GORMAN-RUPP 03H1-GL Self Priming Centrifugal Pump Instruction Manual
- June 9, 2024
- GORMAN-RUPP
Table of Contents
03H1-GL Self Priming Centrifugal Pump
OM-01193-02 January 23, 1981 Rev. K 04/11/22
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
WITH PARTS LIST
0 SERIES PUMP
MODEL
03H1-GL
GORMAN-RUPP PUMPS
www.grpumps.com
e1981 Gorman-Rupp Pumps
Printed in U.S.A.
Register your new 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . PREINSTALLATION INSPECTION . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. VEHICLE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
Tank Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . POSITIONING PUMP . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALIGNMENT . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . SUCTION AND DISCHARGE PIPING . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eductors . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
PAGE B – 1 PAGE B – 2 PAGE B – 2 PAGE B – 2 PAGE B – 2 PAGE B – 2 PAGE B – 3 PAGE B – 4 PAGE B – 5 PAGE B – 6 PAGE B – 6 PAGE B – 7 PAGE B – 7
OPERATION – SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C – 1
PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GROUNDING . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . STARTING . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . Drive . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . Strainer Check . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump
Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . STOPPING . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Cold Weather Preservation . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . GEARBOX TEMPERATURE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
PAGE C – 1 PAGE C – 1 PAGE C – 1 PAGE C – 1 PAGE C – 2 PAGE C – 2 PAGE C – 2 PAGE C – 2 PAGE C – 2 PAGE C – 3 PAGE C – 3 PAGE C – 3 PAGE C – 3
TROUBLESHOOTING – SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE D – 1
PUMP MAINTENANCE AND REPAIR – SECTION E . . . . . . . . . . . . . . . . . PAGE E – 1
PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . PARTS LISTS:
Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . Gearbox Assembly . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . .
. . . . . . . . . . . . . Removing Pump and Gearbox . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Casing and
Wear Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal Removal and
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
PAGE E – 1
PAGE E – 3 PAGE E – 5 PAGE E – 6 PAGE E – 6 PAGE E – 7 PAGE E – 7 PAGE E – 7
i
TABLE OF CONTENTS (continued)
PUMP AND SEAL REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . Seal Reassembly and Installation . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Impeller
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . Pump Casing and Wear Ring Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing
Pump and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . GEARBOX REASSEMBLY . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . Gearbox . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
PAGE E – 7 PAGE E – 7 PAGE E – 9 PAGE E – 9 PAGE E – 10 PAGE E – 10 PAGE E – 11 PAGE E – 13 PAGE E – 13 PAGE E – 13
ii
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OM-01193
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.
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.
HAZARD AND INSTRUCTION DEFINITIONS
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.
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 The Gorman-Rupp Company:
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
For information or technical assistance on the power source, contact the power
source manufac turer’s local dealer or representative.
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.
INTRODUCTION
PAGE I – 1
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OM-01193
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.
If this pump is used with volatile and/or flammable liquids, be certain proper
safety practices are followed before op erating or servicing the pump. Provide
adequate ventilation, prohibit smoking, wear static-resistant clothing and
shoes. Clean up all fuel spills immedi ately after occurrence.
Death or serious personal injury and damage to the pump or components can
occur if proper lifting procedures are not observed. Make certain that hoists,
chains, slings or cables are in good working condition and of suffi cient
capacity and that they are posi tioned so that loads will be balanced and the
pump or components will not be damaged when lifting. Suction and dis charge
hoses and piping must be re moved from the pump before lifting. Lift the pump
or component only as high as necessary and keep personnel away from suspended
objects.
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.
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.
SAFETY
Do not operate the pump without the shields and/or guards in place over the
rotating parts. Exposed rotating parts
PAGE A – 1
OM-01193
0 SERIES
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 to a boil, build pressure, and cause
the pump casing to rupture or explode.
If this pump is used with volatile and/or flammable liquids, overheating may
produce dangerous fumes. Take pre cautions to ensure the area surrounding the
pump is adequately ventilated. Al low the pump to cool and use extreme caution
when venting the pump, or when removing covers, plates, plugs, or fitting.
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.
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.
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.
After the vehicle is positioned for pump
PAGE A – 2
Pumps and related equipment must be in stalled and operated according to all
na tional, local and industry standards.
SAFETY
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OM-01193
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-GL INSTALLATION
PAGE B – 1
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0 SERIES
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.
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.
PAGE B – 2
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
Death or serious personal injury and damage to the pump or components can
occur if proper lifting procedures are not observed. Make certain that hoists,
chains, slings or cables are in good working condition and of suffi cient
capacity and that they are posi tioned so that loads will be balanced and the
pump or components will not be damaged when lifting. Suction and dis charge
hoses and piping must be re moved from the pump before lifting. Lift the pump
or component only as high as necessary and keep personnel away from suspended
objects.
INSTALLATION
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OM-01193
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 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.
NOTE
If the gearbox is rotated out of the standard position shown in Figure 1, the
oil fill and drain plugs must be relocated. The oil vent must be relocated to
the highest port. Consult the factory for correct posi tioning of the fill
plug to provide for proper lubrica tion of the gearbox.
ALIGNMENT
The alignment of the pump and its power source is critical for trouble-free
mechanical operation. Be fore checking alignment, make sure that the gear box
mounting bolts are tight.
When connecting the universal joint drive shaft as sembly to a PTO unit,
install, support, and align the drive shaft in accordance with the
manufacturer’s instructions. The pump and the drive power source are generally
positioned so that shaft centerlines are parallel and horizontal. The maximum
operat ing angle should not exceed 15_ (see Figure 2).
Check the direction of rotation of the PTO unit be fore starting the pump. The
drive shaft must rotate in the direction shown on the body of the pump,
gearbox, and/or decals, tags, and labels.
Do not operate the pump without the guard in place over the rotating parts.
Exposed rotating parts can catch cloth ing, fingers, or tools, causing severe
in jury to personnel.
After the power take-off has been aligned, block the wheels of the external
power source, engage the braking system, or take other precautions to ensure
that the power source will remain station ary. Block the wheels on the unit to
prevent creep ing.
When installing and/or aligning univer sal shaft assemblies, disconnect the power source to ensure that the pump will remain inoperative.
INSTALLATION
PAGE B – 3
OM-01193
LUGS MUST BE IN LINE, REGARDLESS OF OPERATING ANGLE SHOWN BELOW
LUG ALIGNMENT
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SHAFTS PARALLEL, ANGLES EQUAL
SHAFTS NOT PARALLEL, ANGLES EQUAL
Figure 2. Proper Installation And Alignment of Universal Assembly
SUCTION AND DISCHARGE PIPING
tors, related piping and safety accessories. Some of the accessories are available from Gorman- Rupp as optional equipment.
Typical System Installation
Tank filling and dispensing operations require a system utilizing flow- directing (FDF) valves, educ
Refer to Figures 3 and 4 for illustrations of typical piping systems for tank filling and dispensing.
PAGE B – 4
INSTALLATION
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OM-01193
SCHEMATIC SYSTEM USING EDUCTOR FOR DISPENSING AND FILLING
Figure 3. Typical Installation Using Educator For Filling And Dispensing
SCHEMATIC SYSTEM USING PUMP FOR DISPENSING AND FILLING
Figure 4. Typical Installation Using Pump For Filling And Dispensing
Piping
All piping material must be compatible with the liq uid being pumped. If hose
is used in suction lines, it must be the rigid-wall, reinforced type to
prevent collapse under suction. Using piping couplings in suction lines is not
recommended.
A suction strainer was not furnished with this pump since it is not designed to handle liquids containing solids. However, to protect the pump from acciden tal damage a commercially available 80 mesh screen should be installed in the suction line. Make certain that the total open area of the screen is at least three or four times the cross section of the
INSTALLATION
PAGE B – 5
OM-01193
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suction line to ensure an adequate supply of liquid 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.
If a throttling valve is desired in the discharge line, use a valve as large
as the largest pipe to minimize friction losses. Never install a throttling
valve in a suction line.
With high discharge heads, it is recommended that a throttling valve and a
system check valve be in stalled in the discharge line to protect the pump
from excessive shock pressure and reverse rota tion when it is stopped.
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 pie
dope.
Valves
Gorman-Rupp manufactures several sizes of flow- diverting (FDF) valves for use
in truck-mounted pumping applications. The valves are designed to reverse the
flow of liquid with only the turn of a han dle. This allows the same pump to
fill or dispense from the tank.
The FDF valve is designed for directing flow only. it will not serve as a
positive shut off or throttling valve.
See Figure 5 illustrating the theory of operation for a typical FDF valve.
Consult the factory for further assistance or other sizes.
DISPENSING POSITION
FILL POSITION
DISPENSE
TOP VIEW
FILL
Figure 5. FDF Valve Theory of Operation
When the center web of the valve is aligned with the larger ports (filling position), the flow passes straight through. When the handle is turned to the
dispensing position, the web blocks the straight flow and opens two paths of flow through the larger ports to the smaller ports.
PAGE B – 6
INSTALLATION
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OM-01193
Siphoning
Do not terminate the discharge line at a level lower than that of the liquid
being pumped unless a si phon breaker is used in the line. Otherwise, a si
phoning action causing damage to the pump could result.
Eductors
An eductor may be used in conjunction with an
FDF valve to increase dispensing rates and im prove efficiency. An educator
may also be used to collapse the tank service hose after the tank has been
filled or emptied.
Contact the Gorman-Rupp Company or an autho rized distributor for
specifications and perform ance data on eductors or FDF valves.
INSTALLATION
PAGE B – 7
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OM-01193
OPERATION – SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and decals attached to the pump.
This pump is designed for vehicular mounting in petroleum service. Do not
attempt to pump corrosive materials, or any liquids which may damage the pump
or endanger personnel as a result of pump failure.
Add liquid to the pump casing when:
1. The pump is being put into service for the first time.
2. The pump has not been used for a consider able length of time.
3. The liquid in the pump casing has evapo rated.
When installed in a flooded suction application, simply open the system valves
and permit the in coming liquid to evacuate the air. After the pump and piping
system have completely filled, evacu ate any remaining air pockets in the pump
or suc tion line by loosening a pipe plug or opening bleed er valves.
Once the pump casing has been filled, the pump will prime and reprime as
necessary.
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.
PRIMING
Install the pump and piping as described in IN STALLATION. Make sure that the
piping connec tions are tight, and that the pump is securely mounted. Check
that the pump is properly lubri cated (see LUBRICATION in MAINTENANCE AND
REPAIR).
This pump is self-priming, but the pump should never be operated unless there
is liquid in the pump casing.
GROUNDING
To eliminate electrostatic build-up when pumping petroleum products, the pump
must be grounded by attaching a ground wire to a ground rod. Install the
ground rod in accordance with the National Electric Code and all local codes.
Be sure the clamp or fastener has made a tight electrical con nection with the
rod.
Inspect and test the ground wire assembly for conductivity. Replace broken or
frayed wire before resuming operation.
STARTING
Consult the operations manual furnished with the power source.
Never operate this pump unless there is liquid in the pump casing. The pump
will not prime when dry. Extended operation of a dry pump will destroy the
seal assembly.
OPERATION
Rotation
The correct direction of pump rotation is counter clockwise when facing the
input drive shaft. The
PAGE C – 1
OM-01193
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pump could be damaged and performance ad versely affected by incorrect
rotation. If pump per formance is not within the specified limits (see the
curve on Page E-1), check the direction of rotation before further
troubleshooting.
Drive
This pump is designed for operation with a power take-off unit coupled to the
drive shaft on the gear box. The gearbox assembly has a ratio of 4.09:1, and
is designed for operation at 1000 RPM. Do not operate at a higher input speed.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is 160_F (71_C). Do not apply it
at a higher operating temperature.
Overheating can occur if operated with the valves in the suction or discharge
lines closed. Operating against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup ture or explode. If
overheating occurs, stop the pump and allow it to cool before servicing it.
Refill the pump casing with cool liquid.
The gearbox provided on this pump is designed for operation at 1000 RPM
maximum. If operated at a higher rpm, pump components may be destroyed.
OPERATION
Pump speed and operating condition points must be within the continuous per
formance range shown on the curve (see Section E, Page 1).
Partially open the discharge throttling valve so that the discharge line fills
slowly to prevent damage to piping, gaskets, and other devices in the line
which could be affected by shock resulting from rapid fill ing of the line.
When the discharge line is com pletely filled, adjust the discharge throttling
valve to the desired flow rate.
Leakage
No leakage should be visible at pump mating sur faces, or at pump connections
or fittings. Keep all line connections and fittings tight to maintain maxi mum
pump efficiency.
PAGE C – 2
Allow an overheated pump to complete ly cool before servicing. Do not remove
plates, covers, gauges, pipe plugs, or fittings from an overheated pump. Liq
uid within the pump can reach boiling temperatures, and vapor pressure with in
the pump can cause parts being dis engaged to be ejected with great force.
After the pump cools, drain the liquid from the pump by removing the casing
drain plug. Use caution when removing the plug to prevent injury to personnel
from hot liquid.
Strainer Check
If a suction strainer has been shipped with the pump or installed by the user,
check the strainer regularly, and clean it as necessary. The strainer should
also be checked if pump flow rate begins to drop. If a vacuum suction gauge
has been in stalled, monitor and record the readings regularly to detect
strainer blockage.
Never introduce air or steam pressure into the pump casing or piping to remove
a blockage. This could result in personal injury or damage to the equipment.
If backflushing is absolutely neces sary, liquid pressure must be limited to
50% of the maximum permissible operating pressure shown on the pump
performance curve. (See Section E, Page 1.)
OPERATION
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OM-01193
Pump Vacuum Check
Since this pump does not have a suction check valve, the discharge line must
be fitted with a check valve if a pump vacuum reading is to be taken.
With the pump inoperative, install a vacuum gauge in the system, using pipe
dope on the threads. Block the suction line and start the pump. At oper ating
speed the pump should pull a vacuum of 20 inches (508,0 mm) or more of
mercury. If it does not, check for air leaks in the seal, gasket, or dis
charge valve.
Open the suction line, and read the vacuum gauge with the pump primed and at
operation speed. Shut off the pump. The vacuum gauge reading will immediately
drop proportionate to static suction lift, and should then stabilize. If the
vacuum reading falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check the point of installation of
the vacuum gauge.
NOTE
Petroleum products are very sensitive to changes in temperature. Warmer
temperatures elevate the product vapor pressure, resulting in low vacuum
readings. Do not mistake temperature problems for faulty pump installation or
performance.
STOPPING
Never halt the flow of liquid suddenly. If the liquid being pumped is stopped
abruptly, damaging shock waves can be transmitted to the pump and piping
system. Close all connecting valves slowly.
On engine driven pumps, reduce the throttle speed slowly and allow the engine
to idle briefly be fore stopping.
If the application involves a high discharge head, gradually close the
discharge throttling valve before stopping the pump.
After stopping the pump, remove the engine igni tion key to ensure that the
pump will remain inop erative.
Cold Weather Preservation
If the application of this pump is limited to petro leum products, normal
freezing conditions will not damage the pump. However, during extremely se
vere conditions care should be exercised during start-up, especially if the
pump has been idle for more than a few hours.
GEARBOX TEMPERATURE CHECK
The gearbox runs higher than ambient tempera tures because of heat generated
by friction. Tem peratures of approximately 200_F (93_C) are con sidered
normal, and can operate intermittently at 250_F (121_C).
Checking gearbox temperatures by hand is inac curate. Place a contact-type
thermometer against the housing and record this temperature for future
reference.
A sudden increase in gearbox temperature is a warning that the bearings are at
the point of failing. Make certain that the bearing lubricant is of the proper
viscosity and at the correct level (see LU BRICATION in Section E). Bearing
overheating can also be caused by shaft misalignment and/or excessive
vibration.
When pumps are first started, the bearings may seem to run at temperatures
above normal. Con tinued operation should bring the temperatures down to
normal levels within 20 minutes or less.
OPERATION
PAGE C – 3
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TROUBLESHOOTING – SECTION D
Review all SAFETY information in Section A.
OM-01193
Before attempting to open or service the pump:
1. Familiarize yourself with this manual. 2. Switch off the vehicle ignition
and re
move the key, or take other precau tions to ensure that the pump will re main
inoperative. 3. Allow the pump to completely cool if overheated. 4. Check the
temperature before open ing any covers, plates, or plugs. 5. Close the suction
and discharge valves. 6. Vent the pump slowly and cautiously. 7. Drain the
pump.
TROUBLE
POSSIBLE CAUSE
PROBABLE REMEDY
PUMP FAILS TO PRIME
Not enough liquid in casing. Air leak in suction line. Lining of suction hose
collapsed. Leaking or worn seal or pump gasket. Pump speed too slow.
Strainer clogged.
Add liquid to casing. See PRIMING. Correct leak.
Replace suction hose.
Check pump vacuum. Replace leaking or worn seal or gasket. Check power source
output; con sult power source operation man ual.
Check strainer and clean if neces sary.
PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE
Air leak in suction line. Suction intake not submerged at proper level or sump
too small.
Lining of suction hose collapsed. Leaking or worn seal or pump gasket.
Correct leak.
Check installation and correct submergence as needed.
Replace suction hose.
Check pump vacuum. Replace leaking or worn seal or gasket.
TROUBLESHOOTING
PAGE D – 1
OM-01193
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TROUBLE
POSSIBLE CAUSE
PROBABLE REMEDY
PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.)
PUMP REQUIRES TOO MUCH POWER
Impeller or other wearing parts worn or damaged. Suction lift or discharge
head too high.
Pump speed too slow. Discharge line clogged or restricted; hose kinked.
Universal joint drive misaligned. Pump speed too high.
Discharge head too low.
Replace worn or damaged parts. Check that impeller is properly cen tered and
rotates freely. Check piping installation and install bypass line if needed.
See INSTAL LATION.
Check power source output; consult power source operation manual.
Check discharge lines; straighten hose.
Align drive.
Check driver output; check that sheaves or couplings are correctly sized.
Adjust discharge valve.
EXCESSIVE NOISE Cavitation in pump.
Pumping entrained air. Pump or drive not securely mounted. Universal joint
drive misaligned. Low or incorrect lubricant.
Reduce suction lift and/or friction losses in suction line. Record vac uum and
pressure gauge readings and consult local representative or factory.
Locate and eliminate source of air bubble.
Secure mounting hardware.
Align drive.
Check for proper type and level of lubricant.
BEARINGS RUN TOO HOT
Bearing temperature is high, but within Check bearing temperature regu
limits.
larly to monitor any increase.
Low or incorrect lubricant.
Check for proper type and level of lubricant.
Suction and discharge lines not prop Check piping installation for proper
erly supported.
support.
Drive misaligned; piping improperly in stalled.
Bearings in power source or gearbox worn or binding.
Realign drive and piping at operat ing temperature. Add expansion joints if
required.
Check bearings.
PAGE D – 2
TROUBLESHOOTING
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OM-01193
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and pump wear is directly
affected by such things as the abrasive qualities, pressure and temperature of
the liquid being pumped, this section is intended only to provide general
recommendations and practices for preventive maintenance. Regardless of the
application however, following a routine pre ventive maintenance schedule will
help assure trouble-free performance and long life from your Gorman-Rupp pump.
For specific questions con cerning your application, contact your Gorman- Rupp
distributor or the Gorman-Rupp Company.
Record keeping is an essential component of a good preventive maintenance
program. Changes in suction and discharge gauge readings (if so
equipped) between regularly scheduled inspec tions can indicate problems that
can be corrected before system damage or catastrophic failure oc curs. The
appearance of wearing parts should also be documented at each inspection for
comparison as well. Also, if records indicate that a certain part (such as the
seal) fails at approximately the same duty cycle, the part can be checked and
replaced before failure occurs, reducing unscheduled down time.
For new applications, a first inspection of wearing parts at 250 hours will
give insight into the wear rate for your particular application. Subsequent
inspec tions should be performed at the intervals shown on the chart below.
Critical applications should be inspected more frequently.
Preventive Maintenance Schedule
Item
Daily
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.)
I
Pump Performance (Gauges, Speed, Flow)
I
Bearing Lubrication
Seal Lubrication (And Packing Adjustment,
If So Equipped)
V-Belts (If So Equipped)
Air Release Valve Plunger Rod (If So Equipped)
Front Impeller Clearance (Wear Plate)
Rear Impeller Clearance (Seal Plate)
Check Valve
Pressure Relief Valve (If So Equipped)
Pump and Driver Alignment
Shaft Deflection
Bearings
Bearing Housing
Piping
Driver Lubrication – See Mfgr’s Literature
Service Interval*
Weekly Monthly Semi- Annually Annually
I
R
I
R
I
I
C
I
I
I
C
I
I
I
I
I
Legend: I = Inspect, Clean, Adjust, Repair or Replace as Necessary C = Clean R = Replace
- Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually. Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
TROUBLESHOOTING
PAGE D – 3
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OM-01193
PUMP MAINTENANCE AND REPAIR – SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODEL 03H1-GL
Based on 70_F (21_C) clear water corrected to 0.8 specific gravity at sea
level with minimum suc tion lift. Since pump installations are seldom identi
cal, your performance may be difference due to such factors as viscosity,
specific gravity, elevation, temperature, and impeller trim.
If your pump serial number is followed by an “N”, your pump is NOT a standard
production model.
Contact the Gorman-Rupp Company to verify per formance or part numbers.
Pump speed and operating condition points must be within the continuous per
formance range shown on the curve.
MAINTENANCE & REPAIR
PAGE E – 1
OM-01193
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ILLUSTRATION
PARTS PAGE
18
ÏÏ6 ÎÏÏ5ÇÇÇÎÏÏÎÎÎÇÇÇÎÎÎÇÇÇÎÎÎÇÇÇÎÎÎÏÇÇ4 3 ÏÏÏÎÎÏÏÏÇÇÎÎÏÏÏÎÎÇÇÎÎÇÇÎÎÇÇÎÎÏÇ 20
17
SEAL AREA DETAIL
19
16 14
10 9
12 11
28
26
21
27 16
13 19
23
24
18
17
22
1
25
8
2 3
4
5
7
6
15
PAGE E – 2
Figure 1. Pump Model 03H1-GL
MAINTENANCE & REPAIR
0 SERIES
OM-01193
PARTS LIST Pump Model 03H1-GL (From S/N 282480 Up)
If your pump serial number is followed by an “N”, your pump is NOT a standard
production model. Contact the Gorman-Rupp Company to verify part numbers.
ITEM NO.
PART NAME
PART
NUMBER
QTY
.1
PUMP CASING
SEE NOTE BELOW
1
2
GEAR BOX ASSEMBLY
44161-014
1
3
O-RING
S1461
1
4
SHAFT SLEEVE
9140 16000
1
5
MECH SEAL 1-1/4
25271-192
1
6
SEAL GUARD
9834 14090
1
7
IMPELLER
8251 13010
1
8
IMPELLER KEY
N0305-1/2 15990
1
9
IMPELLER WASHER
6750 13090
1
10
NORD-LOCK WASHER
21177-218
1
11
NYLOCK CAP SCREW
BT0605 15991
1
. 12
WEAR RING
62ZL5 14000
1
. 13
STUD
C0605-1/2 15991
8
14
GASKET SET
48211-094
1
15
HEX NUT
D06 15991
8
. 16
STUD
C1009 15991
8
17
GASKET
1318GB 20000
2
18
FLANGE
1390 13040
2
19
HEX NUT
D10 15991
8
. 20
FILL PLUG ASSY W/ WARNING TAG
48271-064
1
. 21
PIPE PLUG
P04 15079
1
. 22
PIPE PLUG
P20 10009
1
23
NAMEPLATE
38818-018 13990
1
24
DRIVE SCREW
BM#04-03 17000
4
25
ROTATION DECAL
2613BM
1
26
DISCHARGE STICKER
6588BJ
1
27
SUCTION STICKER
6588AG
1
28
FILL HERE TO PRIME STICKER
6588AH
1
NOT SHOWN:
G-R DECAL
GR-03
1
INSTRUCTION TAG
38817-038
1
.
INCLUDED W/REPAIR PUMP CASING ASSY 46475-004
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR
PAGE E – 3
OM-01193
ILLUSTRATION
0 SERIES
PAGE E – 4
Figure 2. 44161-014 Gearbox Assembly
MAINTENANCE & REPAIR
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PARTS LIST 44161-014 Gearbox Assembly
OM-01193
ITEM NO.
PART NAME
1
WEAR RING
2
PINION
3
OIL SEAL
4
REDUCER PIPE BUSHING
5
AIR VENT
6
LOCK WASHER
7
HEX HEAD CAP SCREW
8
BALL BEARING
9
COVER PLATE GASKET
10
COVER PLATE
11
DRIVE SHAFT
12
KEY
13
OIL SEAL
14
HELICAL GEAR
15
PIPE PLUG
16
GEAR HOUSING ASSEMBLY
17
DOWEL PIN
18
ADJUSTABLE SHIM SET
19
SPACER SLEEVE
20
WDF KEY
NOT SHOWN:
SHIPPING PLUG
PTO LUBE DECAL
GEAR LUBE DECAL
PART
NUMBER
QTY
62ZL6 14000
1
8896 16020
1
S1764
1
AP0602 15079
1
S1530
1
J06 15991
6
B0604 15991
6
S390
4
8871G 18000
1
8871 10010
1
8837 16040
1
N0404-1/2 15990
1
S389
1
8895 16060
1
P06 15079
5
8914
1
AA0403-1/2 15990
2
S464
2
9142 15990
1
AV1210 15990
1
11495A 15079
1
2613CQ
1
38816-239
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR
PAGE E – 5
OM-01193
0 SERIES
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de cals attached to the pump.
This pump requires little service due to its rugged, minimum-maintenance
design. However, if it be comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to the sectional views (see
Figures 1 and 2) and the accompanying parts list.
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.
Most service functions, such as impeller, wear ring, and seal replacement, may
be performed by drain ing the pump and removing the pump casing. However, due
to the confined mounting location of the pump, it is recommended that the pump
and gearbox be removed from the vehicle for service. The following
instructions assume complete disas sembly is required.
If the gearbox requires repair, proceed with PUMP AND SEAL DISASSEMBLY,
followed by GEAR BOX DISASSEMBLY.
Before attempting to service the pump, switch off the engine ignition and
remove the key, or take oth er safety precautions to ensure that it will
remain inoperative. Close all valves in the suction and dis charge lines.
PAGE E – 6
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, or take other pre
cautions 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.
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 secured before opera
tion.
Death or serious personal injury and damage to the pump or components can
occur if proper lifting procedures are not observed. Make certain that hoists,
chains, slings or cables are in good working condition and of suffi cient
capacity and that they are posi tioned so that loads will be balanced and the
pump or components will not be damaged when lifting. Suction and dis charge
hoses and piping must be re
MAINTENANCE & REPAIR
0 SERIES
OM-01193
moved from the pump before lifting. Lift the pump or component only as high as
necessary and keep personnel away from suspended objects.
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.
Use Only Genuine Gorman-Rupp re placement parts. Failure to do so may cre ate
a hazard and damage the pump or di minish optimal pump performance. Any such
hazard, damage or diminished per formance is not covered by the warranty.
NOTE
When appropriate recycling facilities are available, the user should recycle
components and fluids when doing any routine maintenance / repairs and also at
the end of the pump’s useful life. All other components and fluids shall be
disposed of ac cording to all applicable codes and regulations.
Removing Pump and Gearbox
Due to the confined mounting location, it is recom mended that the pump and
gearbox be removed from the vehicle for service.
The pump assembly can be seriously damaged if the cables or chains used to
lift and move the unit are improperly wrapped
MAINTENANCE & REPAIR
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.
Close all valves in the suction and discharge lines. Remove the pump casing
drain plug (23) and drain the pump.
Disconnect the P.T.O. shaft from the gearbox drive shaft. Remove all the
hardware securing the pump and gearbox to the vehicle chassis. Tie and tag the
any leveling shims used under the casing mount ing feet to ease reassembly.
Move the pump and gearbox to a clean, well-equipped shop for mainte nance and
repair.
Pump Casing and Wear Ring Removal
(Figure 1)
To service the impeller, wear ring or seal assembly, the pump casing (1) must
be separated from the seal plate (27, Figure 2).
Remove the nuts (13) and separate the pump cas ing and casing gasket set (11)
from the seal plate. Tie and tag the gaskets, or measure and record their
thickness for ease of reassembly.
Clean the mating surfaces of the seal plate and pump casing. Inspect the wear
ring (24) for exces sive wear or scoring. The wear ring is secured in the pump
casing by a press fit. If replacement is re quired, use a small bit to drill
two holes through the ring horizontally, 180_ apart. Use a saw and chisel to
complete the cuts through the ring, and remove it from the casing. Use caution
not to damage the pump casing when removing the ring.
Impeller Removal
(Figure 1)
To loosen the impeller screw (21), immobilize the drive shaft (14, Figure 2).
Remove the impeller screw, lockwasher (22), and impeller washer (19).
Use a suitable puller to remove the impeller from the shaft. Retain the
impeller key (20). Use caution when removing the impeller; tension on the seal
spring will be released as the impeller is removed.
NOTE
An alternate method of removing the impeller is to
PAGE E – 7
OM-01193
0 SERIES
use two large screwdrivers on opposite sides be tween the impeller and seal
plate to pry the impeller off the shaft. Use caution not to damage the impel
ler.
Inspect the seal guard (15) for excessive wear or scoring. The seal guard is
secured on the impeller by a press fit. If replacement is required, pull it
off the impeller.
Seal Removal and Disassembly
(Figure 1)
Carefully remove the seal spring. Remove the shaft sleeve (16) and rotating
portion of the seal as a unit. Apply oil to the sleeve and work it up under
the bellows. Slide the rotating portion of the seal off the sleeve.
Use a pair of stiff wires with hooked ends to hook the stationary element from
the back side, and pull the element and O-ring from the seal plate bore.
Remove the sleeve O-ring (17).
If no further disassembly is required, proceed with PUMP AND SEAL REASSEMBLY.
If the gearbox requires disassembly, do not reassemble the pump components at
this time. Refer to GEAR BOX DISASSEMBLY and GEARBOX REAS SEMBLY, followed by
PUMP AND SEAL REAS SEMBLY.
PUMP AND SEAL REASSEMBLY
If the gearbox requires disassembly, refer to GEARBOX DISASSEMBLY and GEARBOX
REASSEMBLY, followed by PUMP AND SEAL REASSEMBLY.
Seal Reassembly and Installation
(Figures 1 and 3)
Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.
Most cleaning solvents are toxic and flammable. Use them only in a well-ven
tilated area free from excessive heat, sparks, and flame. Read and follow all
precautions printed on solvent containers.
The seal is not normally reused because wear pat terns on the finished faces
cannot be realigned during reassembly. This could result in premature failure.
If necessary to reuse an old seal in an emer gency, carefully wash all
metallic parts in fresh cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent damage. Be careful not to
contaminate precision finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a non-oil based solvent
and a clean, lint-free tissue. Wipe lightly in a concentric pattern to avoid
scratching the faces.
Inspect the seal components for wear, scoring, grooves, and other damage that
might cause leak age. Clean and polish the shaft sleeve, or replace it if
there are nicks or cuts on either end. If any com ponents are worn, replace
the complete seal; never mix old and new seal parts.
If a replacement seal is being used, remove it from the container and inspect
the precision finished faces to ensure that they are free of any foreign
matter.
To ease installation of the seal, lubricate the O- rings and shaft sleeve with
water or a very small amount of oil, and apply a drop of light lubricating oil
on the finished faces. Assemble the seal as fol lows, (see Figure E-3).
PAGE E – 8
MAINTENANCE & REPAIR
0 SERIES SEAL GUARD DRIVE BAND SPRING
IMPELLER KEY
IMPELLER SHAFT
OM-01193
SEAL PLATE O-RING
STATIONARY SEAT AND SEAL
SHAFT SLEEVE
IMPELLER
BELLOWS RETAINER
SLEEVE O-RING
ROTATING ELEMENT
Figure 3. Seal Assembly
This seal is not designed for operation at
temperatures above 160_F (71_C). Do not
use at higher operating temperatures.
Inspect the pinion shaft (2, Figure 2) for distortion, nicks, scratches, or
damage to the shaft keyway. Dress small nicks or burrs with a fine file or
emery cloth. If excessive wear exists, refer to GEARBOX DISASSEMBLY and
replace the shaft.
Subassemble the rotating element into the retainer and bellows, and slide this
subassembly over the shaft sleeve until the rotating element is just flush
with the chamfered end of the sleeve. Slide the sleeve and rotating portion of
the seal onto the shaft until the seal faces contact. Continue to push the
sleeve through the seal until the sleeve is fully seated against the shaft
shoulder.
Install the seal spring. Make sure that all compo nents of the seal are seated
squarely.
Impeller Installation
Lightly lubricate the shaft sleeve O-ring (17) and in stall it on the shaft.
Lubricate the stationary seat O-ring with light oil and install it in the
groove in the seat. Use thumb pressure to press this subassembly into the seal
plate until it seats squarely against the shoulder bore. Be careful not to
damage the seal face. After installation, wipe the seal face in a concentric
pat tern with a clean, lint-free cloth to remove any fin gerprints.
(Figures 1 and 4) Inspect the impeller (2), and replace it if cracked or badly
worn. If the seal guard (15) was removed, press the replacement guard onto the
impeller until it seats squarely against the bore shoulder.
The seal guard must seat squarely on the
MAINTENANCE & REPAIR
PAGE E – 9
OM-01193
0 SERIES
impeller or binding and/or excessive wear will result.
Align the impeller and key (20) with the shaft key way, and press the impeller
onto the shaft until fully seated. Be sure the seal spring seats squarely over
the shoulder on the back of the impeller.
NOTE
After the impeller has been installed, check for free rotation. Correct any
scraping or binding before fur ther reassembly.
Align the hole in the impeller washer (19) with the key, and install the
washer. Immobilize the drive shaft (14, Figure 2), and install the impeller
screw and lockwasher (21 and 22). Torque the impeller screw to 20 ft. lbs.
(240 in. lbs. or 2,8 m. kg.).
Pump Casing and Wear Ring Installation
(Figure 1)
If the wear ring (24) was removed for replacement,
press the replacement ring into the pump casing until it seats squarely
against the shoulder bore.
The wear ring must seat squarely in the casing bore or binding and/or
excessive wear will result.
For maximum pump efficiency, the impeller should be centered within the pump
casing. To verify im peller positioning, measure the pump casing and impeller
as shown in Figure 4. Use these measure ments to calculate the required
impeller location (dimension E). Add or remove gaskets in the pump casing
gasket set (44) to obtain dimension E.
NOTE
When calculating pump casing positioning, figure 30% compression for pump
casing gaskets.
C
D
D 2
B
2
E
A
B
Step 1
Step 2
A+
B 2
–
C+
D 2
=E
Step 3
Figure 4. Centering Impeller Within Pump Casing
Install the calculated thickness of pump casing gaskets. Secure the pump casing to the seal plate with the nuts (33).
Reconnect the P.T.O. shaft the the gearbox drive shaft and check the alignment as described in IN STALLATION, Section B.
Installing Pump and Gearbox
(Figure 1)
Secure the pump and gearbox to the truck chassis with the previously removed
hardware. Be sure to install any leveling shims used under the casing mounting
feet.
Install the suction and discharge lines and open all valves. Make certain that
all piping connections are tight, properly supported and secure.
Be sure the pump and gearbox have been prop erly lubricated (see LUBRICATION).
Fill the pump casing with clean liquid. Reinstall the fill plug (6) and
tighten it.
PAGE E – 10
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OM-01193
Refer to OPERATION, Section C, before putting the pump back into service.
GEARBOX DISASSEMBLY
(Figure 2)
When the pump is properly operated and main tained, the gearbox should not
require disassem bly. Disassemble the gearbox only when there is evidence of
wear or damage.
Gearbox disassembly in the field is not rec ommended. These operations should
be performed only in a properly equipped shop by qualified personnel.
If the gearbox requires disassembly, first disas semble the pump components as
indicated in PUMP AND SEAL DISASSEMBLY.
Before attempting to disassemble the gearbox, re move the lower most pipe plug
(23) and drain the lubricant. Clean and reinstall the pipe plug.
With the pump end components removed, use a hammer and punch to drive the
dowel pins (31) out of the gearbox. Remove the hardware (28, 29 and 30)
securing the seal plate (27) to the gearbox housing (25). Slide the seal plate
and oil seal (3) off the shaft. Remove the seal plate gasket (26). In spect
the oil seal (3) and, if replacement is re quired, press it from the seal
plate.
Remove the shaft key (15). Remove the hardware (19 and 20) and slide the cover
plate (9) and as sembled oil seal (12) off the shaft. Remove the cov er plate
gasket (8) and bearing adjusting shims (13 and 17). Tie and tag the shims, or
measure and re cord their thickness for ease of reassembly. In spect the oil
seal (12) and, if replacement is re quired, press it form the cover plate.
Slide the drive shaft (14), bearings (18 and 18A), helical gear (21), pinion
shaft (2) and bearings (7 and 7A) out of the seal plate side of the gear hous
ing. It is not necessary to remove the dowel pins (31) unless they are bent or
damaged. If replace
MAINTENANCE & REPAIR
ment is required, remove them from the gear hous ing.
After removing the shafts and bearings, clean and inspect the bearings in
place as follows.
To prevent damage during removal from the shaft, it is recommended that
bearings be cleaned and inspected in place. It is strongly recommended that
the bearings be replaced any time the shaft and bear ings are removed.
Clean the gear housing, seal plate, shafts and all component parts (except the
bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for
wear or damage and replace as necessary.
Most cleaning solvents are toxic and flammable. Use them only in a well-ven
tilated area free from excessive heat, sparks, and flame. Read and follow all
precautions printed on solvent contain ers.
Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with
filtered compressed air and coat with light oil.
Bearings must be kept free of all dirt and foreign material. failure to do so
will greatly shorten bearing life. Do not spin dry bear ings. This may scratch
the balls or races and cause premature bearing failure.
Rotate the bearings by hand to check for rough ness or binding and inspect the
bearing balls. If ro tation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit onto the shafts and a snug
slip fit into the gear housing and seal plate. Replace the bearings,
PAGE E – 11
OM-01193
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shafts, gear housing, or seal plate if the proper bearing fit is not achieved.
If the bearings, pinion shaft, or helical drive gear re quire replacement, use
a suitable puller to remove the bearings from the shafts. Slide the spacer
(22) and drive gear off the drive shaft. Retain the wood ruff key (16).
GEARBOX REASSEMBLY
Clean and inspect the bearings as indicated in GEARBOX DISASSEMBLY.
Use caution when handling hot bear ings to prevent burns.
After the bearings have been installed and allowed to cool, check to ensure
that they have not moved out of position in shrinking. If movement has oc
curred, use a suitably sized sleeve and a press to reposition the bearings.
If heating the bearings is not practical, use a suit ably sized sleeve and an
arbor (or hydraulic) press to install the bearings onto the shafts.
To prevent damage during removal from the shaft, it is recommended that
bearings be cleaned and inspected in place. It is strongly recommended that
the bearings be replaced any time the shaft and and bearings are removed.
Inspect the helical gear (21) and pinion shaft (2) for excessive wear or
broken teeth and replace as re quired.
Install the woodruff key (16) in the shaft keyway, and slide the helical gear
onto the shaft. Position the spacer (22) against the inboard side of the heli
cal gear.
The bearings (7, 7A, 18 and 18A) may be heated to ease installation. An
induction heater, hot oil bath, electric oven, or hot plate may be used to
heat the bearings. Bearings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the oil and the container
must be absolutely clean. If the oil has been previously used, it must be thor
oughly filtered.
Heat the bearings to a uniform temperature no higher than 250_F (120_C) and
slide them onto the shafts, one at a time, until they are fully seated. This
should be done quickly, in one continuous motion, to prevent the bearings from
cooling and sticking on the shaft.
PAGE E – 12
When installing the bearings onto the shafts, never press or hit against the
outer race, balls, or ball cage. Press only on the inner race.
If the dowel pins (31) were removed, install them in the holes in the gear
housing.
With the bearings, helical gear and spacer in stalled on the drive and pinion
shafts, mesh the teeth on the helical drive gear with those on the pin ion
shaft, and slide both shafts into the gear hous ing (25) until the outboard
bearings are seated in the bearing bores of the gear housing.
If the oil seal (3) was removed, apply a light coating of oil to the lip of
the replacement seal, and position it in the seal plate (27) with the lip
positioned as shown in Figure 2. Press the oil seal into the seal plate until
the inner side of the seal is just flush with the inside of the seal plate.
Install the seal plate gasket (26) and slide the seal plate over the inboard
bearings. Install the cap screws (28) to align the gearbox halves. Use a
hammer and punch to tap the dowel pins (31) into the alignment holes in the
gear housing (25) until flush. Use the remaining hardware (29 and 30) to
secure the seal plate to the gear housing.
If the oil seal (12) was removed, apply a light coat ing of oil to the lip of
the replacement seal, and po sition it in the cover plate (9) with the lip
positioned as shown in Figure 2. Press the oil seal into the cov
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OM-01193
er plate until the inner side of the seal is just flush with the inside of the
cover plate.
Position the cover plate gasket (9) against the gear housing. Install the same
thickness of bearing ad justing shims (13 and 17) as previously removed, and
slide the cover plate over the drive shaft.
Use caution not to damage the oil seal lip on the shaft keyway when installing
the cover plate.
Apply “Loctite Pipe Sealant With Teflon No. 567” or equivalent compound to the
capscrews (20) and secure the cover plate to the gear housing with the
hardware (19 and 20).
NOTE
End play for both the drive and pinion shafts should be between .005 to.012
(0,127 to 0,305 mm). Add or remove bearing shims to achieve the correct
endplay.
When the shaft end play has been correctly estab lished, remove the bottom
three capscrews (20), coat the threads with thread compound, and rein stall
them in the gear housing.
Refer to PUMP AND SEAL REASSEMBLY and in stall the remaining pump components.
After the pump components are installed, lubricate the gearbox as indicated in
LUBRICATION.
LUBRICATION
Seal Assembly
(Figure 1)
The seal assembly is lubricated by the medium be
ing pumped and no additional lubrication is re quired.
Gearbox
(Figures 2 and 5)
The gearbox was fully lubricated when shipped from the factory. Check the oil
level regularly at the oil level pipe plug(s) as shown in Figure 5. When
lubrication is required, add gear oil through the hole for the air vent (4)
the oil level reaches the level shown in the illustration. Clean and reinstall
the air vent plug and pipe plug. Do not over-lubricate. Ov er-lubrication can
cause the bearings to over-heat, resulting in premature bearing failure.
Change the lubricant in a new gearbox after 100 hours of operation or four
weeks, whichever comes first, by draining at operating temperature and
thoroughly cleaning with a flushing oil.
After break-in, drain the gearbox after every 500 hours of operation or every
six months, whichever comes first, under normal operating conditions. Change
the oil more frequently if operated under severe conditions.
Monitor the condition of the bearing lubri cant regularly for evidence of rust
or mois ture condensation. This is especially im portant in areas where
variable hot and cold temperatures are common.
Add 1 ounce (30 ml) of `Molykote M’ Gear Guard, then fill with approximately 2
ounces (59 ml) of premium quality, multi-purpose extreme pressure gear
lubricant as indicated below.
SAE #80 – Below 40_F (4C) SAE #90 – 40-100F (4-38C) SAE #140 – 100-150F
(28-66_C)
MAINTENANCE & REPAIR
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Figure 5. Gearbox Lubrication Positions
PAGE E – 14
MAINTENANCE & REPAIR
For Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.:
419-755-1280 Canada:
519-631-2870
International: +1-419-755-1352
GORMAN-RUPP PUMPS
References
Read User Manual Online (PDF format)
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