ABEGQ OM‐01154‐04 December 5, 1991 Rev. J 12‐30‐13 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST 0 SERIES PUMP MODEL 02F1-GL THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO www.grpumps.com GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Copyright by the Gorman‐Rupp Company Printed in U.S.A.
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TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE I - 1 SAFETY ‐ SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE A - 1 INSTALLATION - SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1 Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (continued) PUMP MAINTENANCE AND REPAIR ‐ SECTION E . . . . . . . . . . . . . . . . . PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARTS LIST: Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP AND SEAL DISASSEMBLY .
0 SERIES OM‐01154 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.
0 SERIES OM‐01154 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.
OM-01154 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.
0 SERIES OM-01154 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.
OM-01154 PREINSTALLATION INSPECTION The pump assembly was inspected and tested be fore shipment from the factory. Before installation, inspect the pump for damage which may have oc curred during shipment. Check as follows: a. Inspect the pump and gearbox for cracks, dents, damaged threads, and other obvious damage. b. Check for and tighten loose attaching hard ware. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces. c.
0 SERIES OM-01154 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.
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.
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 All piping material must be compatible with the liq uid being pumped. If hose is used in suction lines, it must be the rigid‐wall, reinforced type to prevent collapse under suction.
OM-01154 0 SERIES suction line to ensure an adequate supply of liquid to the pump. Damage To the pump resulting from debris in the suction line will not be covered by the pump warranty. Before connecting the suction and dis charge piping, carefully check the storage tank and piping for construction debris such as nuts, bolts, wire, weld slag, and other foreign material. Install a commer cially available 80 mesh screen in the suc tion line to prevent debris from entering the pump.
0 SERIES Siphoning Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line. Otherwise, a si phoning action causing damage to the pump could result. Eductors An eductor may be used in conjunction with an INSTALLATION OM-01154 FDF valve to increase dispensing rates and im prove efficiency. An educator may also be used to collapse the tank service hose after the tank has been filled or emptied.
OM-01154 0 SERIES OPERATION - SECTION C Review all SAFETY information in Section A. Follow the instructions on all tags, labels and decals attached to the pump. This pump is designed for vehicular mounting in petroleum service. Do not attempt to pump corrosive materials, or any liquids which may damage the pump or endanger personnel as a result of pump failure. Add liquid to the pump casing when: 1. The pump is being put into service for the first time. 2.
OM-01154 pump could be damaged and performance ad versely affected by incorrect rotation. If pump per formance is not within the specified limits (see the curve on Page E-1), check the direction of rotation before further troubleshooting. Drive This pump is designed for operation with a power take‐off unit coupled to the drive shaft on the gear box. The gearbox assembly has a ratio of 5.69:1, and is designed for operation at 1000 RPM. Do not operate at a higher input speed.
OM-01154 0 SERIES Pump Vacuum Check Since this pump does not have a suction check valve, the discharge line must be fitted with a check valve if a pump vacuum reading is to be taken. With the pump inoperative, install a vacuum gauge in the system, using pipe dope on the threads. Block the suction line and start the pump. At oper ating speed the pump should pull a vacuum of 20 inches (508,0 mm) or more of mercury. If it does not, check for air leaks in the seal, gasket, or dis charge valve.
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.
OM-01154 TROUBLE PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.) PUMP REQUIRES TOO MUCH POWER EXCESSIVE NOISE BEARINGS RUN TOO HOT PAGE D - 2 0 SERIES POSSIBLE CAUSE PROBABLE REMEDY Impeller or other wearing parts worn or damaged. Replace worn or damaged parts. Check that impeller is properly cen tered and rotates freely. Suction lift or discharge head too high. Check piping installation and install bypass line if needed. See INSTAL LATION. Pump speed too slow.
0 SERIES OM-01154 PREVENTIVE MAINTENANCE Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine pre ventive maintenance schedule will help assure trouble‐free performance and long life from your Gorman‐Rupp pump.
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 70 F (21 C) clear water corrected to 0.8 specific gravity at sea level with minimum suc tion lift. Since pump installations are seldom identi cal, your performance may be difference due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
OM-01154 0 SERIES SECTION DRAWING PARTS PAGE Figure 1.
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 NO.
OM-01154 0 SERIES Figure 2.
0 SERIES OM-01154 PARTS LIST 44161-019 Gear Box Assembly ITEM NO.
OM-01154 PUMP AND SEAL DISASSEMBLY Review all warnings in Section A. Follow the instructions on all tags, label and de cals attached to the pump. This pump requires little service due to its rugged, minimum‐maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional view (see Figures 1 and 2) and the ac companying parts list.
0 SERIES OM-01154 Impeller Removal (Figure 1) The impeller (2), wear ring (5) and seal assembly (3) may serviced by removing the cover plate (16). To remove the cover plate, disengage the nuts (12) securing the cover plate to the pump casing (1). Remove the cover plate gasket (17). To remove the impeller, see Figure 2 and remove one of the pipe plugs (4) located in the gearbox. Screw the threaded sleeve on the gear jam tool (P/N 48781-002, Figure 3) into the pipe plug hole.
OM-01154 0 SERIES Pump Disassembly (Figure 1) If the pump casing, oil seal (4) or gearbox assem bly (9) requires replacement, the casing must be separated from the gearbox housing (5, Figure 2). Remove the hardware (7 and 8) securing the pump casing to the gearbox, and separate the assem blies. Remove the casing gasket (6). Lay the pump casing on an arbor (or hydraulic) press with the cover plate opening up, and use a suitably sized sleeve to press the oil seal out of the casing.
0 SERIES OM-01154 sparks, and flame. Read and follow all precautions printed on solvent containers. The seal is not normally reused because wear pat terns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an old seal in an emer gency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly. Handle the seal parts with extreme care to prevent damage.
OM-01154 0 SERIES ing face, and press the stationary seat into the pump casing until fully seated. A push tube cut from a length of plastic pipe would aid this installa tion. The O.D. of the tube should be approximately 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, lint‐free cloth to remove any fingerprints.
0 SERIES GEARBOX DISASSEMBLY (Figure 2) When the pump is properly operated and main tained, the gearbox should not require disassem bly. Disassemble the gearbox only when there is evidence of wear or damage. Gearbox disassembly in the field is not rec ommended. These operations should be performed only in a properly equipped shop by qualified personnel. If the gearbox requires disassembly, first disas semble the pump components as indicated in PUMP AND SEAL DISASSEMBLY.
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. GEARBOX REASSEMBLY (Figures 2 and 5) Clean and inspect the bearings as indicated in GEARBOX DISASSEMBLY. To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place.
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 care to align the keyway in the drive gear with the slot in the spacer. Make sure gasket remains in position and does not become sandwiched between pinion shaft bearing and bearing cover.
OM-01154 (7), which are shipped loose. The air vent must be installed to prevent the gearbox from overheating during operation. The gearbox assembly was lubricated and tested before it was shipped from the facto ry; however, the lubricant level must be checked before putting the pump into ser vice. Change the lubricant in a new gearbox after an ini tial break‐in period of 24 hours, and before 100 hours of operation. The lubricant should be changed while the pump is at operating tempera ture.
For U.S. and International Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.: 419-755-1280 International: +1-419-755-1352 For Canadian Warranty Information, Please Visit www.grcanada.com/warranty or call: 519-631-2870 THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO GORMAN‐RUPP OF CANADA LIMITED ST.
