User Manual

About Diesel Exhaust Fluid (DEF)
The Fill-Rite DEF pump is designed to pum p AUS32 (Aqueous Urea Solution 32.5%), better known as Diesel Exhaust Fluid, or
“DEF”.
AUS32 is used by modern diesel engin es which are equipped with an SCR (Selectiv e Catalytic Reduction) system. DEF never
comes into contact with the fuel; the common misconception is that it is an additive. DEF is carried o nboard the vehicle in its own
storage tank. It is injected into the exhaust gases as a post combustion process through an SCR where it breaks harmful NOx
(Nitrous Oxide) emissions down into mostly Nitrogen and Oxygen.
Because the specific purit y of the AUS32 solution is critical to the catalytic reaction, the Fill-Rite DEF pu m p is designed to maintain
the integrity by using compone nts made of materials that will not taint or alter the solutions chemical structure.
Trouble Shooting
FR20V & FRHP32V Hand Pumps
Problem Possible Cause Solution
Pump will not prime
 Suction line problem
 Jammed check valve
 Fluid incompatibility

Check for leaks in suction line.
 Inspect inlet and piston valves.
 Consult fluid mfg. for compatibility with
 wetted materials.
Low pump capacity
 Excessive dirt in nozzle screen
 Suction line problem

Remove and clean screen.
 Check for leaks in suction line.
Pump fluid leakage
 Dirty seal
 Bad seal
 Gasket leakage
 Fluid incompatibility

Clean O-ring and seat area.
 Replace seal.
 Tighten covers and joints.
 Consult fluid mfg. for compatibility with
wetted materials.
*After periods of extensive use, usually with a hose kit, the air piston on the FRAP32V air pump may freeze because of excess moisture in the air
supply line. If this condition persists, install a filter, filter / lubricator, or a water separator to reduce moisture content in the air supply to the pump.
FRAP32V Air Operated Pump
Problem Possible Cause Solution
Pump air piston does not operate
 Air pressure is too low; minimum
recommended air pressure is 30 psi
(2 bar)
 Piston frozen in place (frost on air
cylinder)*

Increase air supply pressure to
between 30 psi and 100 psi (2 bar to
6 bar).
 Close air inlet valve and allo w piston
& cylinder to thaw (see * note below).
Air piston stalls
 Low air pressure, or pressure has
dropped below 30 psi (2 bar)
 Piston frozen (see above)

Close & re-open air inlet valve.
 If stalling occurs regularly, adjust the
regulator to increase the air pr essure.
IMPORTANT! Tank Venting: In most cases it is desirable to vent the container being pumped from to p r event
possible collapsing. The FR20V and FRHP32V han d pumps are self venting when screwed into a typical barrel. This
is particularly important when working with Diesel Exhaust Fluid as exposure to air will crystallize the fluid instantly. It is
critical to maintain the seal to a barrel or drum of Diesel Exhaust Fluid to maintain the integrity of the fluid.
IMPORTANT! After initial assembly and installation, flush the entire dispensing system by pumping 1 - 2 gal lons of
DEF through it. This purges the system of air, and ensures any impurities that may have been in the system are
washed out. Dispose of the Diesel Exhaust Fluid used to flush the system using approved Diesel Exhaust F luid
handling procedures; do n ot return the fluid to the drum or tote, or use it in a vehicle.