Installation, Operation, and Maintenance Manual: 0 Series Pump
Installation, Operation, and Maintenance Manual: 0 Series Pump
Installation, Operation, and Maintenance Manual: 0 Series Pump
December 5, 1991
Rev. K 11‐16‐15
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
0 SERIES PUMP
MODEL
02F1-GL
GORMAN‐RUPP PUMPS
www.grpumps.com
Pump Model:
Serial Number:
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE I - 1
i
TABLE OF CONTENTS
(continued)
ii
0 SERIES OM-01154
INTRODUCTION
Thank You for purchasing a Gorman‐Rupp pump. HAZARD AND INSTRUCTION
Read this manual carefully to learn how to safely DEFINITIONS
install and operate your pump. Failure to do so
could result in personal injury or damage to the The following are used to alert maintenance per
pump. sonnel to procedures which require special atten
tion, to those which could damage equipment, and
to those which could be dangerous to personnel:
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 Immediate hazards which WILL result in
manual are performed only after establishing that severe personal injury or death. These
neither operator safety nor pump integrity are com instructions describe the procedure re
promised by the installation. Pumps and related quired and the injury which will result
equipment must be installed and operated ac from failure to follow the procedure.
cording to all national, local and industry stan
dards.
If there are any questions regarding the pump or Hazards or unsafe practices which
its application which are not covered in this man COULD result in severe personal injury
ual or in other literature accompanying this unit, or death. These instructions describe
please contact your Gorman‐Rupp distributor, or the procedure required and the injury
The Gorman‐Rupp Company: which could result from failure to follow
the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
For information or technical assistance on the
power source, contact the power source manufac
turer's local dealer or representative.
INTRODUCTION PAGE I - 1
0 SERIES OM‐01154
SAFETY - SECTION A
can catch clothing, fingers, or tools, maintenance, block the wheels and set
causing severe injury to personnel. 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 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 Do not remove plates, covers, gauges,
to a boil, build pressure, and cause the pipe plugs, or fittings from an over
pump casing to rupture or explode. 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.
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 The gearbox provided on this pump is
low the pump to cool and use extreme designed for operation at 1000 RPM
caution when venting the pump, or maximum input speed. If operated at a
when removing covers, plates, plugs, or higher RPM, pump components may be
fitting. destroyed.
Overheated pumps can cause severe Never run this pump backwards. Be cer
burns and injuries. If overheating of the tain that rotation is correct before fully
pump occurs: engaging the pump.
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, Never run the pump dry of pumping me
gauges, or plugs. dium. There must be a supply of liquid to
5. Vent the pump slowly and cau the pump at all times to prevent destruction
tiously. of the shaft seal faces.
6. Refer to instructions in this manual
before restarting the pump.
INSTALLATION - SECTION B
Review all SAFETY information in Section A. coming pressure to 50% of the maximum permissi
ble operating pressure as shown on the pump per
Since pump installations are seldom identical, this formance curve (see Section E, Page 1).
section offers only general recommendations and
practices required to inspect, position, and ar The integral gearbox is designed to be driven
range the pump and piping. through the vehicle transfer case by a customer‐
supplied universal shaft assembly. The pump cas
ing or gearbox may be rotated in 90 increments to
assist with alignment with the vehicle tank; howev
er, if the gearbox is to be rotated, some modifica
Do not test or operate your pump and in tions must be made to the gearbox to ensure ade
tegral gearbox before reading the in quate lubrication. Consult the factory for details.
stallation and operation instructions in
For further assistance, contact your Gorman‐Rupp
this manual.
distributor or the Gorman‐Rupp Company.
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 Pump Dimensions
liquid is supplied to the pump under pressure.
Since the pressure supplied to the pump is critical See Figure 1 for the approximate physical dimen
to performance and safety, be sure to limit the in sions of this pump.
OUTLINE DRAWING
INSTALLATION PAGE B - 1
OM-01154 0 SERIES
sion jack with custom brackets should be When connecting the universal joint drive shaft as
used to lift and position the pump and sembly to a PTO unit, install, support, and align the
gearbox. drive shaft in accordance with the manufacturer's
instructions. The pump and the drive power source
NOTE are generally positioned so that shaft centerlines
If the gearbox is rotated out of the standard position are parallel and horizontal. The maximum operat
shown in Figure 1, the oil fill and drain plugs must ing angle should not exceed 15 degrees (see Fig
be relocated. The oil vent must be relocated to the ure 3).
highest port. Consult the factory for correct posi
tioning of the fill plug to provide for proper lubrica Check the direction of rotation of the PTO unit be
tion of the gearbox. 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.
ALIGNMENT
INSTALLATION PAGE B - 3
OM-01154 0 SERIES
LUG ALIGNMENT
Tank filling and dispensing operations require a Refer to Figures 3 and 4 for illustrations of typical
system utilizing flow‐directing (FDF) valves, educ piping systems for tank filling and dispensing.
PAGE B - 4 INSTALLATION
0 SERIES OM-01154
INSTALLATION PAGE B - 5
OM-01154 0 SERIES
DISPENSING FILL
POSITION POSITION
PAGE B - 6 INSTALLATION
0 SERIES OM-01154
INSTALLATION PAGE B - 7
0 SERIES OM-01154
OPERATION - SECTION C
Review all SAFETY information in Section A. Add liquid to the pump casing when:
1. The pump is being put into service for the
Follow the instructions on all tags, labels and
first time.
decals attached to the pump.
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,
This pump is designed for vehicular simply open the system valves and permit the in
mounting in petroleum service. Do not coming liquid to evacuate the air. After the pump
attempt to pump corrosive materials, or and piping system have completely filled, evacu
any liquids which may damage the ate any remaining air pockets in the pump or suc
pump or endanger personnel as a result tion line by loosening a pipe plug or opening bleed
of pump failure. er valves.
OPERATION PAGE C - 1
OM-01154 0 SERIES
pump could be damaged and performance ad Liquid Temperature And Overheating
versely affected by incorrect rotation. If pump per
formance is not within the specified limits (see the The maximum liquid temperature for this pump is
curve on Page E-1), check the direction of rotation 160 F (71C). Do not apply it at a higher operating
before further troubleshooting. temperature.
PAGE C - 2 OPERATION
0 SERIES OM-01154
OPERATION PAGE C - 3
0 SERIES OM-01154
TROUBLESHOOTING - SECTION D
PUMP FAILS TO Not enough liquid in casing. Add liquid to casing. See
PRIME PRIMING.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leaking or worn seal or gasket.
Pump speed too slow. Check power source output; con
sult power source operation man
ual.
Strainer clogged. Check strainer and clean if neces
sary.
TROUBLESHOOTING PAGE D - 1
OM-01154 0 SERIES
PUMP STOPS OR Impeller or other wearing parts worn Replace worn or damaged parts.
FAILS TO DELIVER or damaged. Check that impeller is properly cen
RATED FLOW OR tered and rotates freely.
PRESSURE (cont.)
Suction lift or discharge head too high. Check piping installation and install
bypass line if needed. See INSTAL
LATION.
Pump speed too slow. Check power source output; consult
power source operation manual.
Discharge line clogged or restricted; Check discharge lines; straighten
hose kinked. hose.
BEARINGS RUN Bearing temperature is high, but within Check bearing temperature regu
TOO HOT limits. larly to monitor any increase.
Suction and discharge lines not prop Check piping installation for proper
erly supported. support.
Drive misaligned; piping improperly in Realign drive and piping at operat
stalled. ing temperature. Add expansion
joints if required.
Bearings in power source or gearbox Check bearings.
worn or binding.
PAGE D - 2 TROUBLESHOOTING
0 SERIES OM-01154
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
0 SERIES OM-01154
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
Based on 70F (21C) clear water corrected to Contact the Gorman‐Rupp Company to verify per
0.8 specific gravity at sea level with minimum suc formance or part numbers.
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.
Pump speed and operating condition
If your pump serial number is followed by an “N”, points must be within the continuous per
your pump is NOT a standard production model. formance range shown on the curve.
SECTION DRAWING
PARTS PAGE
PARTS LIST
Pump Model 02F1-GL
(From S/N 654607 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.
NOT SHOWN:
INSTRUCTION TAG 38817-039 --- 1
INSTRUCTION TAG 6588U --- 1
PARTS LIST
44161-019 Gear Box Assembly
Impeller Removal while driving the shaft out. Once the assemblies
have been separated, secure the shaft gear teeth in
(Figure 1)
a soft‐jawed vice and proceed with the impeller re
The impeller (2), wear ring (5) and seal assembly moval.
(3) may serviced by removing the cover plate (16).
To remove the cover plate, disengage the nuts (12)
An impeller wrench (P/N 8516) or a 1-inch square
securing the cover plate to the pump casing (1).
steel bar may be used to remove the impeller. In
Remove the cover plate gasket (17).
sert the tool completely into the square recess pro
To remove the impeller, see Figure 2 and remove vided in the impeller hub, and turn the impeller in a
one of the pipe plugs (4) located in the gearbox. counterclockwise direction (when facing the im
Screw the threaded sleeve on the gear jam tool peller). Use caution when removing the impeller;
(P/N 48781-002, Figure 3) into the pipe plug hole. tension on the seal spring will be released as the
Slide the pin through the sleeve until the beveled impeller is removed. If used, leave the gear jam tool
end of the pin engages the teeth of the drive gear in place after removing the impeller.
(25). Screw the adjustment nut onto the sleeve un
til the pin firmly engages the teeth of the drive gear
NOTE
and jams rotation. Check to ensure that the pinion
If the steel insert inside the impeller has stripped
shaft (1) will not turn.
loose, drill two 3/16-inch (5 mm) diameter by 7/16
ADJUSTMENT NUT inch (12 mm) deep holes 180 apart into the impel
ler and steel insert. Be sure not to damage the shaft
threads. Install two pins in the drilled holes to se
cure the impeller to the insert.
PIN
THREADED SLEEVE
The pins are used for impeller removal
Figure 3. 48781-002 Gear Jam Tool only. If the insert has stripped loose from
the impeller, replace the impeller. Do not
reinstall an impeller with the insert secured
NOTE by pins.
If the gear jam tool does not prevent shaft rotation,
the drive gear or key may be damaged. If so, the After removing the impeller, inspect the seal guard
shaft and pump end must be disassembled to un (13) for excessive wear or scoring. The seal guard
screw the impeller. is secured to the impeller by a press fit. If replace
ment is required, apply heat before pulling it off the
See Figure 2 and remove the drive shaft key (16)
impeller.
and slinger ring (15) from the drive shaft (17). Re
move the lower most drain plug (24) and drain the
gearbox lubricant. Clean and reinstall the drain
Seal Removal and Disassembly
plug. Disengage the hardware (10 and 11) and re
move the bearing cover (13), oil seal (18), and gas (Figure 1)
ket (6) from the gearbox housing (5).
Carefully remove the seal spring. Apply oil to the
See Figure 1 and remove the hardware (7 and 8) se shaft and work it up under the bellows. Remove the
curing the pump casing (1) to the gearbox. Use a rotating portion of the seal from the shaft.
1-inch diameter brass rod (or wooden dowel) and
a hammer to tap the shaft and assembled pump Use a pair of stiff wires with hooked ends to remove
parts from the gearbox. Be careful not to damage the stationary seat and O‐ring from the pump cas
the outboard pinion shaft bearing (12, Figure 2) ing.
Pump Disassembly
(Figure 1)
If the pump casing, oil seal (4) or gearbox assem Most cleaning solvents are toxic and
bly (9) requires replacement, the casing must be flammable. Use them only in a well‐ven
separated from the gearbox housing (5, Figure 2). tilated area free from excessive heat,
sparks, and flame. Read and follow all
Remove the hardware (7 and 8) securing the pump precautions printed on solvent
casing to the gearbox, and separate the assem containers.
blies. Remove the casing gasket (6).
Inspect the shaft for distortion, nicks, scratches or
thread damage. Dress small nicks and burrs with a
Lay the pump casing on an arbor (or hydraulic) fine file or emery cloth. If the shaft is defective, see
press with the cover plate opening up, and use a GEARBOX DISASSEMBLY and GEARBOX
suitably sized sleeve to press the oil seal out of the REASSEMBLY.
casing.
If the wear ring (5) was removed, press the replace
Inspect the wear ring (5) for excessive wear or ment wear ring into the pump casing through the
scoring. The wear ring is secured in the pump cas cover plate opening until fully seated.
ing by a press fit. If replacement is required, care
fully cut through the wear ring in two places, 180
apart, and remove the wear ring parts from the
pump casing. Use caution not to damage the
pump casing when removing the ring. The wear ring must seat squarely in the
casing bore or binding and/or excessive
If no further disassembly is required, proceed with wear will result.
PUMP AND SEAL REASSEMBLY. If the gearbox
requires disassembly, do not reassemble the Inspect the pump casing for nicks or burrs and re
pump components at this time. Refer to GEAR move any that exist. Apply a light coating of oil to
BOX DISASSEMBLY and GEARBOX REAS the oil seal (4) and press it into the casing with the
SEMBLY, followed by PUMP AND SEAL REAS lip positioned as shown in Figure 1.
SEMBLY.
Install the casing gasket (6) and slide the casing
over the shaft. Be careful not to damage the lip of
the oil seal (4) on the shaft threads. Secure the cas
ing to the gearbox assembly (9) with the hardware
PUMP AND SEAL REASSEMBLY
(7 and 8).
Pump Reassembly
(Figure 1)
Clean the pump casing (1), shaft and all compo Most cleaning solvents are toxic and
nent parts with a soft cloth soaked in fresh cleaning flammable. Use them only in a well‐ven
solvent. tilated area free from excessive heat,
PAGE E - 8 MAINTENANCE & REPAIR
0 SERIES OM-01154
sparks, and flame. Read and follow all Wipe lightly in a concentric pattern to avoid
precautions printed on solvent scratching the faces.
containers.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
The seal is not normally reused because wear pat
age. If any components are worn, replace the com
terns on the finished faces cannot be realigned
plete seal; never mix old and new seal parts.
during reassembly. This could result in premature
failure. If necessary to reuse an old seal in an emer If a replacement seal is being used, remove it from
gency, carefully wash all metallic parts in fresh the container and inspect the precision finished
cleaning solvent and allow to dry thoroughly. faces to ensure that they are free of any foreign
matter.
Handle the seal parts with extreme care to prevent To ease installation of the seal, lubricate the shaft,
damage. Be careful not to contaminate precision bellows and O‐ring with water or a very small
finished faces; even fingerprints on the faces can amount of oil, and apply a drop of light lubricating
shorten seal life. If necessary, clean the faces with a oil on the finished faces. Assemble the seal as fol
non‐oil based solvent and a clean, lint‐free tissue. lows, (see Figure 4).
RETAINER ROTATING
ELEMENT
SEAL GUARD
STATIONARY
BELLOWS SEAT
IMPELLER
IMPELLER
SHAFT
O-RING
SPRING
DRIVE BAND
ing face, and press the stationary seat into the NOTE
pump casing until fully seated. A push tube cut Do not install the pipe plug in the gearbox until the
from a length of plastic pipe would aid this installa gearbox is properly lubricated as described in LU
tion. The O.D. of the tube should be approximately BRICATION.
the same as the O.D. of the seal spring. Be careful
not to damage the seal face. After installation, wipe
the seal face in a concentric pattern with a clean, Replace the cover plate gasket (50), and secure
lint‐free cloth to remove any fingerprints. the cover plate to the pump casing with the nuts
(45).
Inspect the impeller (2), wear ring (5) and seal Install the suction and discharge piping and open
guard (46), and replace them if cracked or badly all valves.
worn. If the wear ring and seal guard were re
moved, press the replacement parts onto the im
peller until they are fully seated. Final Pump Assembly
When the pump is properly operated and main After removing the shafts and bearings, clean and
tained, the gearbox should not require disassem inspect the bearings in place as follows.
bly. Disassemble the gearbox only when there is
evidence of wear or damage.
If the gearbox requires disassembly, first disas Clean the gearbox housing, shafts and all compo
semble the pump components as indicated in nent parts (except the bearings) with a soft cloth
PUMP AND SEAL DISASSEMBLY. Protect the ex soaked in cleaning solvent. Inspect the parts for
posed pinion shaft (1) and bearing (2) with a card wear or damage and replace as necessary.
board tube or barrier paper taped to hold it in
place.
Slide the outboard spacer sleeve (3A) onto the Install the slinger ring (15) and the drive shaft key
drive shaft, aligning the slot in the spacer with the (16) on the drive shaft.
shaft key. Press the outboard drive shaft bearing
(14) onto the shaft and into the gearbox housing Refer to PUMP AND SEAL REASSEMBLY and in
until fully seated against the shaft shoulder. The stall the remaining pump components. After the
outboard bearing should not project more than pump components are installed, lubricate the
.129 inch (3,28 mm) from the gearbox housing. gearbox as indicated in LUBRICATION.
LUBRICATION
Seal Assembly
(7), which are shipped loose. The air vent level hole. Always clean the drain plug thoroughly
must be installed to prevent the gearbox before reinstalling it.
from overheating during operation.
SAE RATING TEMPERATURE RANGE
The gearbox assembly was lubricated and
80 Below 40 F/4 C
tested before it was shipped from the facto
90 From 40 F/4 C to 100 F/38 C
ry; however, the lubricant level must be 140 From 100 F/38 C to 150 F/66 C
checked before putting the pump into ser
vice. After the initial change, change the lubricant after
every 500 hours of operation or every six months,
Change the lubricant in a new gearbox after an ini whichever comes first. Change the oil more fre
tial break‐in period of 24 hours, and before 100 quently if the pump is operated continuously or in
hours of operation. The lubricant should be stalled in an environment with rapid temperature
changed while the pump is at operating tempera change.
ture. Remove the gearbox drain plug to drain the
gearbox.
GORMAN‐RUPP PUMPS