VP12 High Viscosity Piston Pump

5252 East 36th Street North Wichita, KS USA 67220-3205 TEL: 316-686-7361 FAX: 316-686-6746 VP12 High Viscosity Piston Pump Owner s Manual A Great Plains Ventures Subsidiary www.gpi.net 1-800-835-0113 INSTALLATION INSTRUCTIONS Unpack and inspect all components. Inspect for any damage which may have occurred during shipping. If shipping damage is found, a claim should be filed with the carrier as soon as possible. Remove the two protective plugs from the inlet and outlet ports of the pump. Install Bung Adapter 1. Apply sealant (furnished) to the threads on one end of the bung adapter bushing. 2. Install onto tank or container and tighten snugly with a pipe wrench. To the owner: Congratulations on your purchase of the VP12 Pump. Your pump is manufactured in accordance with the highest standards. Following the operation and maintenance procedures provided in this manual will help you achieve years of dependable performance and trouble-free operation. Please read this manual carefully and keep for future use. 01/06 GENERAL INFORMATION!!! W A R N I N G!!! The GPI VP12 pump is for use with non-flammable fluids only. The pump should not be used for gasoline, diesel, other fuels, herbicides or chemicals. The VP12 has been designed for use with viscous petroleum products. Pump is not for use with flammable liquids. Install Suction Pipe 1. If using the adjustable suction pipe, apply thread sealer to threaded end of the suction pipe. 2. Insert gasket into the union nut on the bung adapter. 3. Insert the strainer into the suction pipe and thread suction pipe into the housing. A suction pipe can also be created using a 1 inch pipe with 1 in. NPT threads on one end. Proper length can be determined by inserting the threaded end through the bung adapter and down to the bottom of the tank. Mark the pipe even with top of bung adapter. Remove the pipe and cut off the pipe on the mark. NOTE: Be sure that pipe material is compatible with fluid. 1. Clean pipe of all foreign material and apply sealant to the threads. 2. Insert gasket into the union nut on the bung adapter and thread pipe into base of pump. 3. Tighten snugly with a pipe wrench. Install Pump and Suction Pipe Onto Tank 1. If using the adjustable suction pipe, extend suction pipe to full length. 2. Insert suction pipe, attached to pump, into the tank carefully. The suction pipe will telescope back to the proper length needed to rest on the bottom of the tank. 3. Thread union nut onto the bung adapter bushing and tighten union nut snugly with a pipe wrench. 1 Rev. A 921641-5

4. If using a self-made suction pipe, insert the suction pipe attached to the pump into the tank. Thread the union nut onto the bung adapter bushing and tighten the union nut snugly with a pipe wrench. Install Hose, Nozzle and Optional Meter 1. Apply thread sealer to all threads. 2. Thread the hose adapter into the pump outlet port. 3. Install hose into the hose adapter. 4. Install optional meter. (If using an electronic meter, thread meter onto the discharge-end of hose.) NOTE: Flow direction is marked by an arrow on meter housing. 5. Thread the optional nipple into the meter and then install the nozzle onto nipple. NOTE: If optional meter is not used, simply thread hose into inlet end of nozzle. OPERATING PROCEDURES Turning On the Pump 1. The On / Off switch is located on the handle of the motor assembly. 2. To prevent motor and pump damage, do not operate pump in By-Pass mode (i.e., recirculation with nozzle closed) for more than 10 minutes. 3. Do not leave the pump running with fluids. Dry running causes damage to piston seals and other pump components. 4. Inspect pump wiring to ensure it is correctly attached to the battery and properly grounded. To avoid electrical shock, use extra care when connecting the pump system to the battery or power supply. 5. Pump is for use with viscous petroleum products only. Pump is not for use with flammable liquids. MAINTENANCE / STORAGE!!! C A U T I O N!!! Proper maintenance and storage will ensure a long pump life. Failure to follow the recommended cleaning and storage procedures will increase pump failures and void warranty. It is very important that the following procedures are followed to assure the reliable, trouble-free operation you expect from your GPI pump. If the pump system is not going to be used for an extended period of time, it is important that the pump be correctly flushed clean of all residue. These extra steps help avoid down time! Daily Care It is mandatory that the pump system always be kept full of liquids. Do not allow liquids to dry inside the pump. If this should happen, DO NOT START THE PUMP. Refer to Liquid Has Dried Inside Pump section for additional instructions. Each time the pump is used, visually check for leakage under the pump housing. A small drain hole will relieve any fluid which may by-pass around the pistons. If even a small amount of liquid is found, new seals are needed on the pistons. Refer to Assembly/Disassembly section for instructions. End of Season Care If the pump has been used for any fluid other than oil, flush the complete system as follows: 1. Remove pump from tank. 2. Insert inlet portion of pump into sufficient water supply to allow pump to run at least 10 to 15 minutes. NOTE: It may be easier to remove the suction pipe and attach a smaller inlet pipe. These steps will allow the complete pump system to be thoroughly rinsed. While flushing, open and close nozzle 15 to 20 times. This forces the dampener to open and close, insuring self-priming and clean internal components at next usage. NOTE: If the optional electronic meter is installed, the meter reading will change when flushed with the pump system. Flushing the meter is also essential to clean sticky fluids from rotor and housing. 3. Do not leave water inside the pump. Water deposits may form, causing the pump system to freeze-up. Refer to Liquid Has Dried Inside Pump section before turning the pump on. 4. Fill the entire system with a light motor oil by inserting inlet portion of pump into 3 or 4 quarts of oil. 5. Turn pump on, open the ball valve and allow oil to recirculate back into the container. While the pump is running, open and close the ball valve several times. Allow the pump to recirculate for a few minutes. 2

6. When completed, turn off pump and close the ball valve nozzle. Store pump indoors. 7. Check the camshaft assembly and the two bearings (top and bottom of camshaft) for proper grease. NOTE: See Assembly/Disassembly section for proper removal of camshaft. 8. If no grease is found, lubricate camshaft, bearings and all seals with a high-temperature lithium based grease. Check every 50 hours of operation thereafter. Liquid Has Dried Inside Pump!!! W A R N I N G!!! If liquid has dried inside of the pump, DO NOT start the motor. 1. Remove motor assembly and both end covers from housing. 2. Apply a penetrating lubricant such as WD-40 onto the pistons and piston liners in the housing. Allow to soak for several minutes. 3. After soaking, use a protective cloth and pliers or other gripping tool to carefully rotate the camshaft back and forth. This will free-up pistons prior to operating. 4. Remove and clean the poppet assembly following the instructions in the Assembly/Disassembly section. 5. Remove the two spacers and four valve cage assemblies from housing, noting relative positions. 6. Check the valve balls to be sure they are not sticking. 7. Reassemble above components only after they are free, clean and working properly. ASSEMBLY / DISASSEMBLY When disassembling your pump, carefully inspect all components for wear or damage. Replace as necessary to assure the reliable, trouble-free operation from your GPI pump. Refer to the list of Replacement Parts, Kits and Accessories found on the Illustrated Parts Drawing page. Motor Removal / Replacement 1. Loosen V-clamp retainer until T-bolt slips out of yoke. 2. Remove motor assembly and seal by sliding motor straight away from the pump housing. Be careful not to damage the seal. 3. Replace with new motor by first removing reduction gear (see following section). 4. Remove screws on motor cover and disconnect motor wires from switch. 5. Replace with new motor by reversing the procedure. Reduction Gearcase Removal / Replacement 1. Remove the four screws on the bottom of motor. 2. Slip reduction gear assembly off motor shaft. 3. When reassembling, do not overtorque (10 lb.-in. maximum). Switch Removal / Replacement 1. Remove the six screws from one side of plastic motor cover. 2. Disconnect the wires from the old switch and remove. Replace with new switch by reversing procedure. 3. When re-installing screws, tighten until snug; do not overtorque. Camshaft & Bearing Mount Assembly Removal / Replacement 1. Remove motor then remove the four screws from the bearing mount assembly. 2. Carefully slide bearing mount assembly from the camshaft assembly, noting the location of thrust washer for replacement. Check all bearings for wear and proper lubrication. NOTE: The bottom bearing is part of the housing and is not easily removed. Replacement of housing may be necessary if bearing is worn. Replace camshaft & bearing mount assembly as follows: 1. Lubricate camshaft, piston rod, all bearings, and lip seal in bearing mount assembly with high temperature lithium grease. 2. Align camshaft with bottom bearing, thrust washer and piston rod. 3. Rotate until camshaft slips into place, resting in the bottom bearing and in the slot of the piston rod. 4. Replace the bearing mount assembly onto the camshaft, carefully aligning the bearing mount assembly to prevent damage to the seal in the assembly. 5. Continue carefully working the bearing mount assembly until it slips onto the spline of the camshaft. 6. Replace the four screws retaining the bearing mount assembly and tighten to a snug fit (10-12 lb.-in torque). Do not overtighten. 3

Poppet Assembly Removal / Inspection NOTE: If the pump pulsates heavily during operation, cleaning of the dampener may be necessary. Some pulsation of the pump is normal. 1. Carefully remove poppet valve/plug, seal, and spring from the pump housing. NOTE: The poppet valve/plug retains the spring and support in a compressed state, so take care not to lose these components when the plug is loosened. 2. Remove the dampener from the housing with a slight back-and-forth motion. Wash the entire poppet assembly in warm soapy water. NOTE: The dampener should not be taken apart. 3. While washing the dampener, push in and rotate the plug to be sure the spring and plug are free and clean of residue. 4. Rinse and reinstall the entire poppet assembly. Tighten to a snug fit. Valve Gage Assemblies Removal / Replacement 1. Remove seven bolts and washers on each side of the end covers. Note the position of the valve cage assemblies and the two spacers for proper replacement. 2. Carefully remove the valve cage assemblies and inspect for damage or residue. NOTE: The valve cage assemblies should not be taken apart. Pistons Removal / Replacement Removal and replacement of the pistons is somewhat involved, requiring a ring compressor (supplied with the Piston Assembly Kit). Damage to piston liners will require replacement of the housing. 1. To remove pistons, remove the screws on each side of the piston rod. 2. After removing both screws, pull the piston assemblies out of their respective sides. NOTE: Remove pistons only in this manner. If an attempt is made to pull the piston through the opposite side, or to remove the piston rod without first removing both pistons, one piston may become lodged in the center of the housing. 3. After removing the pistons, remove the camshaft by following the steps described in the Camshaft & Bearing Mount Assembly Removal/Replacement section. The piston rod may then be removed from the housing. 4. Inspect piston seals and piston rod for wear or damage. If either is evident, replace them. NOTE: Reverse this procedure to install piston rod, pistons and valve cage assemblies. Refer to Illustrated Parts Drawing for correct positioning of parts. 4

TROUBLESHOOTING SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION A. LOW FLOWRATE 1. Leakage Check under pump for leakage through drain hole in bottom of pump housing assembly. 2. Poppet spring is weak Check and/or clean poppet assembly. Replace if necessary. Do not disassemble the dampener. 3. Suction pipe clogged or Check suction pipe for leaks or clogs. Clean or replace as damaged necessary. 4. Poor connections or Check for low battery voltage. low voltage 5. Damaged seal Check for worn piston seal. B. PUMP FAILS TO 1. System air leak Check for air leak in suction side of system and around all PRIME fittings, connections and suction pipe. 2. Sticking valve cage Check valve cage assemblies for sticking. assemblies 3. Poppet assembly is Check and/or clean poppet assembly. Replace components, damaged or binding as necessary. 4. Failed gearbox Check gearbox on the motor to see if it is turning. C. MOTOR OVERHEATS, 1. Poppet assembly is Check and/or clean poppet assembly. Replace components, STALLS WHEN damaged or binding as necessary. Do not disassemble the dampener. NOZZLE IS CLOSED, OR PULSATES 2. Suction pipe clogged or Check suction pipe for leaks or clogs. Clean or replace as EXCESSIVELY damaged needed. 3. Inlet screen clogged Check inlet screen for clogs. 4. Duty cycle too long Avoid excessive operating time. Duty cycle is 30 minutes ON, 30 minutes OFF. D. MOTOR WON T RUN 1. Poor connections Check battery connections. WHEN THE SWITCH IS TURNED ON 2. Electrical connections Check for blown fuse (replace with 20 amp fuse) or dead faulty battery. Check for faulty switch or motor. Replace if burned out. Contact factory for assistance troubleshooting switch or motor problems. 5

ILLUSTRATED PARTS DRAWING 3 12 13 34 24 35 23 22 38 14 1 15 21 36 2 4 6 10 9 9A 16 11 25 2A 5 7 8 32 33 15 17 3A 26 18 27 20 28 29 30 31 19 20 Item No. No. Part No. Description Req d. 1 115002-1 Housing Assembly...1 115015-1 Hose Adapter (Outlet port of Housing)...1 2 115008-1 12 VDC Motor Assembly...1 2 902002-91 Switch (not shown)...1 3 115003-1 End Cover...1 3A 115003-2 End Cover...1 4 901001-91 Seal, Motor Adapter...1 5 906001-69 V-Clamp Retainer (order 115548-1)... 1 6 904003-7 Screw, 1/4-20 x 1/2"...4 7 115010-1 Bearing Mount Assembly...1 8 901001-90 Seal, Bearing Mount...1 9 115009-1 Camshaft Assembly...1 9A 906001-87 Bearing...1 9A 904003-10 Snap Ring...1 10 906001-68 Bearing (order 115522-1 Kit )...1 11 904003-5 Washer, Thrust...1 12 901001-92 Seal, End Cover...2 13 904003-9 Hex Cap Screw, 1/4-20 x 7/8"...2 14 904003-11 Washer...2 15 115012-1 Piston Assembly...2 16 115031-1 Piston Rod...1 17 115021-1 Valve Cage Assembly...4 18 115099-1 Spacer...2 19 904001-21 Washer (order 904003-49 )...14 20 904001-30 Screw, 1/4-20 x 1" (order 904003-49 )...14 21 115011-1 Dampener Assembly...1 22 115035-1 Spring, Poppet...1 23 901001-94 Seal, Bypass Plug...1 24 115044-2 Plug, Dampener...1 25 901001-93 Seal, Lower Cover...1 26 904003-1 Nut...6 27* 115108-1 Lower Cover...1 28* 115013-1 Union Ring...1 29* 114030-1 Inlet Fitting (Internal By-Pass)...1 30 114029-1 Gasket...1 31 115097-2 Bushing, Tank Bung Adapter...1 32 115037-1 Back-up Ring...2 33 115037-2 Back-up Ring...2 34 110188-1 Hose, 1" x 12' Buna-N...1 35 113900-9511 03N31GM EDM (optional)...1 36 110098-1 Nipple, 1 in. Plastic (optional)...1 37 110107-2 Ball Valve Nozzle...1 38 110100-1 22 to 44 in. Adj. Suction Pipe...1 115005-3 Strainer...1 39 115016-1 Power Cord Assembly (not shown)... 1 * Order 115018-2 Assembly below. 37 Accessories and Kits 115018-2 Lower Cover Assembly (Internal By-Pass) Includes Item No s. 25, 27, 28 and 29 (1 each). 115519-1 Wet Seal Kit (Pump) Includes Item No s. 23 and 25 (2 each) and 12. 115522-1 Bearing Mount Assembly Kit Includes Item No s. 4, 7 and 8 (1 each). 115523-1 Piston Assembly Kit Includes Item No s. 13, 14 and 15 (2 each). 115525-1 Motor Kit Includes 12 Volt DC Motor (115006-1) and Gear Box (906001-71). 115526-1 Motor Cover Kit Includes 115014-2 and 115014-1 Covers. 116000-1 Calibration Container 5 Gallon (not shown). 6

SPECIFICATIONS Pump is designed for use with viscous petroleum products. DO NOT use with flammable liquids. 1. Lightweight, corrosion-resistant, durable, molded Nylon housing with built-in handle and convenient spin collar. 2. 1 in. NPT inlet and outlet ports. 3. 1" x 12' Buna-N hose, ball valve nozzle, and adjustable plastic suction pipe. 4. VP12, 12 Volt DC model, comes with 20' - 14 ga. power cord with 20 Amp fuse and battery clips. 5. 20 psi maximum working pressure. 6. Typical Duty Cycle of 30 minutes ON, 30 minutes OFF. The more viscous the fluid (cold/thick) the shorter the duty cycle. Use with fluids up to 2,000 centipoise viscosity. Flowrange up to 8 GPM (30 LPM). 7. The VP12 will pump viscous petroleum products at temperatures within the range of +40 F to +104 F. 8. Shipping weight (approx.): 25 lbs. PARTS AND SERVICE 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, efficient service, always be prepared with the following information: 1. The model number of your pump. 2. The serial number or manufacturing date code of your pump. 3. Part descriptions and numbers. Part information can be found on the Illustrated Parts Drawing page. 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 shipping fuel dispensing equipment. CAUTION: 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. 7

Limited Warranty Policy Great Plains Industries, Inc. 5252 E. 36 th 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. 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 enforcement 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. The warranty period shall begin on the date of manufacture or on the date of purchase with an original sales receipt. This warranty shall not apply if: A. the product has been altered or modified 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 accordance 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. 36 th St. North Wichita, KS, USA 67220-3205 The company shall, notify the customer to either send the product, transportation prepaid, to the company at its office in Wichita, Kansas, or to a duly authorized service center. The company shall perform all obligations imposed on it by the terms of this warranty within 60 days of receipt of the defective product. 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 fitness for any particular purpose other than for which it was designed. This warranty gives you specific 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 warranty terms). 5252 East 36th Street North Wichita, KS USA 67220-3205 TEL: 316-686-7361 FAX: 316-686-6746 GPI and the electric gear pump are registered trademarks of Great Plains Industries, Inc. A Great Plains Ventures Subsidiary www.gpi.net 1-800-835-0113 2006 GREAT PLAINS INDUSTRIES, INC., Wichita, KS Printed in U.S.A. 01/06 Rev. A 921641-5