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ABEGQ |
OM-01194-02 |
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April 9, 1981 |
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Rev. G 02 03 14 |
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INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
0 SERIES PUMP
MODEL
03H1-GR
THE GORMAN RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
GORMAN RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
e1981 The Gorman Rupp Company
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 |
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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 |
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 |
PUMP MAINTENANCE AND REPAIR SECTION E . . . . . . . . . . . . . . . . . |
PAGE E - 1 |
PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 1 |
PARTS LISTS: |
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Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 3 |
Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 5 |
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 6 |
Removing Pump and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 6 |
Pump Casing and Wear Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 7 |
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 7 |
Seal Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 7 |
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TABLE OF CONTENTS (continued)
PUMP AND SEAL REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 7 |
Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 7 |
Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 9 |
Pump Casing and Wear Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 9 |
Installing Pump and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 10 |
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 10 |
GEARBOX REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 11 |
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 12 |
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 12 |
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
PAGE E - 13 |
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0 SERIES |
OM 01194 |
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INTRODUCTION
Thank You for purchasing a Gorman Rupp pump.
Read this manual carefully to learn how to safely install and operate your pump. Failure to do so could result in personal injury or damage to the pump.
This pump is an 0 Series, enclosed impeller, cen trifugal model, with straight in suction and without a suction check valve. The basic material of con struction for wetted parts is aluminum. The pump is close coupled to an integral 1000 RPM gearbox speed increaser with a 4.09:1 ratio. Power is trans mitted to the gearbox through a customer installed universal shaft assembly.
Because pump installations are seldom identical, this manual cannot possibly provide detailed in structions and precautions for every aspect of each specific application. Therefore, it is the re sponsibility of the owner/installer of the pump to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are com promised by the installation. Pumps and related equipment must be installed and operated ac cording to all national, local and industry stan dards.
If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit, please contact your Gorman Rupp distributor, or write:
The Gorman Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
or:
Gorman Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
The following are used to alert maintenance per sonnel to procedures which require special atten tion, to those which could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure.
NOTE
Instructions to aid in installation, operation, and maintenance or which clarify a procedure.
INTRODUCTION |
PAGE I - 1 |
0 SERIES |
OM 01194 |
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SAFETY - SECTION A
These warnings apply to 0 Series power take off pumps. Refer to the manual accompanying the power source before attempting to begin operation.
Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and pre cautions for each specific application. Therefore, it is the owner/installer's re sponsibility to ensure that applications not addressed in this manual are per formed only after establishing that nei ther operator safety nor pump integrity are compromised by the installation.
Before attempting to open or service the pump:
1.Familiarize yourself with this man ual.
2.Switch off the vehicle ignition and remove the key to ensure that the pump will remain inoperative.
3.Allow the pump to completely cool if overheated.
4.Check the temperature before opening any covers, plates, or plugs.
5.Close the suction and discharge valves.
6.Vent the pump slowly and cau tiously.
7.Drain the pump.
This pump is designed for vehicular mounting in petroleum service. Do not attempt to pump corrosive materials which may damage the pump or endan ger personnel as a result of pump fail ure.
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.
Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment. Suction and dis charge hoses and piping must be re moved from the pump before lifting.
After the pump has been positioned, make certain that the pump and all pip ing connections are tight, properly sup ported and secure before operation.
Do not operate the pump without the shields and/or guards in place over the rotating parts. Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to personnel.
SAFETY |
PAGE A - 1 |
OM-01194 |
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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.
Overheated pumps can cause severe burns and injuries. If overheating of the pump occurs:
1.Stop the pump immediately.
2.Ventilate the area.
3.Allow the pump to completely cool.
4.Check the temperature before opening any covers, plates, gauges, or plugs.
5.Vent the pump slowly and cau tiously.
6.Refer to instructions in this manual before restarting the pump.
After the vehicle is positioned for pump maintenance, block the wheels and set the emergency brake before attempting
to disconnect the drive shaft or remove the pump. Be sure the pump is properly reinstalled and secure before opera tion.
Do not remove plates, covers, gauges, pipe plugs, or fittings from an over heated pump. Vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Al low the pump to completely cool before servicing.
The gearbox provided on this pump is designed for operation at 1000 RPM maximum input speed. If operated at a higher RPM, pump components may be destroyed.
Never run this pump backwards. Be cer tain that rotation is correct before fully engaging the pump.
Never run the pump dry of pumping me dium. There must be a supply of liquid to the pump at all times to prevent destruction of the shaft seal faces.
Pumps and related equipment must be in stalled and operated according to all na tional, local and industry standards.
PAGE A - 2 |
SAFE |
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0 SERIES |
OM-01194 |
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INSTALLATION - SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping.
Do not test or operate your pump and in tegral gearbox before reading the in stallation and operation instructions in this manual.
This pump is a self priming centrifugal model with an integral gearbox assembly. It is designed for ve hicular mounting in petroleum service, where the liquid is supplied to the pump under pressure.
Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the in
coming pressure to 50% of the maximum permissi ble operating pressure as shown on the pump per formance curve (see Section E, Page 1).
The integral gearbox is designed to be driven through the vehicle transfer case by a customer supplied universal shaft assembly. The pump cas ing or gearbox may be rotated in 45_ increments to assist with alignment with the vehicle tank; howev er, if the gearbox is to be rotated, some modifica tions must be made to the gearbox to ensure ade quate lubrication. Consult the factory for details.
For further assistance, contact your Gorman Rupp distributor or the Gorman Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimen sions of this pump.
OUTLINE DRAWING
Figure 1. Pump Model 03H1 GR
INSTALLATION |
PAGE B - 1 |
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PREINSTALLATION INSPECTION |
VEHICLE REQUIREMENTS |
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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.
The following instructions apply equally to new in stallations, rebuilds or retrofits.
Tank Preparation
It is essential that any tank scale, dirt, or other for eign material be removed from the tank and piping prior to pump installation. Failure to do so could re sult in clogging or damage to the pump.
Damage to the pump resulting from debris in the suction line will not be covered by the pump warranty.
Before connecting the suction and dis charge piping, carefully check the storage tank and piping for construction debris such as nuts, bolts, wire, weld slag, and other foreign material. Install a commer cially available 80 mesh screen in the suc tion line to prevent debris from entering the pump.
POSITIONING PUMP
Lifting
Pump unit weights will vary depending on the mounting and drive provided. Check the shipping tag on the unit packaging for the actual weight, and 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.
PAGE B - 2 |
INSTALLATION |
0 SERIES |
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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
When installing and/or aligning univer sal shaft assemblies, disconnect the power source to ensure that the pump will remain inoperative.
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.
INSTALLATION |
PAGE B - 3 |
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0 SERIES |
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LUGS MUST BE IN LINE, REGARDLESS
OF OPERATING ANGLE SHOWN BELOW
LUG ALIGNMENT
SHAFTS PARALLEL, ANGLES EQUAL
SHAFTS NOT PARALLEL, ANGLES EQUAL
Figure 2. Proper Installation And Alignment of Universal Assembly
SUCTION AND DISCHARGE PIPING
Typical System Installation
Tank filling and dispensing operations require a system utilizing flow directing (FDF) valves, educ
tors, related piping and safety accessories. Some of the accessories are available from Gorman
Rupp as optional equipment.
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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