GORMAN-RUPP PUMPS 0 Series Application guide

OM‐03756-02

January 11, 1993

Rev. C 09‐27‐19

GORMAN‐RUPP PUMPS

www.grpumps.com

e1993 Gorman‐Rupp Pumps Printed in U.S.A.

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

0 SERIES PUMP

MODEL

03H1-GR /S2

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the

spaces provided below. Your Gorman‐Rupp distributor

needs this information when you require parts or service.

Pump Model:

Serial Number:

TABLE OF CONTENTS

INTRODUCTION PAGE I - 1.................................................

SAFETY SECTION A PAGE A - 1...........................................

INSTALLATION - SECTION B PAGE B - 1....................................

Pump Dimensions PAGE B - 1.....................................................

PREINSTALLATION INSPECTION PAGE B - 1............................................

POSITIONING PUMP PAGE B - 2.......................................................

Lifting PAGE B - 2.................................................................

Mounting PAGE B - 2.............................................................

SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................

Materials PAGE B - 2..............................................................

Line Configuration PAGE B - 2......................................................

Connections to Pump PAGE B - 2..................................................

Gauges PAGE B - 3...............................................................

SUCTION LINES PAGE B - 3...........................................................

Fittings PAGE B - 3...............................................................

Strainers PAGE B - 3..............................................................

Sealing PAGE B - 3...............................................................

Suction Lines In Sumps PAGE B - 3.................................................

Suction Line Positioning PAGE B - 3................................................

DISCHARGE LINES PAGE B - 4........................................................

Siphoning PAGE B - 4.............................................................

Valves PAGE B - 4................................................................

ALIGNMENT PAGE B - 4..............................................................

SUCTION AND DISCHARGE PIPING PAGE B - 5.........................................

Typical System Installation PAGE B - 5..............................................

Piping PAGE B - 6................................................................

Sealing PAGE B - 7...............................................................

Valves PAGE B - 7................................................................

Siphoning PAGE B - 8.............................................................

Eductors PAGE B - 8..............................................................

OPERATION - SECTION C PAGE C - 1......................................

PRIMING PAGE C - 1.................................................................

STARTING PAGE C - 1................................................................

Rotation PAGE C - 1..............................................................

Drive PAGE C - 1.................................................................

OPERATION PAGE C - 2..............................................................

Leakage PAGE C - 2..............................................................

Liquid Temperature And Overheating PAGE C - 2.....................................

Strainer Check PAGE C - 2.........................................................

Pump Vacuum Check PAGE C - 2..................................................

STOPPING PAGE C - 3................................................................

Cold Weather Preservation PAGE C - 3..............................................

GEARBOX TEMPERATURE CHECK PAGE C - 3..........................................

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

TABLE OF CONTENTS

(continued)

PUMP MAINTENANCE AND REPAIR SECTION E PAGE E - 1.................

PERFORMANCE CURVE PAGE E - 1...................................................

PARTS LIST:

Pump Model PAGE E - 3..........................................................

Gear Box Assembly PAGE E - 5....................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 6.........................

Removing Pump and Gearbox PAGE E - 6...........................................

Pump Casing and Wear Ring Removal PAGE E - 7....................................

Impeller Removal PAGE E - 7......................................................

Seal Removal and Disassembly PAGE E - 7..........................................

PUMP AND SEAL REASSEMBLY PAGE E - 7............................................

Seal Reassembly and Installation PAGE E - 8........................................

Impeller Installation PAGE E - 9.....................................................

Pump Casing and Wear Ring Installation PAGE E - 9..................................

Installing Pump and Gearbox PAGE E - 10............................................

GEARBOX DISASSEMBLY PAGE E - 10..................................................

GEARBOX REASSEMBLY PAGE E - 11...................................................

LUBRICATION PAGE E - 13.............................................................

Seal Assembly PAGE E - 13.........................................................

Gearbox PAGE E - 13..............................................................

0 SERIES OM‐03756

PAGE I - 1INTRODUCTION

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump.

Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so

could result in personal injury or damage to the

pump.

This Installation, Operation, and Maintenance

manual is designed to help you achieve the best

performance and longest life from your Gorman‐

Rupp pump.

This pump is an 0 Series, enclosed impeller, cen

trifugal model, with straight‐in suction and without

a suction check valve. The basic material of con

struction for wetted parts is aluminum. The pump is

close‐coupled to an integral, 1000 RPM gearbox

speed increaser with a 4.09:1 ratio that is rotated

180_from the standard position. Power is trans

mitted to the gearbox through a customer‐installed

universal shaft assembly.

Because pump installations are seldom identical,

this manual cannot possibly provide detailed in

structions and precautions for every aspect of

each specific application. Therefore, it is the re

sponsibility of the owner/installer of the pump to

ensure that applications not addressed in this

manual are performed only after establishing that

neither operator safety nor pump integrity are com

promised by the installation. Pumps and related

equipment must be installed and operated ac

cording to all national, local and industry stan

dards.

If there are any questions regarding the pump or

its application which are not covered in this man

ual or in other literature accompanying this unit,

please contact your Gorman‐Rupp distributor, or

write:

The Gorman‐Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-1217

Phone: (419) 755-1011

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2870

The following are used to alert maintenance per

sonnel to procedures which require special atten

tion, to those which could damage equipment, and

to those which could be dangerous to personnel:

Immediate hazards which WILL result in

severe personal injury or death. These

instructions describe the procedure re

quired and the injury which will result

from failure to follow the procedure.

Hazards or unsafe practices which

COULD result in severe personal injury

or death. These instructions describe

the procedure required and the injury

which could result from failure to follow

the procedure.

Hazards or unsafe practices which COULD

result in minor personal injury or product

or property damage. These instructions

describe the requirements and the possi

ble damage which could result from failure

to follow the procedure.

NOTE

Instructions to aid in installation, operation, and

maintenance or which clarify a procedure.

0 SERIES OM‐03756

PAGE A - 1SAFETY

SAFETY - SECTION A

This information applies to 0 Series

power take‐off pumps. Refer to the man

ual accompanying the power source be

fore attempting to begin operation.

Because pump installations are seldom

identical, this manual cannot possibly

provide detailed instructions and pre

cautions for each specific application.

Therefore, it is the owner/installer's re

sponsibility to ensure that applications

not addressed in this manual are per

formed only after establishing that nei

ther operator safety nor pump integrity

are compromised by the installation.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Switch off the vehicle ignition and

remove the key to ensure that the

pump will remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Check the temperature before

opening any covers, plates, or

plugs.

5. Close the suction and discharge

valves.

6. Vent the pump slowly and cau

tiously.

7. Drain the pump.

This pump is designed for vehicular

mounting in petroleum service. Do not

attempt to pump corrosive materials

which may damage the pump or endan

ger personnel as a result of pump fail

ure.

Be certain proper safety practices are

followed before operating or servicing

the pump. Provide adequate ventilation,

prohibit smoking, wear static‐resistant

clothing and shoes. Clean up all fuel

spills immediately after occurrence.

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam

age to equipment. Suction and dis

charge hoses and piping must be re

moved from the pump before lifting.

After the pump has been positioned,

make certain that the pump and all pip

ing connections are tight, properly sup

ported and secure before operation.

Do not operate the pump without the

shields and/or guards in place over the

rotating parts. Exposed rotating parts

can catch clothing, fingers, or tools,

causing severe injury to personnel.

Do not operate the pump against a

closed discharge valve for long periods

of time. If operated against a closed dis

charge valve, pump components will

deteriorate, and the liquid could come

0 SERIESOM-03756

PAGE A - 2 SAFETY

to a boil, build pressure, and cause the

pump casing to rupture or explode.

Overheating may produce dangerous

fumes. Take precautions to ensure the

area surrounding the pump is ade

quately ventilated. Allow the pump to

cool and use extreme caution when

venting the pump, or when removing

covers, plates, plugs, or fitting.

Overheated pumps can cause severe

burns and injuries. If overheating of the

pump occurs:

1. Stop the pump immediately.

2. Ventilate the area.

3. Allow the pump to completely cool.

4. Check the temperature before

opening any covers, plates,

gauges, or plugs.

5. Vent the pump slowly and cau

tiously.

6. Refer to instructions in this manual

before restarting the pump.

After the vehicle is positioned for pump

maintenance, block the wheels and set

the emergency brake before attempting

to disconnect the drive shaft or remove

the pump. Be sure the pump is properly

reinstalled and secure before opera

tion.

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over

heated pump. Vapor pressure within the

pump can cause parts being disen

gaged to be ejected with great force. Al

low the pump to completely cool before

servicing.

The gearbox provided on this pump is

designed for operation at 1000 RPM

maximum input speed. If operated at a

higher RPM, pump components may be

destroyed.

Never run this pump backwards. Be cer

tain that rotation is correct before fully

engaging the pump.

Never run the pump dry of pumping me

dium. There must be a supply of liquid to

the pump at all times to prevent destruction

of the shaft seal faces.

Pumps and related equipment must be in

stalled and operated according to all na

tional, local and industry standards.

0 SERIES OM-03756

PAGE B - 1INSTALLATION

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this

section offers only general recommendations and

practices required to inspect, position, and ar

range the pump and piping.

Do not test or operate your pump and in

tegral gearbox before reading the in

stallation and operation instructions in

this manual.

This pump is a self‐priming centrifugal model with

an integral gearbox assembly. It is designed for ve

hicular mounting in petroleum service, where the

liquid is supplied to the pump under pressure.

Since the pressure supplied to the pump is critical

to performance and safety, be sure to limit the in

coming pressure to 50% of the maximum permissi

ble operating pressure as shown on the pump per

formance curve (see Section E, Page 1).

The integral gearbox is designed to be driven

through the vehicle transfer case by a customer‐

supplied universal shaft assembly. The pump cas

ing or gearbox may be rotated in 45_increments to

assist with alignment with the vehicle tank; howev

er, if the gearbox is to be rotated, some modifica

tions must be made to the gearbox to ensure ade

quate lubrication. Consult the factory for details.

For further assistance, contact your Gorman‐Rupp

distributor or the Gorman‐Rupp Company.

Pump Dimensions

See Figure 1 for the approximate physical dimen

sions of this pump.

OUTLINE DRAWING

Figure 1. Pump Model 03H1‐GR /S2

OM-03756 0 SERIES

PAGE B - 2 INSTALLATION

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be

fore shipment from the factory. Before installation,

inspect the pump for damage which may have oc

curred during shipment. Check as follows:

a. Inspect the pump and gearbox for cracks,

dents, damaged threads, and other obvious

damage.

b. Check for and tighten loose attaching hard

ware. Since gaskets tend to shrink after dry

ing, check for loose hardware at mating sur

faces.

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated. Note the direction of rotation indi

cated on the pump. Check that the pump

shaft rotates in the required direction.

Only operate this pump in the direction in

dicated on the pump body and/or the ac

companying decal. Reverse rotation of the

shaft will adversely effect pump perform

ance, and the pump and/or gearbox could

be seriously damaged.

d. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the MAINTENANCE

AND REPAIR section of this manual and per

form duties as instructed.

Before operation, remove the shipping

plug (6) and replace with the reducing

bushing (5) and air vent (4), which are

shipped loose. The air vent must be

installed to prevent the gearbox from over

heating during operation.

The gearbox assembly was lubricated and

tested before it was shipped from the fac

tory; however, the lubricant level must be

checked before putting the pump into ser

vice.

e. If the pump and gearbox have been stored for

more than 12 months, some of the compo

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

or replaced to ensure maximum pump serv

ice.

If the maximum shelf life has been exceeded, or if

anything appears to be abnormal, contact your

Gorman‐Rupp distributor or the factory to deter

mine the repair or updating policy. Do not put the

pump into service until appropriate action has

been taken.

VEHICLE REQUIREMENTS

The following instructions apply equally to new in

stallations, rebuilds or retrofits.

Tank Preparation

It is essential that any tank scale, dirt, or other for

eign material be removed from the tank and piping

prior to pump installation. Failure to do so could re

sult in clogging or damage to the pump.

Damage to the pump resulting from debris

in the suction line will not be covered by

the pump warranty.

Before connecting the suction and dis

charge piping, carefully check the storage

tank and piping for construction debris

such as nuts, bolts, wire, weld slag, and

other foreign material. Install a commer

cially available 80 mesh screen in the suc

tion line to prevent debris from entering the

pump.

POSITIONING PUMP

Lifting

Pump unit weights will vary depending on the

mounting and drive provided. Check the shipping

tag on the unit packaging for the actual weight, and

0 SERIES OM-03756

PAGE B - 3INSTALLATION

use lifting equipment with appropriate capacity.

Drain the pump and remove all customer‐installed

equipment such as suction and discharge hoses

or piping before attempting to lift existing, installed

units.

The pump assembly can be seriously

damaged if the cables or chains used to lift

and move the unit are improperly wrapped

around the pump.

Due to the confined mounting location,

specialized equipment such as a transmis

sion jack with custom brackets should be

used to lift and position the pump and

gearbox.

SUCTION LINES

To avoid air pockets which could affect pump prim

ing, the suction line must be as short and direct as

possible. When operation involves a suction lift, the

line must always slope upward to the pump from

the source of the liquid being pumped; if the line

slopes down to the pump at any point along the

suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump

inlet. If reducers are used in suction lines, they

should be the eccentric type, and should be in

stalled with the flat part of the reducers uppermost

to avoid creating air pockets. Valves are not nor

mally used in suction lines, but if a valve is used,

install it with the stem horizontal to avoid air pock

ets.

Strainers

If a strainer is furnished with the pump, be certain

to use it; any spherical solids which pass through a

strainer furnished with the pump will also pass

through the pump itself.

If a strainer is not furnished with the pump, but is

installed by the pump user, make certain that the

total area of the openings in the strainer is at least

three or four times the cross section of the suction

line, and that the openings will not permit passage

of solids larger than the solids handling capability

of the pump.

This pump is designed to handle up to 7/16 inch

(11,1 mm) diameter spherical solids.

Sealing

Since even a slight leak will affect priming, head,

and capacity, especially when operating with a

high suction lift, all connections in the suction line

should be sealed with pipe dope to ensure an air

tight seal. Follow the sealant manufacturer's rec

ommendations when selecting and applying the

pipe dope. The pipe dope should be compatible

with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it

should be positioned away from the wall of the

sump at a distance equal to 1‐1/2 times the diame

ter of the suction line.

If there is a liquid flow from an open pipe into the

sump, the flow should be kept away from the suc

tion inlet because the inflow will carry air down into

the sump, and air entering the suction line will re

duce pump efficiency.

If it is necessary to position inflow close to the suc

tion inlet, install a baffle between the inflow and the

suction inlet at a distance 1‐1/2 times the diameter

of the suction pipe. The baffle will allow entrained

air to escape from the liquid before it is drawn into

the suction inlet.

If two suction lines are installed in a single sump,

the flow paths may interact, reducing the efficiency

of one or both pumps. To avoid this, position the

suction inlets so that they are separated by a dis

tance equal to at least 3 times the diameter of the

suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is

critical to efficient pump operation. Figure 2 shows

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