the drive key removed. Replace any worn or damaged parts.
6. Discharge hose too long Long hoses reduce owrate. Shorten hose.
7. Power cord too long Long cords reduce owrate. Shorten cord.
D. RAPID OVERHEATING 1. Duty cycle too long Do not exceed the standard duty cycle of 30 minutes ON and 30 minutes
OF MOTOR OFF. Allow the pump to cool for 30 minutes.
2. Strainer clogged Remove coverplate. Clean strainer. Install again.
TROUBLESHOOTING – P-120DEF
RUN

10
Item No.n
No. Part No. Description Req’d.
14 118021-1 Handle ................................................................1
15 118023-1 Handle Grip ........................................................1
16 119006-1 Motor Assembly .................................................1
17 119107-1 Cover Assembly (standard) ................................1
18 902002-91 Rocker Switch w/gasket .....................................1
19 904001-99 Screw, Pan HD Mach, #8-32 x 5/16"..................4
20 901001-91 O-Ring ................................................................1
21 904002-24 Sems Screw & Washer Assembly ......................2
22 904003-49 Sems, Hex HD, 1/4-20 x 1 & Flat Washer..........6
23 904003-70 Flat Washer, 5/16" ID x 1" OD x .0303 ...............1
24 904003-92 Sems, Hex HD, 5/16-18 x 7/8, INT Lockwash ...2
25 118108-2 Bung Adapter, 2 in. NPS (Pup) .........................1
26 901002-38 O-Ring, Fluorocarbon ........................................1
27 904003-91 Sems, Hex HD, 1/4-20 x 3/4, Plain Washer .......6
Item No.n
No. Part No. Description Req’d.
1 110100-1 Suction Pipe Assembly, Adjustable ....................1
2 117204-1 Fitting, Reducer Bushing, 1" x 3/4" NPT ............1
904008-44 Fitting, Reducer Bushing, 1" x 3/4" BSPP ..........1
3 115084-1 Gasket, 2 in. .......................................................1
4 115085-1 Teon® Ring .......................................................1
5 110017-6 Motor Shaft Key .................................................1
6 110063-2 Inlet Strainer .......................................................1
7 110078-8 Motor Shaft Seal ................................................1
8 110204-2 Drive Shaft Assembly .........................................1
9 118006-1 Pump Housing ...................................................1
10 118007-1 Gear Coverplate .................................................1
11 118016-1 Shaft Adapter .....................................................1
12 118017-1 O-Ring ................................................................1
13 118020-1 Bearing ...............................................................2
Kits and Accessories
118508-2 Bypass Poppet Assembly Kit (Automatic bypass)
118501-1 Gear Kit (Includes two gears and key)
906006-83 3/4 in. NPT DEF Automatic Nozzle (or)
906008-01 3/4 in. BSPP DEF Automatic Nozzle
906008-02 DEF Manual Nozzle, 3/4 in. Hose Barb
ANOT SHOWN:
118505-1 Drive Shaft Kit (Includes two bearings, motor shaft seal, motor
shaft washer, drive shaft assembly and motor adapter seal
150200-01 DEF Hose EPDM, 3/4 in. NPT x 3/4 in. x 12 ft. (3.7 m)
150200-21 DEF Hose EPDM, 3/4 in. BSPP x 3/4 in. x 12 ft. (3.7 m)
150200-22 DEF Hose EPDM, 3/4 in. NPT x Barb x 12 ft. (3.7 m)
150200-23 DEF Hose EPDM, 3/4 in. BSPP x Barb x 12 ft. (3.7 m)
C
D
B
ILLUSTRATED PARTS LIST – PA-120DEF


11
Item No.n
No. Part No. Description Req’d.
15 118023-1 Handle Grip ........................................................1
16 119002-17 Motor Assembly (12V) P-120H, Standard CSA ..1
17 115016-11 Power Cord Assembly, CSA (14 gauge) ............1
18 119077-2 Switch Coverplate ..............................................1
19 902002-91 Rocker Switch w/gasket .....................................1
20 902004-12 Strain Relief .......................................................1
21 904001-99 Screw, Pan HD Mach, #8-32 x 5/16"..................4
22 901001-91 O-Ring ................................................................1
23 904002-24 Sems Screw & Washer Assembly ......................2
24 904003-49 Sems, Hex HD, 1/4-20 x 1 & Flat Washer..........6
25 904003-70 Flat Washer, 5/16" ID x 1" OD x .0303 ...............1
26 904003-92 Sems, Hex HD, 5/16-18 x 7/8, INT Lockwash ...2
27 118108-2 Bung Adapter, 2 in. NPS (Pup) .........................1
28 901002-38 O-Ring, Fluorocarbon ........................................1
29 904003-91 Sems, Hex HD, 1/4-20 x 3/4, Plain Washer .......6
Item No.n
No. Part No. Description Req’d.
1 110100-1 Suction Pipe Assembly, Adjustable ....................1
2 117204-1 Fitting, Reducer Bushing, 1" x 3/4" NPT ............1
904008-44 Fitting, Reducer Bushing, 1" x 3/4" BSPP ..........1
3 115084-1 Gasket, 2 in. .......................................................1
4 115085-1 Teon® Ring .......................................................1
5 110017-6 Motor Shaft Key .................................................1
6 110063-2 Inlet Strainer .......................................................1
7 110078-8 Motor Shaft Seal ................................................1
8 110204-2 Drive Shaft Assembly .........................................1
9 118006-1 Pump Housing ...................................................1
10 118007-1 Gear Coverplate .................................................1
11 118016-1 Shaft Adapter .....................................................1
12 118017-1 O-Ring ................................................................1
13 118020-1 Bearing ...............................................................2
14 118021-1 Handle ................................................................1
Kits and Accessories
118508-2 Bypass Poppet Assembly Kit (Automatic bypass)
118501-1 Gear Kit (Includes two gears and key)
906006-83 3/4 in. NPT DEF Automatic Nozzle
906008-01 3/4 in. BSPP DEF Automatic Nozzle
906008-02 DEF Manual Nozzle, 3/4 in. Hose Barb
NOT SHOWN:
118505-1 Drive Shaft Kit (Includes two bearings, motor shaft seal, motor
shaft washer, drive shaft assembly and motor adapter seal
150200-01 DEF Hose EPDM, 3/4 in. NPT x 3/4 in. x 12 ft. (3.7 m)
150200-21 DEF Hose EPDM, 3/4 in. BSPP x 3/4 in. x 12 ft. (3.7 m)
150200-22 DEF Hose EPDM, 3/4 in. NPT x Barb x 12 ft. (3.7 m)
150200-23 DEF Hose EPDM, 3/4 in. BSPP x Barb x 12 ft. (3.7 m)
ILLUSTRATED PARTS LIST – P-120DEF
A
C
D
B

12
PA-120DEF:
Applications
Fluids: Diesel Exhaust Fluid (DEF)
Operating
Environment: Outdoor, operating temperature
range of -20° F to +120° F
(-30° C to +50° C).
Operating Pressure 10 PSI
Pump Housing
Lightweight, durable, molded plastic housing.
Convenient 2-inch NPS bung adapter for easy
installation.
Performance
Pump Rate: Up to 12 GPM (45 LPM).
Rate will vary with temperature.
Duty Cycle: 30 minutes ON, 30 minutes OFF.
Duty cycle will vary with
temperature.
Electrical Specications
Input: 115-volt AC, grounded,
GFCI protected
Cord: 18 ga., 3 wire, grounded plug
equipped with circuit breaker.
Mechanical Connections
Bung: 2 inch NPS
Inlet: 1 inch NPT
Outlet: 3/4 inch NPT or 3/4 inch BSPP
Recommended Accessories
3/4 in. x 12 ft. (3.7m) DEF discharge hose
3/4 in. NPT DEF automatic nozzle
3/4 in. NPT DEF ball valve
Weight
Shipping: 15 lbs. (6.8 kg)
P-120DEF:
Applications
Fluids: Diesel Exhaust Fluid (DEF)
Operating
Environment: Outdoor, operating temperature
range of -20° F to +120° F
(-30° C to +50° C).
Operating Pressure 10 PSI
Pump Housing
Lightweight, durable, molded plastic housing.
Convenient 2-inch NPS bung adapter for easy
installation.
Performance
Pump Rate: Up to 12 GPM (45 LPM). Rate
will vary with temperature.
Duty Cycle: 30 minutes ON, 30 minutes OFF.
Duty cycle will vary with
temperature.
Electrical Specications
Input: 12-volt DC
Current: 12-15 amps
Cord: 14 ga., 20 ft. (6.0 m)
Fuse: 20 amps AGC
Mechanical Connections
Bung: 2 inch NPS
Inlet: 1 inch NPT
Outlet: 3/4 inch NPT or 3/4 inch BSPP
Recommended Accessories
3/4 in. x 12 ft. (3.7 m) DEF discharge hose
3/4 in. NPT DEF automatic nozzle
3/4 in. NPT DEF ball valve
Weight
Shipping: 15 lbs. (6.8kg)
SPECIFICATIONS

13
For warranty consideration, parts or other service
information, please contact your local distributor. If you
need further assistance, contact the GPI Customer
Service Department in Wichita, Kansas, during normal
business hours.
A toll free number is provided for your convenience.
1-800-835-0113
To obtain prompt, efcient service, always be prepared
with the following information:
• The model number of your pump
• The serial number or manufacturing date code of your
pump
• Parts descriptions and numbers
Part information can be obtained from the Illustrated
Parts List.
For warranty work, always be prepared with your original
sales slip or other evidence of purchase date.
Please contact GPI before returning any parts. It may be
possible to diagnose the trouble and identify needed parts
in a telephone call. GPI can also inform you of any special
requirements you will need to follow for transportation
and handling of uid equipment.
Do not return the pump or parts without authority
from the Customer Service Department. Due to
strict government regulations, GPI cannot accept
parts unless they have been drained and cleaned.
SERVICE
CAUTION

©2011 by GREAT PLAINS INDUSTRIES, INC., Wichita, KS
Printed in U.S.A.
5252 East 36th Street North
Wichita, KS USA 67220-3205
TEL: [phone]
FAX: [phone]

Limited Warranty Policy
Great Plains Industries, Inc. 5252 E. 36th Street North, Wichita, KS USA 67220-3205, hereby provides a limited warranty against
defects in material and workmanship on all products manufactured by Great Plains Industries, Inc. This product includes a 2 year
warranty from date of purchase as evidenced by the original sales receipt. A 30 month warranty from product date of manufacture
will apply in cases where the original sales receipt is not available. Reference product labeling for the warranty expiration date based
on 30 months from date of manufacture. Manufacturer’s sole obligation under the foregoing warranties will be limited to either, at
Manufacturer’s option, replacing or repairing defective Goods (subject to limitations hereinafter provided) or refunding the purchase
price for such Goods theretofore paid by the Buyer, and Buyer’s exclusive remedy for breach of any such warranties will be enforce-
ment of such obligations of Manufacturer. The warranty shall extend to the purchaser of this product and to any person to whom such
product is transferred during the warranty period.
This warranty shall not apply if:
A. the product has been altered or modied outside the warrantor’s duly appointed representative;
B. the product has been subjected to neglect, misuse, abuse or damage or has been installed or operated other than in ac-
cordance with the manufacturer’s operating instructions.
To make a claim against this warranty, contact the GPI Customer Service Department at 316-686-7361 or 800-835-0113. Or by mail at:
Great Plains Industries, Inc.
5252 E. 36th St. North
Wichita, KS, USA 67220-3205
GPI will step you through a product troubleshooting process to determine appropriate corrective actions.
GREAT PLAINS INDUSTRIES, INC., EXCLUDES LIABILITY UNDER THIS WARRANTY FOR DIRECT, INDIRECT, INCIDENTAL
AND CONSEQUENTIAL DAMAGES INCURRED IN THE USE OR LOSS OF USE OF THE PRODUCT WARRANTED HEREUNDER.
The company herewith expressly disclaims any warranty of merchantability or tness for any particular purpose other than for which
it was designed.
This warranty gives you specic rights and you may also have other rights which vary from U.S. state to U.S. state.
Note: In compliance with MAGNUSON MOSS CONSUMER WARRANTY ACT – Part 702 (governs the resale availability of the war-
ranty terms).
Rev. A 9217620111/11