OM‐01154‐04

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

1991 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1

PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
VEHICLE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Tank Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 3
SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 4
Typical System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 4
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 5
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 6
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 6
Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 7
Eductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 7

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

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

GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C-1
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C-1
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C-1
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C-2
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-3
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C-3
Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C-3
GEARBOX TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C-3

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

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE D - 3

i
 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 6
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 7
Seal Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 7
Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 8
PUMP AND SEAL REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 8
Pump Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 8
Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 8
Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 7
Impeller and Wear Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 10
Securing Pump and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 10
Final Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 10
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 11
GEARBOX REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12

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.

The Gorman‐Rupp Company

P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011 Hazards or unsafe practices which COULD
or: result in minor personal injury or product
Gorman‐Rupp of Canada Limited or property damage. These instructions
70 Burwell Road describe the requirements and the possi­
St. Thomas, Ontario N5P 3R7 ble damage which could result from failure
Phone: (519) 631-2870
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

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.
If this pump is used with volatile and/or
Because pump installations are seldom flammable liquids, be certain proper
identical, this manual cannot possibly safety practices are followed before op­
provide detailed instructions and pre­ erating or servicing the pump. Provide
cautions for each specific application. adequate ventilation, prohibit smoking,
Therefore, it is the owner/installer's re­ wear static‐resistant clothing and
sponsibility to ensure that applications shoes. Clean up all fuel spills immedi­
not addressed in this manual are per­ ately after occurrence.
formed only after establishing that nei­
ther operator safety nor pump integrity
are compromised by the installation.

Death or serious personal injury and

damage to the pump or components
can occur if proper lifting procedures
Before attempting to open or service the are not observed. Make certain that
pump: hoists, chains, slings or cables are in
1. Familiarize yourself with this man­ good working condition and of suffi­
ual. cient capacity and that they are posi­
2. Switch off the vehicle ignition and tioned so that loads will be balanced
remove the key to ensure that the and the pump or components will not be
pump will remain inoperative. damaged when lifting. Suction and dis­
3. Allow the pump to completely cool charge hoses and piping must be re­
if overheated. moved from the pump before lifting. Lift
4. Check the temperature before the pump or component only as high as
opening any covers, plates, or necessary and keep personnel away
plugs. from suspended objects.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau­
tiously.
7. Drain the pump. 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 Do not operate the pump without the
ger personnel as a result of pump fail­ shields and/or guards in place over the
ure. rotating parts. Exposed rotating parts
SAFETY PAGE A - 1
OM-01154 0 SERIES

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.

Pumps and related equipment must be in­

stalled and operated according to all na­
After the vehicle is positioned for pump tional, local and industry standards.
PAGE A - 2 SAFE­
TY
0 SERIES OM-01154

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

Figure 1. Pump Model 02F1‐GL

INSTALLATION PAGE B - 1
OM-01154 0 SERIES

PREINSTALLATION INSPECTION VEHICLE REQUIREMENTS

The following instructions apply equally to new in­

The pump assembly was inspected and tested be­ stallations, rebuilds or retrofits.
fore shipment from the factory. Before installation,
inspect the pump for damage which may have oc­ Tank Preparation
curred during shipment. Check as follows:
It is essential that any tank scale, dirt, or other for­
a. Inspect the pump and gearbox for cracks, eign material be removed from the tank and piping
dents, damaged threads, and other obvious prior to pump installation. Failure to do so could re­
damage. sult in clogging or damage to the pump.

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.
Damage to the pump resulting from debris
in the suction line will not be covered by
c. Carefully read all tags, decals, and markings
the pump warranty.
on the pump assembly, and perform all duties
indicated. Note the direction of rotation indi­
cated on the pump. Check that the pump
Before connecting the suction and dis­
shaft rotates in the required direction.
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
Only operate this pump in the direction in­ pump.
dicated on the pump body and/or the ac­
companying decal. Reverse rotation of the POSITIONING PUMP
shaft will adversely effect pump perform­
ance, and the pump and/or gearbox could Lifting
be seriously damaged.
Pump unit weights will vary depending on the
d. Check levels and lubricate as necessary. Re­
mounting and drive provided. Check the shipping
fer to LUBRICATION in the MAINTENANCE
tag on the unit packaging for the actual weight, and
AND REPAIR section of this manual and per­
use lifting equipment with appropriate capacity.
form duties as instructed.
Drain the pump and remove all customer‐installed
equipment such as suction and discharge hoses
e. If the pump and gearbox have been stored for or piping before attempting to lift existing, installed
more than 12 months, some of the compo­ units.
nents or lubricants may have exceeded their
maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv­
ice.
The pump assembly can be seriously
If the maximum shelf life has been exceeded, or if damaged if the cables or chains used to lift
anything appears to be abnormal, contact your and move the unit are improperly wrapped
Gorman‐Rupp distributor or the factory to deter­ around the pump.
mine the repair or updating policy. Do not put the
pump into service until appropriate action has Due to the confined mounting location,
been taken. specialized equipment such as a transmis­
PAGE B - 2 INSTALLATION
0 SERIES OM-01154

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

Do not operate the pump without the

guard in place over the rotating parts.
Exposed rotating parts can catch cloth­
When installing and/or aligning univer­ ing, fingers, or tools, causing severe in­
sal shaft assemblies, disconnect the jury to personnel.
power source to ensure that the pump
will remain inoperative. After the power take‐off has been aligned, block
the wheels of the external power source, engage
The alignment of the pump and its power source is the braking system, or take other precautions to
critical for trouble‐free mechanical operation. Be­ ensure that the power source will remain station­
fore checking alignment, make sure that the gear­ ary. Block the wheels on the unit to prevent creep­
box mounting bolts are tight. ing.

INSTALLATION PAGE B - 3
OM-01154 0 SERIES

LUGS MUST BE IN LINE, REGARDLESS

OF OPERATING ANGLE SHOWN BELOW

LUG ALIGNMENT

SHAFTS PARALLEL, ANGLES EQUAL

SHAFTS NOT PARALLEL, ANGLES EQUAL

Figure 3. 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 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

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 A suction strainer was not furnished with this pump
since it is not designed to handle liquids containing
All piping material must be compatible with the liq­ solids. However, to protect the pump from acciden­
uid being pumped. If hose is used in suction lines, tal damage a commercially available 80 mesh
it must be the rigid‐wall, reinforced type to prevent screen should be installed in the suction line. Make
collapse under suction. Using piping couplings in certain that the total open area of the screen is at
suction lines is not recommended. least three or four times the cross section of the

INSTALLATION PAGE B - 5
OM-01154 0 SERIES

suction line to ensure an adequate supply of liquid Sealing

to the pump.
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
Damage To the pump resulting from debris ommendations when selecting and applying the
in the suction line will not be covered by pie dope.
the pump warranty.

Before connecting the suction and dis­ Valves

charge piping, carefully check the storage
tank and piping for construction debris Gorman‐Rupp manufactures several sizes of flow‐
such as nuts, bolts, wire, weld slag, and diverting (FDF) valves for use in truck‐mounted
other foreign material. Install a commer­ pumping applications. The valves are designed to
cially available 80 mesh screen in the suc­ reverse the flow of liquid with only the turn of a han­
tion line to prevent debris from entering the dle. This allows the same pump to fill or dispense
pump. from the tank.

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. The FDF valve is designed for directing
flow only. it will not serve as a positive shut­
With high discharge heads, it is recommended that
off or throttling valve.
a throttling valve and a system check valve be in­
stalled in the discharge line to protect the pump See Figure 5 illustrating the theory of operation for
from excessive shock pressure and reverse rota­ a typical FDF valve. Consult the factory for further
tion when it is stopped. assistance or other sizes.

DISPENSING FILL
POSITION POSITION

DISPENSE TOP VIEW FILL

Figure 5. FDF Valve Theory of Operation

When the center web of the valve is aligned with the dispensing position, the web blocks the straight
larger ports (filling position), the flow passes flow and opens two paths of flow through the larger
straight through. When the handle is turned to the ports to the smaller ports.

PAGE B - 6 INSTALLATION
0 SERIES OM-01154

Siphoning FDF valve to increase dispensing rates and im­

prove efficiency. An educator may also be used to
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a si­ collapse the tank service hose after the tank has
phon breaker is used in the line. Otherwise, a si­ been filled or emptied.
phoning action causing damage to the pump
could result.
Contact the Gorman‐Rupp Company or an autho­
Eductors
rized distributor for specifications and perform­
An eductor may be used in conjunction with an ance data on eductors or FDF valves.

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.

Once the pump casing has been filled, the pump

will prime and reprime as necessary.

The gearbox provided on this pump is GROUNDING

designed for operation at 1000 RPM
maximum input speed. If operated at a To eliminate electrostatic build‐up when pumping
higher RPM, pump components may be petroleum products, the pump must be grounded
destroyed. 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
PRIMING clamp or fastener has made a tight electrical con­
nection with the rod.
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 Inspect and test the ground wire assembly
AND REPAIR). for conductivity. Replace broken or frayed
wire before resuming operation.
This pump is self‐priming, but the pump should
never be operated unless there is liquid in the
pump casing. STARTING

Consult the operations manual furnished with the

power source.

Never operate this pump unless there is Rotation

liquid in the pump casing. The pump will
not prime when dry. Extended operation of The correct direction of pump rotation is counter­
a dry pump will destroy the seal assembly. clockwise when facing the input drive shaft. The

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.

Overheating can occur if operated with the valves

Drive in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
This pump is designed for operation with a power boil, build pressure, and cause the pump to rup­
take‐off unit coupled to the drive shaft on the gear­ ture or explode. If overheating occurs, stop the
box. The gearbox assembly has a ratio of 5.69:1, pump and allow it to cool before servicing it. Refill
and is designed for operation at 1000 RPM. Do not the pump casing with cool liquid.
operate at a higher input speed.

Allow an overheated pump to complete­

The gearbox provided on this pump is ly cool before servicing. Do not remove
designed for operation at 1000 RPM plates, covers, gauges, pipe plugs, or
maximum. If operated at a higher rpm, fittings from an overheated pump. Liq­
pump components may be destroyed. uid within the pump can reach boiling
temperatures, and vapor pressure with­
in the pump can cause parts being dis­
OPERATION 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.
Pump speed and operating condition
points must be within the continuous per­
formance range shown on the curve (see Strainer Check
Section E, Page 1).
If a suction strainer has been shipped with the
Partially open the discharge throttling valve so that
pump or installed by the user, check the strainer
the discharge line fills slowly to prevent damage to
regularly, and clean it as necessary. The strainer
piping, gaskets, and other devices in the line which
should also be checked if pump flow rate begins to
could be affected by shock resulting from rapid fill­
drop. If a vacuum suction gauge has been in­
ing of the line. When the discharge line is com­
stalled, monitor and record the readings regularly
pletely filled, adjust the discharge throttling valve to
to detect strainer blockage.
the desired flow rate.

Never introduce air or steam pressure into the

pump casing or piping to remove a blockage. This
Leakage could result in personal injury or damage to the
equipment. If backflushing is absolutely neces­
No leakage should be visible at pump mating sur­ sary, liquid pressure must be limited to 50% of the
faces, or at pump connections or fittings. Keep all maximum permissible operating pressure shown
line connections and fittings tight to maintain maxi­ on the pump performance curve. (See Section E,
mum pump efficiency. Page 1.)

PAGE C - 2 OPERATION
0 SERIES OM-01154

Pump Vacuum Check

Since this pump does not have a suction check

valve, the discharge line must be fitted with a check If the application involves a high discharge
valve if a pump vacuum reading is to be taken. head, gradually close the discharge
throttling valve before stopping the pump.
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads. After stopping the pump, remove the engine igni­
Block the suction line and start the pump. At oper­ tion key to ensure that the pump will remain inop­
erative.
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 Cold Weather Preservation
charge valve.
If the application of this pump is limited to petro­
leum products, normal freezing conditions will not
Open the suction line, and read the vacuum gauge
damage the pump. However, during extremely se­
with the pump primed and at operation speed.
vere conditions care should be exercised during
Shut off the pump. The vacuum gauge reading will
start‐up, especially if the pump has been idle for
immediately drop proportionate to static suction
more than a few hours.
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
GEARBOX TEMPERATURE CHECK
the point of installation of the vacuum gauge.
The gearbox runs higher than ambient tempera­
tures because of heat generated by friction. Tem­
NOTE peratures of approximately 200F (93C) are con­
Petroleum products are very sensitive to changes sidered normal, and can operate intermittently at
in temperature. Warmer temperatures elevate the 250F (121C).
product vapor pressure, resulting in low vacuum
readings. Do not mistake temperature problems for Checking gearbox temperatures by hand is inac­
faulty pump installation or performance. curate. Place a contact‐type thermometer against
the housing and record this temperature for future
reference.

A sudden increase in gearbox temperature is a

STOPPING 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
Never halt the flow of liquid suddenly. If the liquid
BRICATION in Section E). Bearing overheating
being pumped is stopped abruptly, damaging
can also be caused by shaft misalignment and/or
shock waves can be transmitted to the pump and
excessive vibration.
piping system. Close all connecting valves slowly.
When pumps are first started, the bearings may
On engine driven pumps, reduce the throttle seem to run at temperatures above normal. Con­
speed slowly and allow the engine to idle briefly be­ tinued operation should bring the temperatures
fore stopping. down to normal levels within 20 minutes or less.

OPERATION PAGE C - 3
0 SERIES OM-01154

TROUBLESHOOTING - SECTION D

Review all SAFETY information in Section A.

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 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.

PUMP STOPS OR Air leak in suction line. Correct leak.

FAILS TO DELIVER
RATED FLOW OR Suction intake not submerged at Check installation and correct
PRESSURE proper level or sump too small. submergence as needed.

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.

TROUBLESHOOTING PAGE D - 1
OM-01154 0 SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

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.

PUMP REQUIRES Universal joint drive misaligned. Align drive.

TOO MUCH
POWER Pump speed too high. Check driver output; check that
sheaves or couplings are correctly
sized.
Discharge head too low. Adjust discharge valve.

EXCESSIVE NOISE Cavitation in pump. Reduce suction lift and/or friction

losses in suction line. Record vac­
uum and pressure gauge readings
and consult local representative or
factory.
Pumping entrained air. Locate and eliminate source of air
bubble.

Pump or drive not securely mounted. Secure mounting hardware.

Universal joint drive misaligned. Align drive.

Low or incorrect lubricant. Check for proper type and level of

lubricant.

BEARINGS RUN Bearing temperature is high, but within Check bearing temperature regu­
TOO HOT 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 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

PREVENTIVE MAINTENANCE equipped) between regularly scheduled inspec­

tions can indicate problems that can be corrected
Since pump applications are seldom identical, and before system damage or catastrophic failure oc­
pump wear is directly affected by such things as curs. The appearance of wearing parts should also
the abrasive qualities, pressure and temperature be documented at each inspection for comparison
of the liquid being pumped, this section is intended as well. Also, if records indicate that a certain part
only to provide general recommendations and (such as the seal) fails at approximately the same
practices for preventive maintenance. Regardless duty cycle, the part can be checked and replaced
of the application however, following a routine pre­ before failure occurs, reducing unscheduled down
ventive maintenance schedule will help assure time.
trouble‐free performance and long life from your
Gorman‐Rupp pump. For specific questions con­
For new applications, a first inspection of wearing
cerning your application, contact your Gorman‐
parts at 250 hours will give insight into the wear rate
Rupp distributor or the Gorman‐Rupp Company.
for your particular application. Subsequent inspec­
Record keeping is an essential component of a tions should be performed at the intervals shown
good preventive maintenance program. Changes on the chart below. Critical applications should be
in suction and discharge gauge readings (if so inspected more frequently.

Preventive Maintenance Schedule

Service Interval*
Item Daily Weekly Monthly Semi‐ Annually
Annually
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearing Lubrication I R
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V‐Belts (If So Equipped) I
Air Release Valve Plunger Rod (If So Equipped) I C
Front Impeller Clearance (Wear Plate) I
Rear Impeller Clearance (Seal Plate) I
Check Valve I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Bearings I
Bearing Housing I
Piping I
Driver Lubrication - See Mfgr's Literature

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

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 02F1-GL

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.

MAINTENANCE & REPAIR PAGE E - 1

OM-01154 0 SERIES

SECTION DRAWING
PARTS PAGE

Figure 1. Pump Model 02F1-GL

PAGE E - 2 MAINTENANCE & REPAIR
0 SERIES OM-01154

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.

ITEM PART MAT'L

NO. PART NAME NUMBER CODE QTY

 1 PUMP CASING SEE NOTE BELOW

2 IMPELLER 8101A 1304F 1
3 SEAL ASSEMBLY 25271-851 --- 1
4 OIL SEAL 25217-165 --- 1
 5 WEAR RING 8099 14000 1
6 GASKET 8102G 18000 1
7 HEX HEAD CAPSCREW B0604 15991 3
8 LOCK WASHER J06 15991 3
9 GEAR BOX ASSEMBLY 44161-019 --- 1
 10 PIPE PLUG P06 15079 1
 11 STUD C0606 15991 8
12 HEX NUT D06 15991 8
13 SEAL GUARD 31143-056 14090 1
14 NAME PLATE 38818-020 13990 1
15 DRIVE SCREW BM#04-03 17000 4
16 COVER PLATE 11156 10010 1
17 COVER PLATE GASKET 8098G 20000 1
 18 PIPE PLUG P04 15079 2
19 FLANGE GASKET 9288A 20000 2
20 HEX HEAD CAPSCREW B0603 15991 12
21 FLANGE 9586A 10010 2
22 DISCHARGE STICKER 6588BJ --- 1
23 SUCTION STICKER 6588AG --- 1
24 LUBRICATION DECAL 8382B --- REF
25 GEAR LUBE DECAL 38816-077 --- 2
26 G‐R DECAL GR-02 --- 1

NOT SHOWN:
INSTRUCTION TAG 38817-039 --- 1
INSTRUCTION TAG 6588U --- 1

INDICATES PARTS RECOMMENDED FOR STOCK

 INCLUDED WITH REPAIR PUMP CASING ASSY 46471-239 --- 1

MAINTENANCE & REPAIR PAGE E - 3

OM-01154 0 SERIES

Figure 2. 44161-019 Gear Box Assembly

PAGE E - 4 MAINTENANCE & REPAIR

0 SERIES OM-01154

PARTS LIST
44161-019 Gear Box Assembly

ITEM PART MAT'L

NO. PART NAME NUMBER CODE QTY

1 PINION SHAFT 38521-017 16020 1

2 BALL BEARING S1120 --- 1
3 SPACER SLEEVE 8104 15160 2
4 PIPE PLUG P08 15079 1
5 GEAR BOX 8103B 10010 1
6 GASKET 8097G 18000 1
7 AIR VENT S1530 --- 1
8 REDUCING PIPE BUSHING AP0802 15079 1
9 STREET ELBOW RS08 11999 1
10 HEX HEAD CAPSCREW B0503 15991 6
11 LOCK WASHER J05 15991 6
12 BALL BEARING S1120 --- 1
13 BEARING COVER 8097 10010 1
14 BALL BEARING S1120 --- 1
15 SLINGER RING 31131-063 19330 1
16 KEY N0305 15990 1
17 DRIVE SHAFT 8095 15010 1
18 OIL SEAL S1617 --- 1
19 GASKET 10332G 18000 1
20 OIL SUMP 38354-032 13040 1
21 HEX HEAD CAPSCREW B0406 15991 2
22 HEX HEAD CAPSCREW B0403 15991 4
23 DECAL 8382B --- 2
24 PIPE PLUG P08 15079 5
25 DRIVE GEAR 8022 16060 1
26 COVER PLATE 8120 15990 1
27 HEX HEAD CAPSCREW BW#10-01-1/4S 15990 3
28 BALL BEARING S1120 --- 1
29 KEY N0506 15990 1
30 COVER GASKET 8120G 20020 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 5

 OM-01154 0 SERIES

PUMP AND SEAL DISASSEMBLY 5. Close the suction and discharge

valves.
Review all warnings in Section A. 6. Vent the pump slowly and cau­
tiously.
Follow the instructions on all tags, label and de­ 7. Drain the pump.
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
After the vehicle is positioned for pump
parts, follow these instructions which are keyed to
maintenance, block the wheels and set
the sectional view (see Figures 1 and 2) and the ac­
companying parts list.
the emergency brake before attempting
to disconnect the drive shaft or remove
Most service functions, such as impeller, wear ring, the pump. Be sure the pump is properly
and seal replacement, may be performed by drain­ reinstalled and secured before opera­
ing the pump and removing the cover plate. How­ tion.
ever, due to the confined mounting location of the
pump, it is recommended that the pump and gear­
Removing Pump and Gearbox from Vehicle
box be removed from the vehicle for service. The
following instructions assume complete disas­
Due to the confined mounting location of the
sembly is required.
pump, it is recommended that the pump be re­
If the gearbox requires repair, proceed with PUMP moved from the vehicle for service.
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
The pump assembly can be seriously
er safety precautions to ensure that it will remain
damaged if the cables or chains used to lift
inoperative. Close all valves in the suction and dis­
and move the unit are improperly wrapped
charge lines.
around the pump.

Due to the confined mounting location,

specialized equipment such as a transmis­
sion jack with custom brackets should be
Before attempting to open or service the
used to lift and position the pump and
pump:
gearbox.
1. Familiarize yourself with this man­
ual. Close all valves in the suction and discharge lines.
2. Switch off the vehicle ignition and Remove the casing drain plug (34) and drain the
pump. Clean and reinstall the drain plug.
remove the key, or take other pre­
cautions to ensure that the pump Disconnect the P.T.O. shaft from the gearbox drive
will remain inoperative. shaft. Remove all the hardware securing the pump
3. Allow the pump to completely cool and gearbox to the vehicle chassis. Tie and tag the
if overheated. any leveling shims used under the casing mount­
4. Check the temperature before ing feet to ease reassembly. Move the pump and
opening any covers, plates, or gearbox to a clean, well‐equipped shop for mainte­
plugs. nance and repair.

PAGE E - 6 MAINTENANCE & REPAIR

0 SERIES OM-01154

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.

MAINTENANCE & REPAIR PAGE E - 7

 OM-01154 0 SERIES

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).

If the gearbox requires disassembly, refer to

GEARBOX DISASSEMBLY and GEARBOX Seal Reassembly and Installation
REASSEMBLY, followed by PUMP AND SEAL (Figures 1 and 4)
REASSEMBLY.
Clean the seal cavity and shaft with a cloth soaked
in fresh cleaning solvent.

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

Figure 4. 25271-851 Seal Assembly

Inspect the pinion shaft (1, Figure 2) for distortion,
SPRING nicks, scratches, or damage. Dress small nicks or
burrs with a fine file or emery cloth. If excessive
wear exists, refer to GEARBOX DISASSEMBLY
and replace the shaft.
This seal is not designed for operation at
temperatures above 160F (71C). Do not Lubricate the O‐ring with light oil and install it in the
use at higher operating temperatures. stationary seat. Place a clean tissue over the seal­

MAINTENANCE & REPAIR PAGE E - 9

 OM-01154 0 SERIES

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).

NOTE Securing Pump and Gearbox to Vehicle

It is recommended that a tapered sleeve be in­
stalled over the threads of the impeller shaft to ease
installation of the rotating seal elements.

The pump assembly can be seriously

Subassemble the rotating element into the retainer damaged if the cables or chains used to lift
and bellows. Slide this subassembly onto the and move the unit are improperly wrapped
shaft, and use the push tube to press against the around the pump.
shoulder of the seal retainer until the seal faces
contact.
Due to the confined mounting location,
specialized equipment such as a transmis­
Install the seal spring. Make sure that all compo­ sion jack with custom brackets should be
nents of the seal are seated squarely. used to lift and position the pump and
gearbox
Secure the pump casing and gearbox to the ve­
hicle frame with the previously removed hardware.
Impeller And Wear Ring Installation
Install the P.T.O. coupling and secure it to the ve­
hicle universal shaft. Check shaft alignment as de­
(Figure 1) scribed in INSTALLATION, Section B.

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

Be sure the pump and gearbox are securely

mounted.

Open any valves in the suction and discharge

lines. Make certain that all piping connections are
The seal guard must seat squarely on the
tight, properly supported and secure.
impeller or binding and/or excessive wear
will result. Be sure the pump, gearbox and power source
have been properly lubricated, see LUBRICA­
Use the impeller wrench or similar tool to screw the TION.
impeller onto the shaft. After the impeller is tight on
the shaft, remove the gear jam tool. Turn the shaft Refer to OPERATION, Section C, before putting
to ensure that the impeller rotates freely. the pump back into service.

PAGE E - 10 MAINTENANCE & REPAIR

0 SERIES OM-01154

GEARBOX DISASSEMBLY Reposition the gearbox housing on the press with

the pump side down, and press the pinion shaft (1)
(Figure 2) and bearings (2 and 12) from the housing.

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.

To prevent damage during removal from

the shaft, it is recommended that bearings
Gearbox disassembly in the field is not rec­ be cleaned and inspected in place. It is
ommended. These operations should be strongly recommended that the bearings
performed only in a properly equipped be replaced any time the shaft and bear­
shop by qualified personnel. ings are removed.

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.

Before attempting to disassemble the gearbox, re­

move the drain plug (24) and drain the lubricant. Most cleaning solvents are toxic and
Clean and reinstall the drain plug. flammable. Use them only in a well‐ven­
tilated area free from excessive heat,
After draining the gearbox lubricant, remove the sparks, and flame. Read and follow all
hardware (21 and 22) securing the oil sump (20) precautions printed on solvent contain­
and gasket (19) to the gearbox housing (5).
ers.
Remove the drive shaft key (16) and slinger ring Clean the bearings thoroughly in fresh cleaning
(15) from the shaft. Disengage the hardware (13 solvent. Dry the bearings with filtered compressed
and 14) and remove the bearing cover (13), oil seal air and coat with light oil.
(18) and gasket (6) from the gearbox housing. In­
spect the oil seal and, if replacement is required,
press it from the bearing cover.

Disengage the capscrews (27) and remove the

Bearings must be kept free of all dirt and
cover plate (26) and gasket (30). Position the gear­
foreign material. failure to do so will greatly
box on the bed of an arbor (or hydraulic) press with
shorten bearing life. Do not spin dry bear­
the pump side up. Press the drive shaft (17) and
bearing (14) from the gearbox housing. Pull the
ings. This may scratch the balls or races
spacers (3 and 3A) and drive gear (25) from the and cause premature bearing failure.
housing as the shaft is forced out. Remove the key Rotate the bearings by hand to check for rough­
(29) from the drive shaft. ness or binding and inspect the bearing balls. If ro­
tation is rough or the bearing balls are discolored,
The inboard bearing (28) will remain in the gearbox replace the bearings.
housing. Inspect the bearing in place as described
in the following paragraphs and, if replacement is The bearing tolerances provide a tight press fit
required, pull the bearing out of the housing. onto the shaft and a snug slip fit into the gearbox

MAINTENANCE & REPAIR PAGE E - 11

 OM-01154 0 SERIES

housing. Replace the bearings, shaft, or gearbox

housing if the proper bearing fit is not achieved.

If the bearings require replacement, use a suitable

puller to remove them from the shafts. Use caution when handling hot bear­
ings to prevent burns.
After the bearings have been installed and allowed
GEARBOX REASSEMBLY to cool, check to ensure that they have not moved
(Figures 2 and 5) out of position in shrinking. If movement has oc­
curred, use a suitably sized sleeve and a press to
Clean and inspect the bearings as indicated in reposition the bearings.
GEARBOX DISASSEMBLY.
If heating the bearings is not practical, use a suit­
ably sized sleeve and an arbor (or hydraulic) press
to install the bearings on the shaft.

To prevent damage during removal from

the shaft, it is recommended that bearings
be cleaned and inspected in place. It is When installing the bearings onto the
strongly recommended that the bearings shafts, never press or hit against the outer
be replaced any time the shaft and and race, balls, or ball cage. Press only on the
bearings are removed. inner race.
The pinion shaft bearings (2 and 12) may be Slide the assembled pinion shaft and bearings into
heated to ease installation. Do not heat the drive the gearbox housing so that the bearing (2) proj­
shaft bearings (14 and 28). ects no more than .200 inch (5,08 mm) maximum
from the gearbox housing, and the bearing (12)
projects no more than .015 inch (0,38 mm). These
NOTE dimensions are critical to prevent bearing pre‐
In the following steps, install the pinion shaft bear­ load and to assure proper component alignment
ings (2 and 12) with the loading grooves on both when the pump is completely reassembled. If the
bearings facing toward the shaft shoulders. installation dimensions do not match those shown
above, check the mounting of the bearings on the
An induction heater, hot oil bath, electric oven, or shaft to ensure proper positioning.
hot plate may be used to heat the bearings. Bear­
Lay the gearbox housing on the bed of an arbor (or
ings should never be heated with a direct flame or
hydraulic) press with the drive side facing up. Lu­
directly on a hot plate.
bricate the inboard bearing (28) and use a suitably
sized sleeve to press it into the housing until fully
NOTE seated.
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.
When installing the shaft and bearing into
the bearing bore, push against the outer
Heat the bearings to a uniform temperature no
race. never hit the balls or ball cage.
higher than 250F (120C), and slide the bearings
onto the shaft, one at a time, until they are fully After installing the inboard bearing, support the in­
seated. This should be done quickly, in one con­ ner race with a suitable jig or fixture. See Figure 5
tinuous motion, to prevent the bearings from cool­ for fixture dimensions, drive gear and shaft installa­
ing and sticking on the shaft. tion.

PAGE E - 12 MAINTENANCE & REPAIR

0 SERIES OM-01154

Figure 5. Fixture Dimensions, Drive Gear And Shaft Installation

Center the inboard spacer sleeve (3) on the inner
bearing race. Center the drive gear (25) in the gear­
box housing and engage the teeth of the pinion
shaft. Rest the gear on the spacer sleeve, taking
Make sure gasket remains in position and
care to align the keyway in the drive gear with the
slot in the spacer. does not become sandwiched between
pinion shaft bearing and bearing cover.
Install the drive gear key (29) in the shaft keyway. Replace the cover plate gasket (30), and secure
Align the key with the keyway in the drive gear and the cover plate (26) to the gearbox housing with the
the slot in the spacer, and press the shaft through capscrews (27).
the drive gear, spacer sleeve and bearing until the
shaft shoulder seats firmly against the inner race of Replace the oil sump gasket (19), and secure the
the bearing. oil sump (20) to the gearbox housing with the cap­
screws (21 and 22).

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

The seal assembly is lubricated by the medium be­

When installing the bearings onto the ing pumped, and no additional lubrication is re­
shafts, never press or hit against the outer quired.
race, balls, or ball cage. Press only on the
inner race.
Gearbox

Apply a light coating of oil to the lip of the oil seal

(18), and press it into the bearing cover with the lip
positioned as shown in Figure 1. Replace the bear­
ing cover gasket (6), and secure the bearing cover
(13) to the gearbox housing using the hardware Before operation, remove the shipping
(10 and 11). Be careful not to damage the oil seal plug from the street elbow (9) and replace
lip on the shaft keyway. with the reducing bushing (8) and air vent
MAINTENANCE & REPAIR PAGE E - 13
 OM-01154 0 SERIES

(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.

Add 2 ounces (0,1 liter) of Dow Corning `Molykote

M Gear Guard' to the gearbox, then top off with ap­ Monitor the condition of the bearing lubri­
proximately 20 ounces (591 ml) of premium quali­ cant regularly for evidence of rust or mois­
ty, multi‐purpose, extreme pressure gear lubricant ture condensation. This is especially im­
with an SAE rating per the ambient temperatures portant in areas where variable hot and
shown below ‐ or until lubricant runs out of the oil cold temperatures are common.

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