advertisement
OM-01193-02
January 23, 1981
Rev. F 03‐30‐15
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
0 SERIES PUMP
MODEL
03H1-GL
GORMAN‐RUPP PUMPS
www.grpumps.com
e
1981 Gorman‐Rupp Pumps Printed in U.S.A.
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service.
Pump Model:
Serial Number:
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE I - 1
SAFETY ‐ SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE A - 1
INSTALLATION - SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE B - 1
Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE REQUIREMENTS
Tank Preparation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing
Valves
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE B - 1
PAGE B - 2
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PAGE B - 2
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PAGE B - 3
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PAGE B - 6
PAGE B - 6
PAGE B - 7
PAGE B - 7
OPERATION - SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE C - 1
PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation
Drive
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION
Leakage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE C - 1
PAGE C - 1
PAGE C - 1
PAGE C - 1
PAGE C - 2
PAGE C - 2
PAGE C - 2
PAGE C - 2
PAGE C - 2
PAGE C - 3
PAGE C - 3
PAGE C - 3
PAGE C - 3
TROUBLESHOOTING - SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE D - 1
PUMP MAINTENANCE AND REPAIR ‐ SECTION E . . . . . . . . . . . . . . . . .
PAGE E - 1
PERFORMANCE CURVE
PARTS LISTS:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Pump and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Casing and Wear Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE E - 1
PAGE E - 3
PAGE E - 5
PAGE E - 6
PAGE E - 6
PAGE E - 7
PAGE E - 7
PAGE E - 7 i
TABLE OF CONTENTS
(continued)
PUMP AND SEAL REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Casing and Wear Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Pump and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE E - 7
PAGE E - 7
PAGE E - 9
PAGE E - 9
PAGE E - 10
PAGE E - 10
PAGE E - 11
PAGE E - 13
PAGE E - 13
PAGE E - 13 ii
0 SERIES
OM-01193
INTRODUCTION
Thank You for purchasing a Gorman‐Rupp pump.
Read this manual carefully to learn how to safely install and operate your pump. Failure to do so could result in personal injury or damage to the pump.
HAZARD AND INSTRUCTION
DEFINITIONS
The following are used to alert maintenance per sonnel to procedures which require special atten tion, to those which could damage equipment, and to those which could be dangerous to personnel:
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.
Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure.
If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit, please contact your Gorman‐Rupp distributor, or
The Gorman‐Rupp Company:
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.
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
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.
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‐01193
SAFETY - SECTION A
This information applies to 0 Series power take‐off pumps. Refer to the man ual accompanying the power source be fore attempting to begin operation.
Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and pre cautions for each specific application.
Therefore, it is the owner/installer's re sponsibility to ensure that applications not addressed in this manual are per formed only after establishing that nei ther operator safety nor pump integrity are compromised by the installation.
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.
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.
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.
After the pump has been positioned, make certain that the pump and all pip ing connections are tight, properly sup ported and secure before operation.
This pump is designed for vehicular mounting in petroleum service. Do not attempt to pump corrosive materials which may damage the pump or endan ger personnel as a result of pump fail ure.
SAFETY
Do not operate the pump without the shields and/or guards in place over the rotating parts. Exposed rotating parts
PAGE A - 1
OM-01193 0 SERIES can catch clothing, fingers, or tools, causing severe injury to personnel.
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 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.
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.
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.
The gearbox provided on this pump is designed for operation at 1000 RPM maximum input speed. If operated at a higher RPM, pump components may be destroyed.
Overheated pumps can cause severe burns and injuries. If overheating of the pump occurs:
1. Stop the pump immediately.
2. Ventilate the area.
3. Allow the pump to completely cool.
4. Check the temperature before opening any covers, plates, gauges, or plugs.
5. Vent the pump slowly and cau tiously.
6. Refer to instructions in this manual before restarting the pump.
Never run this pump backwards. Be cer tain that rotation is correct before fully engaging the pump.
Never run the pump dry of pumping me dium. There must be a supply of liquid to the pump at all times to prevent destruction of the shaft seal faces.
After the vehicle is positioned for pump
PAGE A - 2
Pumps and related equipment must be in stalled and operated according to all na tional, local and industry standards.
SAFETY
0 SERIES OM-01193
INSTALLATION - SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping.
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.
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
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
INSTALLATION
Figure 1. Pump Model 03H1‐GL
PAGE B - 1
OM-01193 0 SERIES
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be fore shipment from the factory. Before installation, inspect the pump for damage which may have oc curred during shipment. Check as follows: a. Inspect the pump and gearbox for cracks, dents, damaged threads, and other obvious damage.
b. Check for and tighten loose attaching hard ware. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces.
c. Carefully read all tags, decals, and markings on the pump assembly, and perform all duties indicated. Note the direction of rotation indi cated on the pump. Check that the pump shaft rotates in the required direction.
VEHICLE REQUIREMENTS
The following instructions apply equally to new in stallations, rebuilds or retrofits.
Tank Preparation
It is essential that any tank scale, dirt, or other for eign material be removed from the tank and piping prior to pump installation. Failure to do so could re sult in clogging or damage to the pump.
Damage to the pump resulting from debris in the suction line will not be covered by the pump warranty.
Before connecting the suction and dis charge piping, carefully check the storage tank and piping for construction debris such as nuts, bolts, wire, weld slag, and other foreign material. Install a commer cially available 80 mesh screen in the suc tion line to prevent debris from entering the pump.
Only operate this pump in the direction in dicated on the pump body and/or the ac companying decal. Reverse rotation of the shaft will adversely effect pump perform ance, and the pump and/or gearbox could be seriously damaged.
d. Check levels and lubricate as necessary. Re fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per form duties as instructed.
e. If the pump and gearbox have been stored for more than 12 months, some of the compo nents or lubricants may have exceeded their maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv ice.
If the maximum shelf life has been exceeded, or if anything appears to be abnormal, contact your
Gorman‐Rupp distributor or the factory to deter mine the repair or updating policy. Do not put the pump into service until appropriate action has been taken.
PAGE B - 2
POSITIONING PUMP
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.
INSTALLATION
0 SERIES OM-01193
Lifting
Pump unit weights will vary depending on the mounting and drive provided. Check the shipping tag on the unit packaging for the actual weight, and use lifting equipment with appropriate capacity.
Drain the pump and remove all customer‐installed equipment such as suction and discharge hoses or piping before attempting to lift existing, installed units.
The 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.
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.
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.
ALIGNMENT
When installing and/or aligning univer sal shaft assemblies, disconnect the power source to ensure that the pump will remain inoperative.
INSTALLATION PAGE B - 3
OM-01193 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 2. Proper Installation And Alignment of Universal Assembly
SUCTION AND DISCHARGE PIPING
tors, related piping and safety accessories. Some of the accessories are available from Gorman‐
Rupp as optional equipment.
Typical System Installation
Tank filling and dispensing operations require a system utilizing flow‐directing (FDF) valves, educ
Refer to Figures 3 and 4 for illustrations of typical piping systems for tank filling and dispensing.
PAGE B - 4 INSTALLATION
0 SERIES OM-01193
SCHEMATIC SYSTEM USING EDUCTOR FOR DISPENSING AND FILLING
Figure 3. Typical Installation Using Educator For Filling And Dispensing
SCHEMATIC SYSTEM USING PUMP FOR DISPENSING AND FILLING
Piping
Figure 4. Typical Installation Using Pump For Filling And Dispensing
All piping material must be compatible with the liq uid being pumped. If hose is used in suction lines, it must be the rigid‐wall, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended.
A suction strainer was not furnished with this pump since it is not designed to handle liquids containing solids. However, to protect the pump from acciden tal damage a commercially available 80 mesh screen should be installed in the suction line. Make certain that the total open area of the screen is at least three or four times the cross section of the
INSTALLATION PAGE B - 5
OM-01193 0 SERIES
suction line to ensure an adequate supply of liquid to the pump.
Sealing
Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight seal. Follow the sealant manufacturer's rec ommendations when selecting and applying the pie dope.
Damage To the pump resulting from debris in the suction line will not be covered by the pump warranty.
Before connecting the suction and dis charge piping, carefully check the storage tank and piping for construction debris such as nuts, bolts, wire, weld slag, and other foreign material. Install a commer cially available 80 mesh screen in the suc tion line to prevent debris from entering the pump.
If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line.
With high discharge heads, it is recommended that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped.
Valves
Gorman‐Rupp manufactures several sizes of flow‐ diverting (FDF) valves for use in truck‐mounted pumping applications. The valves are designed to reverse the flow of liquid with only the turn of a han dle. This allows the same pump to fill or dispense from the tank.
The FDF valve is designed for directing flow only. it will not serve as a positive shut off or throttling valve.
See Figure 5 illustrating the theory of operation for a typical FDF valve. Consult the factory for further assistance or other sizes.
DISPENSING
POSITION
FILL
POSITION
DISPENSE TOP VIEW FILL
Figure 5. FDF Valve Theory of Operation
When the center web of the valve is aligned with the larger ports (filling position), the flow passes straight through. When the handle is turned to the dispensing position, the web blocks the straight flow and opens two paths of flow through the larger ports to the smaller ports.
PAGE B - 6 INSTALLATION
0 SERIES OM-01193
Siphoning
Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line. Otherwise, a si phoning action causing damage to the pump could result.
Eductors
An eductor may be used in conjunction with an
FDF valve to increase dispensing rates and im prove efficiency. An educator may also be used to collapse the tank service hose after the tank has been filled or emptied.
Contact the Gorman‐Rupp Company or an autho rized distributor for specifications and perform ance data on eductors or FDF valves.
INSTALLATION PAGE B - 7
0 SERIES
OM-01193
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and decals attached to the pump.
This pump is designed for vehicular mounting in petroleum service. Do not attempt to pump corrosive materials, or any liquids which may damage the pump or endanger personnel as a result of pump failure.
Add liquid to the pump casing when:
1. The pump is being put into service for the first time.
2. The pump has not been used for a consider able length of time.
3. The liquid in the pump casing has evapo rated.
When installed in a flooded suction application, simply open the system valves and permit the in coming liquid to evacuate the air. After the pump and piping system have completely filled, evacu ate any remaining air pockets in the pump or suc tion line by loosening a pipe plug or opening bleed er valves.
Once the pump casing has been filled, the pump will prime and reprime as necessary.
The gearbox provided on this pump is designed for operation at 1000 RPM maximum input speed. If operated at a higher RPM, pump components may be destroyed.
GROUNDING
To eliminate electrostatic build‐up when pumping petroleum products, the pump must be grounded by attaching a ground wire to a ground rod. Install the ground rod in accordance with the National
Electric Code and all local codes. Be sure the clamp or fastener has made a tight electrical con nection with the rod.
PRIMING
Install the pump and piping as described in IN
STALLATION. Make sure that the piping connec tions are tight, and that the pump is securely mounted. Check that the pump is properly lubri cated (see LUBRICATION in MAINTENANCE
AND REPAIR).
This pump is self‐priming, but the pump should never be operated unless there is liquid in the pump casing.
Inspect and test the ground wire assembly for conductivity. Replace broken or frayed wire before resuming operation.
STARTING
Consult the operations manual furnished with the power source.
Never operate this pump unless there is liquid in the pump casing. The pump will not prime when dry. Extended operation of a dry pump will destroy the seal assembly.
OPERATION
Rotation
The correct direction of pump rotation is counter clockwise when facing the input drive shaft. The
PAGE C - 1
OM-01193 0 SERIES
pump could be damaged and performance ad versely affected by incorrect rotation. If pump per formance is not within the specified limits (see the curve on Page E-1), check the direction of rotation before further troubleshooting.
Drive
This pump is designed for operation with a power take‐off unit coupled to the drive shaft on the gear box. The gearbox assembly has a ratio of 4.09:1, and is designed for operation at 1000 RPM. Do not operate at a higher input speed.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160
_
F (71
_
C). Do not apply it at a higher operating temperature.
Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rup ture or explode. If overheating occurs, stop the pump and allow it to cool before servicing it. Refill the pump casing with cool liquid.
The gearbox provided on this pump is designed for operation at 1000 RPM maximum. If operated at a higher rpm, pump components may be destroyed.
OPERATION
Allow an overheated pump to complete ly cool before servicing. Do not remove plates, covers, gauges, pipe plugs, or fittings from an overheated pump. Liq uid within the pump can reach boiling temperatures, and vapor pressure with in the pump can cause parts being dis engaged to be ejected with great force.
After the pump cools, drain the liquid from the pump by removing the casing drain plug. Use caution when removing the plug to prevent injury to personnel from hot liquid.
Pump speed and operating condition points must be within the continuous per formance range shown on the curve (see
Section E, Page 1).
Partially open the discharge throttling valve so that the discharge line fills slowly to prevent damage to piping, gaskets, and other devices in the line which could be affected by shock resulting from rapid fill ing of the line. When the discharge line is com pletely filled, adjust the discharge throttling valve to the desired flow rate.
Leakage
No leakage should be visible at pump mating sur faces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maxi mum pump efficiency.
PAGE C - 2
Strainer Check
If a suction strainer has been shipped with the pump or installed by the user, check the strainer regularly, and clean it as necessary. The strainer should also be checked if pump flow rate begins to drop. If a vacuum suction gauge has been in stalled, monitor and record the readings regularly to detect strainer blockage.
Never introduce air or steam pressure into the pump casing or piping to remove a blockage. This could result in personal injury or damage to the equipment. If backflushing is absolutely neces sary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve. (See Section E,
Page 1.)
OPERATION
0 SERIES
OM-01193
Pump Vacuum Check
Since this pump does not have a suction check valve, the discharge line must be fitted with a check valve if a pump vacuum reading is to be taken.
With the pump inoperative, install a vacuum gauge in the system, using pipe dope on the threads.
Block the suction line and start the pump. At oper ating speed the pump should pull a vacuum of 20 inches (508,0 mm) or more of mercury. If it does not, check for air leaks in the seal, gasket, or dis charge valve.
Open the suction line, and read the vacuum gauge with the pump primed and at operation speed.
Shut off the pump. The vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check the point of installation of the vacuum gauge.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
After stopping the pump, remove the engine igni tion key to ensure that the pump will remain inop erative.
Cold Weather Preservation
If the application of this pump is limited to petro leum products, normal freezing conditions will not damage the pump. However, during extremely se vere conditions care should be exercised during start‐up, especially if the pump has been idle for more than a few hours.
STOPPING
NOTE
Petroleum products are very sensitive to changes in temperature. Warmer temperatures elevate the product vapor pressure, resulting in low vacuum readings. Do not mistake temperature problems for faulty pump installation or performance.
Never halt the flow of liquid suddenly. If the liquid being pumped is stopped abruptly, damaging shock waves can be transmitted to the pump and piping system. Close all connecting valves slowly.
On engine driven pumps, reduce the throttle speed slowly and allow the engine to idle briefly be fore stopping.
GEARBOX TEMPERATURE CHECK
The gearbox runs higher than ambient tempera tures because of heat generated by friction. Tem peratures of approximately 200
_
F (93
_
C) are con sidered normal, and can operate intermittently at
250
_
F (121
_
C).
Checking gearbox temperatures by hand is inac curate. Place a contact‐type thermometer against the housing and record this temperature for future reference.
A sudden increase in gearbox temperature is a warning that the bearings are at the point of failing.
Make certain that the bearing lubricant is of the proper viscosity and at the correct level (see LU
BRICATION in Section E). Bearing overheating can also be caused by shaft misalignment and/or excessive vibration.
When pumps are first started, the bearings may seem to run at temperatures above normal. Con tinued operation should bring the temperatures down to normal levels within 20 minutes or less.
OPERATION PAGE C - 3
0 SERIES
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
OM-01193
Before attempting to open or service the pump:
1. Familiarize yourself with this manual.
2. Switch off the vehicle ignition and re move the key, or take other precau tions to ensure that the pump will re main inoperative.
3. Allow the pump to completely cool if overheated.
4. Check the temperature before open ing any covers, plates, or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
TROUBLE
PUMP FAILS TO
PRIME
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
POSSIBLE CAUSE PROBABLE REMEDY
Not enough liquid in casing.
Air leak in suction line.
Lining of suction hose collapsed.
Add liquid to casing. See
PRIMING.
Correct leak.
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.
Air leak in suction line.
Suction intake not submerged at proper level or sump too small.
Correct leak.
Check installation and correct 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-01193 0 SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE (cont.)
PUMP REQUIRES
TOO MUCH
POWER
Impeller or other wearing parts worn or damaged.
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.
Discharge line clogged or restricted; hose kinked.
Check power source output; consult power source operation manual.
Check discharge lines; straighten hose.
Universal joint drive misaligned.
Pump speed too high.
Discharge head too low.
Align drive.
Check driver output; check that sheaves or couplings are correctly sized.
Adjust discharge valve.
EXCESSIVE NOISE
BEARINGS RUN
TOO HOT
Cavitation in pump.
Pumping entrained air.
Pump or drive not securely mounted.
Universal joint drive misaligned.
Low or incorrect lubricant.
Reduce suction lift and/or friction losses in suction line. Record vac uum and pressure gauge readings and consult local representative or factory.
Locate and eliminate source of air bubble.
Secure mounting hardware.
Align drive.
Check for proper type and level of lubricant.
Bearing temperature is high, but within limits.
Low or incorrect lubricant.
Suction and discharge lines not prop erly supported.
Drive misaligned; piping improperly in stalled.
Bearings in power source or gearbox worn or binding.
Check bearing temperature regu larly to monitor any increase.
Check for proper type and level of lubricant.
Check piping installation for proper support.
Realign drive and piping at operat ing temperature. Add expansion joints if required.
Check bearings.
PAGE D - 2 TROUBLESHOOTING
0 SERIES OM-01193
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine pre ventive maintenance schedule will help assure trouble‐free performance and long life from your
Gorman‐Rupp pump. For specific questions con cerning your application, contact your Gorman‐
Rupp distributor or the Gorman‐Rupp Company.
Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so equipped) between regularly scheduled inspec tions can indicate problems that can be corrected before system damage or catastrophic failure oc curs. The appearance of wearing parts should also be documented at each inspection for comparison as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced before failure occurs, reducing unscheduled down time.
For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. Subsequent inspec tions should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.
Item
Preventive Maintenance Schedule
Daily
Service Interval*
Weekly Monthly Semi‐
Annually
Annually
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.)
Pump Performance (Gauges, Speed, Flow)
Bearing Lubrication
Seal Lubrication (And Packing Adjustment,
If So Equipped)
V‐Belts (If So Equipped)
Air Release Valve Plunger Rod (If So Equipped)
Front Impeller Clearance (Wear Plate)
Rear Impeller Clearance (Seal Plate)
Check Valve
Pressure Relief Valve (If So Equipped)
Pump and Driver Alignment
Shaft Deflection
Bearings
Bearing Housing
Piping
Driver Lubrication - See Mfgr's Literature
I
I
I
I
I
I
C
I
I
R
R
I
I
I
I
I
I
C
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-01193
PUMP MAINTENANCE AND REPAIR ‐ SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODEL 03H1-GL
Based on 70
_
F (21
_
C) clear water corrected to
0.8 specific gravity at sea level with minimum suc tion lift. Since pump installations are seldom identi cal, your performance may be difference due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
Contact the Gorman‐Rupp Company to verify per formance or part numbers.
If your pump serial number is followed by an “N”, your pump is NOT a standard production model.
Pump speed and operating condition points must be within the continuous per formance range shown on the curve.
MAINTENANCE & REPAIR PAGE E - 1
OM-01193
PARTS PAGE
SECTION DRAWING
0 SERIES
PAGE E - 2
Figure 1. Pump Model 03H1-GL
MAINTENANCE & REPAIR
0 SERIES OM-01193
PARTS LIST
Pump Model 03H1-GL
(From S/N 282480 Up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact the Gorman‐Rupp Company to verify part numbers.
ITEM
NO.
18
19
20
21
22
13
14
15
16
17
8
9
10
11
12
3
4
5
1
2
6
7
28
29
30
31
32
23
24
25
26
27
PART NAME
PUMP CASING
IMPELLER
SEAL ASSEMBLY
DISCHARGE STICKER
FL HERE TO PRM STK
FILL PLUG ASSY
DISCHARGE FLANGE
STUD
HEX NUT
DISCH GASKET
PUMP CASING GSKT SET
STUD
HEX NUT
ROTATION DECAL
SEAL GUARD
SHAFT SLEEVE
SHAFT SLEEVE O‐RING
GEARBOX ASSEMBLY
IMPELLER WASHER
IMPELLER KEY
NYLOCK CAPSCREW
LOCKWASHER
CASING DRAIN PLUG
WEAR RING
SUCT FLANGE GSKT
STUD
HEX NUT
SUCTION FLANGE
SUCTION STICKER
NAME PLATE
DRIVE SCREW
PIPE PLUG
INDICATES PARTS RECOMMENDED FOR STOCK
MAT'L
CODE
15991
---
14090
16000
---
---
13090
15990
15991
15991
13040
13010
---
---
---
---
13040
15991
15991
20000
20010
15991
11990
14000
20000
15991
15991
13040
---
13990
17000
15079
PART
NUMBER
8274
8251
25271-192
6588BJ
6588AH
48271-064
1390
C1009
D10
1318GB
3GC
C0605-1/2
D06
2613BM
9834
9140
S1461
44161-014
6750
N0305-1/2
BT0604
J06
P20
62ZL5
1318GB
C1009
D10
1390
6588AG
38818-018
BM#04-03
P04
QTY
1
1
1
1
1
8
1
1
1
1
4
4
1
1
8
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
4
4
MAINTENANCE & REPAIR PAGE E - 3
OM-01193 0 SERIES
PAGE E - 4
Figure 2. 44161-014 Gearbox Assembly
MAINTENANCE & REPAIR
0 SERIES OM-01193
PARTS LIST
44161-014 Gearbox Assembly
ITEM
NO.
18
18A
19
20
21
13
14
15
16
17
7
7A
8
9
10
11
12
3
4
5
6
1
2
27
28
29
30
31
22
23
24
25
26
PART NAME
WEAR RING
PINION SHAFT
OIL SEAL
AIR VENT
REDUCING PIPE BUSHING
SHIPPING PLUG
BALL BEARING
BALL BEARING
GASKET
COVER PLATE
LUBRICATION DECAL
PTO LUBRICATION DECAL
OIL SEAL
ADJUSTING SHIM SET
DRIVE SHAFT
KEY
WDF KEY
ADJUSTING SHIM SET
BALL BEARING
BALL BEARING
LOCK WASHER
HEX HEAD CAPSCREW
HELICAL GEAR
SPACER SLEEVE
PIPE PLUG
GEAR HOUSING ASSEMBLY
{
-GEAR HOUSING
-GASKET
{
-SEAL PLATE
-FLANGED CAPSCREW
-LOCK WASHER
-HEX NUT
DOWEL PIN
PART
NUMBER
MAT'L
CODE
62ZL6
8896
S1764
S1530
AP0602
11495A
S390
S390
8871G
8871
38816-239
2613CQ
S389
S464
8837
N0404-1/2
AV1210
S464
S390
S390
J06
B0604
8895
9142
P06
8914
15990
15079
---
NOT AVAILABLE
8870G
NOT AVAILABLE
18000
31871-065
J06
15991
15991
D06
AA0403 -1/2
15991
15990
14000
16020
---
---
15079
15079
---
---
18000
10010
---
---
---
---
16040
15990
15990
---
---
---
15991
15991
16060
INDICATES PARTS RECOMMENDED FOR STOCK
{ INDICATES THE MATING SURFACES OF ITEMS 25 AND 27 ARE MACHINED AT THE FACTORY FOR A
FLUSH FIT. THESE ITEMS ARE AVAIABLE ONLY BY ORDERING THE COMPLETE GEARBOX HOUSING
ASSEMBLY (ITEM 24).
QTY
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
8
8
2
1
5
1
1
1
MAINTENANCE & REPAIR PAGE E - 5
OM-01193
PUMP AND SEAL DISASSEMBLY
AND REASSEMBLY
0 SERIES
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de cals attached to the pump.
This pump requires little service due to its rugged, minimum‐maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional views (see Figures 1 and 2) and the accompanying parts list.
If the gearbox requires repair, proceed with PUMP
AND SEAL DISASSEMBLY, followed by GEAR
BOX DISASSEMBLY.
Before attempting to service the pump, switch off the engine ignition and remove the key, or take oth er safety precautions to ensure that it will remain inoperative. Close all valves in the suction and dis charge lines.
PAGE E - 6
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Switch off the vehicle ignition and remove the key, or take other pre cautions to ensure that the pump will remain inoperative.
3. Allow the pump to completely cool if overheated.
4. Check the temperature before opening any covers, plates, or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cau tiously.
7. Drain the pump.
Because pump installations are seldom identical, this manual cannot possibly provide detailed in structions and precautions for every aspect of each specific application. Therefore, it is the re sponsibility of the owner/installer of the pump to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are com promised by the installation. Pumps and related equipment must be installed and operated ac cording to all national, local and industry stan dards.
Most service functions, such as impeller, wear ring, and seal replacement, may be performed by drain ing the pump and removing the pump casing.
However, due to the confined mounting location of the pump, it is recommended that the pump and gearbox be removed from the vehicle for service.
The following instructions assume complete disas sembly is required.
After the vehicle is positioned for pump maintenance, block the wheels and set the emergency brake before attempting to disconnect the drive shaft or remove the pump. Be sure the pump is properly reinstalled and secured before opera tion.
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re
MAINTENANCE & REPAIR
0 SERIES OM-01193 moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.
The pump assembly can be seriously damaged if the cables or chains used to lift and move the unit are improperly wrapped around the pump.
Due to the confined mounting location, specialized equipment such as a transmis sion jack with custom brackets should be used to lift and position the pump and gearbox.
Removing Pump and Gearbox
Due to the confined mounting location, it is recom mended that the pump and gearbox be removed from the vehicle for service.
The pump assembly can be seriously damaged if the cables or chains used to lift and move the unit are improperly wrapped around the pump.
Due to the confined mounting location, specialized equipment such as a transmis sion jack with custom brackets should be used to lift and position the pump and gearbox.
Close all valves in the suction and discharge lines.
Remove the pump casing drain plug (23) and drain the pump.
Disconnect the P.T.O. shaft from the gearbox drive shaft. Remove all the hardware securing the pump and gearbox to the vehicle chassis. Tie and tag the any leveling shims used under the casing mount ing feet to ease reassembly. Move the pump and gearbox to a clean, well‐equipped shop for mainte nance and repair.
MAINTENANCE & REPAIR
Pump Casing and Wear Ring Removal
(Figure 1)
To service the impeller, wear ring or seal assembly, the pump casing (1) must be separated from the seal plate (27, Figure 2).
Remove the nuts (13) and separate the pump cas ing and casing gasket set (11) from the seal plate.
Tie and tag the gaskets, or measure and record their thickness for ease of reassembly.
Clean the mating surfaces of the seal plate and pump casing. Inspect the wear ring (24) for exces sive wear or scoring. The wear ring is secured in the pump casing by a press fit. If replacement is re quired, use a small bit to drill two holes through the ring horizontally, 180
_ apart. Use a saw and chisel to complete the cuts through the ring, and remove it from the casing. Use caution not to damage the pump casing when removing the ring.
Impeller Removal
(Figure 1)
To loosen the impeller screw (21), immobilize the drive shaft (14, Figure 2). Remove the impeller screw, lockwasher (22), and impeller washer (19).
Use a suitable puller to remove the impeller from the shaft. Retain the impeller key (20). Use caution when removing the impeller; tension on the seal spring will be released as the impeller is removed.
NOTE
An alternate method of removing the impeller is to use two large screwdrivers on opposite sides be tween the impeller and seal plate to pry the impeller off the shaft. Use caution not to damage the impel ler.
Inspect the seal guard (15) for excessive wear or scoring. The seal guard is secured on the impeller by a press fit. If replacement is required, pull it off the impeller.
Seal Removal and Disassembly
(Figure 1)
Carefully remove the seal spring. Remove the shaft sleeve (16) and rotating portion of the seal as a unit. Apply oil to the sleeve and work it up under the bellows. Slide the rotating portion of the seal off the sleeve.
PAGE E - 7
OM-01193 0 SERIES
Use a pair of stiff wires with hooked ends to hook the stationary element from the back side, and pull the element and O‐ring from the seal plate bore.
Remove the sleeve O‐ring (17).
If no further disassembly is required, proceed with
PUMP AND SEAL REASSEMBLY. If the gearbox requires disassembly, do not reassemble the pump components at this time. Refer to GEAR
BOX DISASSEMBLY and GEARBOX REAS
SEMBLY, followed by PUMP AND SEAL REAS
SEMBLY.
PUMP AND SEAL REASSEMBLY
If the gearbox requires disassembly, refer to
GEARBOX DISASSEMBLY and GEARBOX
REASSEMBLY, followed by PUMP AND SEAL
REASSEMBLY.
Seal Reassembly and Installation
(Figures 1 and 3)
Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.
Most cleaning solvents are toxic and flammable. Use them only in a well‐ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.
The seal is not normally reused because wear pat terns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an old seal in an emer gency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non‐oil based solvent and a clean, lint‐free tissue.
Wipe lightly in a concentric pattern to avoid scratching the faces.
Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. Clean and polish the shaft sleeve, or replace it if there are nicks or cuts on either end. If any com ponents are worn, replace the complete seal;
never mix old and new seal parts.
If a replacement seal is being used, remove it from the container and inspect the precision finished faces to ensure that they are free of any foreign matter.
To ease installation of the seal, lubricate the O‐ rings and shaft sleeve with water or a very small amount of oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as fol lows, (see Figure E-3).
PAGE E - 8 MAINTENANCE & REPAIR
0 SERIES
SEAL GUARD
SPRING
DRIVE BAND
IMPELLER
KEY
IMPELLER
SHAFT
OM-01193
SEAL PLATE
O‐RING
STATIONARY
SEAT AND SEAL
SHAFT
SLEEVE
IMPELLER
BELLOWS
RETAINER
ROTATING
ELEMENT
SLEEVE
O‐RING
Figure 3. Seal Assembly
This seal is not designed for operation at temperatures above 160
_
F (71
_
C). Do not use at higher operating temperatures.
Inspect the pinion shaft (2, Figure 2) for distortion, nicks, scratches, or damage to the shaft keyway.
Dress small nicks or burrs with a fine file or emery cloth. If excessive wear exists, refer to GEARBOX
DISASSEMBLY and replace the shaft.
Subassemble the rotating element into the retainer and bellows, and slide this subassembly over the shaft sleeve until the rotating element is just flush with the chamfered end of the sleeve. Slide the sleeve and rotating portion of the seal onto the shaft until the seal faces contact. Continue to push the sleeve through the seal until the sleeve is fully seated against the shaft shoulder.
Install the seal spring. Make sure that all compo nents of the seal are seated squarely.
Impeller Installation
(Figures 1 and 4)
Lightly lubricate the shaft sleeve O‐ring (17) and in stall it on the shaft.
Inspect the impeller (2), and replace it if cracked or badly worn. If the seal guard (15) was removed, press the replacement guard onto the impeller until it seats squarely against the bore shoulder.
Lubricate the stationary seat O‐ring with light oil and install it in the groove in the seat. Use thumb pressure to press this subassembly into the seal plate until it seats squarely against the shoulder bore. Be careful not to damage the seal face. After installation, wipe the seal face in a concentric pat tern with a clean, lint‐free cloth to remove any fin gerprints.
The seal guard must seat squarely on the
MAINTENANCE & REPAIR PAGE E - 9
OM-01193 0 SERIES
impeller or binding and/or excessive wear will result.
Align the impeller and key (20) with the shaft key way, and press the impeller onto the shaft until fully seated. Be sure the seal spring seats squarely over the shoulder on the back of the impeller.
NOTE
After the impeller has been installed, check for free rotation. Correct any scraping or binding before fur ther reassembly.
Align the hole in the impeller washer (19) with the key, and install the washer. Immobilize the drive shaft (14, Figure 2), and install the impeller screw and lockwasher (21 and 22). Torque the impeller screw to 20 ft. lbs. (240 in. lbs. or 2,8 m. kg.).
Pump Casing and Wear Ring Installation
(Figure 1)
If the wear ring (24) was removed for replacement, press the replacement ring into the pump casing until it seats squarely against the shoulder bore.
The wear ring must seat squarely in the casing bore or binding and/or excessive wear will result.
For maximum pump efficiency, the impeller should be centered within the pump casing. To verify im peller positioning, measure the pump casing and impeller as shown in Figure 4. Use these measure ments to calculate the required impeller location
(dimension E). Add or remove gaskets in the pump casing gasket set (44) to obtain dimension E.
NOTE
When calculating pump casing positioning, figure
30% compression for pump casing gaskets.
C
D
2
D
A
B
2
B
E
Step 1
A+
B
2
Step 2
-
C+
D
2
=
E
Step 3
Figure 4. Centering Impeller Within Pump Casing
Install the calculated thickness of pump casing gaskets. Secure the pump casing to the seal plate with the nuts (33).
Reconnect the P.T.O. shaft the the gearbox drive shaft and check the alignment as described in IN
STALLATION, Section B.
Installing Pump and Gearbox
(Figure 1)
Secure the pump and gearbox to the truck chassis with the previously removed hardware. Be sure to install any leveling shims used under the casing mounting feet.
PAGE E - 10
Install the suction and discharge lines and open all valves. Make certain that all piping connections are tight, properly supported and secure.
Be sure the pump and gearbox have been prop erly lubricated (see LUBRICATION).
Fill the pump casing with clean liquid. Reinstall the fill plug (6) and tighten it.
MAINTENANCE & REPAIR
0 SERIES OM-01193
Refer to OPERATION, Section C, before putting the pump back into service.
ment is required, remove them from the gear hous ing.
After removing the shafts and bearings, clean and inspect the bearings in place as follows.
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.
To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is
strongly recommended that the bearings be replaced any time the shaft and bear ings are removed.
Clean the gear housing, seal plate, shafts and all component parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary.
Gearbox disassembly in the field is not rec ommended. These operations should be performed only in a properly equipped shop by qualified personnel.
If the gearbox requires disassembly, first disas semble the pump components as indicated in
PUMP AND SEAL DISASSEMBLY.
Before attempting to disassemble the gearbox, re move the lower most pipe plug (23) and drain the lubricant. Clean and reinstall the pipe plug.
With the pump end components removed, use a hammer and punch to drive the dowel pins (31) out of the gearbox. Remove the hardware (28, 29 and
30) securing the seal plate (27) to the gearbox housing (25). Slide the seal plate and oil seal (3) off the shaft. Remove the seal plate gasket (26). In spect the oil seal (3) and, if replacement is re quired, press it from the seal plate.
Remove the shaft key (15). Remove the hardware
(19 and 20) and slide the cover plate (9) and as sembled oil seal (12) off the shaft. Remove the cov er plate gasket (8) and bearing adjusting shims (13 and 17). Tie and tag the shims, or measure and re cord their thickness for ease of reassembly. In spect the oil seal (12) and, if replacement is re quired, press it form the cover plate.
Slide the drive shaft (14), bearings (18 and 18A), helical gear (21), pinion shaft (2) and bearings (7 and 7A) out of the seal plate side of the gear hous ing. It is not necessary to remove the dowel pins
(31) unless they are bent or damaged. If replace
MAINTENANCE & REPAIR
Most cleaning solvents are toxic and flammable. Use them only in a well‐ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.
Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.
Bearings must be kept free of all dirt and foreign material. failure to do so will greatly shorten bearing life. Do not spin dry bear ings. This may scratch the balls or races and cause premature bearing failure.
Rotate the bearings by hand to check for rough ness or binding and inspect the bearing balls. If ro tation is rough or the bearing balls are discolored, replace the bearings.
The bearing tolerances provide a tight press fit onto the shafts and a snug slip fit into the gear housing and seal plate. Replace the bearings,
PAGE E - 11
OM-01193 0 SERIES
shafts, gear housing, or seal plate if the proper bearing fit is not achieved.
If the bearings, pinion shaft, or helical drive gear re quire replacement, use a suitable puller to remove the bearings from the shafts. Slide the spacer (22) and drive gear off the drive shaft. Retain the wood ruff key (16).
GEARBOX REASSEMBLY
Clean and inspect the bearings as indicated in
GEARBOX DISASSEMBLY.
Use caution when handling hot bear ings to prevent burns.
After the bearings have been installed and allowed to cool, check to ensure that they have not moved out of position in shrinking. If movement has oc curred, use a suitably sized sleeve and a press to reposition the bearings.
If heating the bearings is not practical, use a suit ably sized sleeve and an arbor (or hydraulic) press to install the bearings onto the shafts.
To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is
strongly recommended that the bearings be replaced any time the shaft and and bearings are removed.
Inspect the helical gear (21) and pinion shaft (2) for excessive wear or broken teeth and replace as re quired.
Install the woodruff key (16) in the shaft keyway, and slide the helical gear onto the shaft. Position the spacer (22) against the inboard side of the heli cal gear.
The bearings (7, 7A, 18 and 18A) may be heated to ease installation. An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bearings should never be heated with a direct flame or directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thor
oughly filtered.
Heat the bearings to a uniform temperature no
higher than 250
_
F (120
_
C), and slide them onto the shafts, one at a time, until they are fully seated.
This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft.
PAGE E - 12
When installing the bearings onto the shafts, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.
If the dowel pins (31) were removed, install them in the holes in the gear housing.
With the bearings, helical gear and spacer in stalled on the drive and pinion shafts, mesh the teeth on the helical drive gear with those on the pin ion shaft, and slide both shafts into the gear hous ing (25) until the outboard bearings are seated in the bearing bores of the gear housing.
If the oil seal (3) was removed, apply a light coating of oil to the lip of the replacement seal, and position it in the seal plate (27) with the lip positioned as shown in Figure 2. Press the oil seal into the seal plate until the inner side of the seal is just flush with the inside of the seal plate.
Install the seal plate gasket (26) and slide the seal plate over the inboard bearings. Install the cap screws (28) to align the gearbox halves. Use a hammer and punch to tap the dowel pins (31) into the alignment holes in the gear housing (25) until flush. Use the remaining hardware (29 and 30) to secure the seal plate to the gear housing.
If the oil seal (12) was removed, apply a light coat ing of oil to the lip of the replacement seal, and po sition it in the cover plate (9) with the lip positioned as shown in Figure 2. Press the oil seal into the cov
MAINTENANCE & REPAIR
0 SERIES OM-01193
er plate until the inner side of the seal is just flush with the inside of the cover plate.
Position the cover plate gasket (9) against the gear housing. Install the same thickness of bearing ad justing shims (13 and 17) as previously removed, and slide the cover plate over the drive shaft.
Use caution not to damage the oil seal lip on the shaft keyway when installing the cover plate.
Secure the cover plate to the gear housing with the hardware (19 and 20).
NOTE
End play for both the drive and pinion shafts should be between .005 to.012 (0,127 to 0,305 mm). Add or remove bearing shims to achieve the correct endplay.
When the shaft end play has been correctly estab lished, remove the bottom three capscrews (20), coat the threads with thread compound, and rein stall them in the gear housing.
Refer to PUMP AND SEAL REASSEMBLY and in stall the remaining pump components. After the pump components are installed, lubricate the gearbox as indicated in LUBRICATION.
LUBRICATION
Seal Assembly
(Figure 1)
The seal assembly is lubricated by the medium be ing pumped and no additional lubrication is re quired.
Gearbox
(Figures 2 and 5)
The gearbox was fully lubricated when shipped from the factory. Check the oil level regularly at the oil level pipe plug(s) as shown in Figure 5. When lubrication is required, add gear oil through the hole for the air vent (4) the oil level reaches the level shown in the illustration. Clean and reinstall the air vent plug and pipe plug. Do not over‐lubricate. Ov er‐lubrication can cause the bearings to over‐heat, resulting in premature bearing failure.
Change the lubricant in a new gearbox after 100 hours of operation or four weeks, whichever comes first, by draining at operating temperature and thoroughly cleaning with a flushing oil.
After break‐in, drain the gearbox after every 500 hours of operation or every six months, whichever comes first, under normal operating conditions.
Change the oil more frequently if operated under severe conditions.
Monitor the condition of the bearing lubri cant regularly for evidence of rust or mois ture condensation. This is especially im portant in areas where variable hot and cold temperatures are common.
Add 1 ounce (30 ml) of `Molykote M' Gear Guard, then fill with approximately 2 ounces (59 ml) of premium quality, multi‐purpose extreme pressure gear lubricant as indicated below.
SAE #80 - Below 40
_
F (4
_
SAE #90 - 40
SAE #140 - 100
_
-100
_
F (4
_
-150
_
_
F (28
_
C)
-38
_
C)
-66
_
C)
MAINTENANCE & REPAIR PAGE E - 13
OM-01193
Figure 5. Gearbox Lubrication Positions
0 SERIES
PAGE E - 14 MAINTENANCE & REPAIR
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
GORMAN‐RUPP PUMPS
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