Gorman-Rupp Pumps 03A52-B 1327255 and up User Manual

C OM‐01177‐03

November 18, 2005

Rev. D 08‐28‐2020

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

0 SERIES PUMP

MODEL

03A52-B

GORMAN‐RUPP PUMPS

www.grpumps.com

2005 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to Pump

Gauges

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fittings

Strainers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning

Valves

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bypass Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coupled Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE BELT TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Rules of Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMING

STARTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lines With a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lines Without a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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OPERATION - SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE C - 1

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PAGE C - 3

TROUBLESHOOTING - SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE D - 1

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE D - 3 i

TABLE OF CONTENTS

(continued)

PUMP MAINTENANCE AND REPAIR ‐ SECTION E . . . . . . . . . . . . . . . . .

PAGE E - 1

STANDARD PERFORMANCE CURVE

PARTS LISTS:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Pump Disassembly

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Removal and Disassembly

Shaft and Bearing Reassembly and Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PAGE E - 9 ii

0 SERIES OM-01177

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 Installation, Operation, and Maintenance manual is designed to help you achieve the best performance and longest life from your Gorman‐

Rupp pump.

This pump is an 0 Series, enclosed impeller, self‐ priming centrifugal model, designed with straight in suction, without a suction check valve. It is de signed to handle clear liquids containing specified entrained solids. The basic material of construc tion for wetted parts is gray iron.

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

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

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.

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-01177

SAFETY ‐ SECTION A

This information applies to 0 Series ba sic pumps. Gorman‐Rupp has no con trol over or particular knowledge of the power source which will be used. Refer to the manual accompanying the power source before attempting to begin oper ation.

This manual will alert personnel to known procedures which require spe cial attention, to those which could damage equipment, and to those which could be dangerous to personnel.

How ever, this manual cannot possibly antici pate and provide detailed instructions and precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance personnel to ensure that only safe, established main tenance procedures are used, and that any procedures not addressed in this manual are performed only after estab lishing that neither personal safety nor pump integrity are compromised by such practices.

6. Vent the pump slowly and cau tiously.

7. Drain the pump.

This pump is designed to handle clear liquids containing specified entrained solids. Do not attempt to pump volatile, flammable or corrosive materials, or any liquids which may damage the pump or endanger personnel as a result of pump failure.

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.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Lock out or disconnect the power source 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.

After the pump has been installed, make certain that the pump and all piping or hose connections are tight, properly supported and secure before operation.

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.

SAFETY PAGE A - 1

OM-01177 0 SERIES low the pump to completely cool before servicing.

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

Pumps and related equipment must be in stalled and operated according to all na tional, local and industry standards.

PAGE A - 2 SAFETY

0 SERIES OM-01177

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.

configuration, and priming must be tailored to the specific application. Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve.

Most of the information pertains to a standard static lift application where the pump is positioned above the free level of liquid to be pumped.

For further assistance, contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company.

Pump Dimensions

If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line

See Figure 1 for the approximate physical dimen sions of this pump.

OUTLINE DRAWING

INSTALLATION

Figure 1. Pump Model 03A52-B

PAGE B - 1

OM-01177 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 engine 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.

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.

Only operate this pump in the direction in dicated by the arrow on the pump body and on the accompanying decal. Refer to

ROTATION in OPERATION , Section C.

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 power source have been stored for more than 12 months, some of the components or lubricants may have ex ceeded their maximum shelf life. These must be inspected or replaced to ensure maxi mum pump service.

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

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.

Mounting

Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mount ing is essential for proper operation.

The pump may have to be supported or shimmed to provide for level operation or to eliminate vibra tion.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. Contact the factory to be sure your overall application allows pump to operate within the safe operation range.

Materials

Either pipe or hose maybe used for suction and discharge lines; however, the materials must be

INSTALLATION

0 SERIES OM-01177 compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended.

Line Configuration

Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or cou plings.

Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose‐type lines are used, they should have adequate support to secure them when filled with liquid and under pressure.

Gauges

Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges.

If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches from the suction and discharge ports and install the lines. Installation closer to the pump may result in erratic readings.

SUCTION LINES

To avoid air pockets which could affect pump prim ing, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be in

INSTALLATION stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ets.

Strainers

If a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a strainer furnished with the pump will also pass through the pump itself.

If a strainer is not furnished with the pump, but is installed by the pump user, make certain that the total area of the openings in the strainer is at least three or four times the cross section of the suction line, and that the openings will not permit passage of solids larger than the solids handling capability of the pump.

This pump is designed to handle up to 3/8‐inch

(9,7 mm) diameter spherical solids.

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 pipe dope. The pipe dope should be compatible with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1 1/2 times the diame ter of the suction line.

If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump, and air entering the suction line will re duce pump efficiency.

If it is necessary to position inflow close to the suc tion inlet, install a baffle between the inflow and the suction inlet at a distance 1‐1/2 times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet.

PAGE B - 3

OM-01177 0 SERIES

If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a dis tance equal to at least 3 times the diameter of the suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is critical to efficient pump operation.

Figure 2 shows recommended minimum submergence vs. veloc ity.

NOTE

The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).

DISCHARGE LINES

Siphoning

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

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.

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.

Valves

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.

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

Bypass Lines

If a system check valve is used due to high dis charge head, it may be necessary to vent trapped

PAGE B - 4 INSTALLATION

0 SERIES OM-01177 air from the top of the pump during the priming pro cess. This may be accomplished by installing a by pass line from the top of the pump, back to the source of the liquid. The end of the bypass line must be submerged. The line must be large enough to prevent clogging, but not so large as to affect pump discharge capacity.

ALIGNMENT

Coupled Drives

When using couplings, the axis of the power source must be aligned to the axis of the pump shaft in both the horizontal and vertical planes.

Most couplings require a specific gap or clearance between the driving and the driven shafts. Refer to the coupling manufacturer's service literature.

Align spider insert type couplings by using calipers to measure the dimensions on the circumference of the outer ends of the coupling hub every 90 .

The coupling is in alignment when the hub ends are the same distance apart at all points (see Fig ure 3).

The alignment of the pump and its power source is critical for trouble‐free mechanical operation. In either a flexible coupling or V‐belt driven system, the driver and pump must be mounted so that their shafts are aligned with and parallel to each other. It is imperative that alignment be checked after the pump and piping are installed, and before opera tion.

NOTE

Check Rotation , Section C, before final alignment of the pump.

Figure 3. Aligning Spider‐Type Couplings

When mounted at the Gorman‐Rupp factory, driver and pump are aligned before shipment. Misalign ment will occur in transit and handling. Pumps must be checked and realigned before operation.

Before checking alignment, tighten the foundation bolts. The pump casing feet and/or pedestal feet, and the driver mounting bolts should also be tightly secured.

When checking alignment, disconnect the power source to ensure that the pump will remain inoperative.

Adjusting the alignment in one direction may alter the alignment in another direc tion. check each procedure after altering alignment.

INSTALLATION

Figure 4. Aligning Non‐Spider Type

Couplings

Align non‐spider type couplings by using a feeler gauge or taper gauge between the coupling halves every 90 . The coupling is in alignment when the hubs are the same distance apart at all points (see

Figure 4).

Check parallel adjustment by laying a straightedge across both coupling rims at the top, bottom, and side. When the straightedge rests evenly on both halves of the coupling, the coupling is in horizontal parallel alignment. If the coupling is misaligned, use a feeler gauge between the coupling and the

PAGE B - 5

OM-01177 0 SERIES straightedge to measure the amount of misalign ment.

Drive Belts

When using drive belts, the power source and the pump must be parallel. Use a straightedge along the sides of the pulleys to ensure that the pulleys are properly aligned (see Figure 5). In drive sys tems using two or more belts, make certain that the belts are a matched set; unmatched sets will cause accelerated belt wear.

MISALIGNED:

SHAFTS

NOT PARALLEL

MISALIGNED:

SHAFTS

NOT IN LINE

ALIGNED: SHAFTS

PARALLEL AND

SHEAVES IN LINE

Figure 5. Alignment of V‐Belt Driven Pumps

Tighten the belts in accordance with the belt manu facturer's instructions. If the belts are too loose, they will slip; if the belts are too tight, there will be excessive power loss and possible bearing failure.

Select pulleys that will match the proper speed ra tio; overspeeding the pump may damage both pump and power source.

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.

DRIVE BELT TENSIONING

General Rules of Tensioning

For new drive belts, check the tension after 5, 20 and 50 hours of operation and re‐tension as re quired (see the following procedure for measuring belt tension). Thereafter, check and re‐tension if re quired monthly or at 500 hour intervals, whichever comes first.

Ideal drive belt tension is the lowest tension at which the belt will not slip under peak load condi tions. Do not over‐tension drive belts. Over‐ten sioning will shorten both drive belt and bearing life.

Under‐tensioning will cause belt slippage. Always keep belts free from dirt, grease, oil and other for eign material which may cause slippage.

PAGE B - 6 INSTALLATION

0 SERIES OM-01177

OPERATION - SECTION C


Follow the instructions on all tags, labels and decals attached to the pump.

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 pipe plug or opening bleeder valves.

Once the pump casing has been filled, the pump will prime and reprime as necessary.

This pump is designed to handle clear liquids containing specified entrained solids. Do not attempt to pump volatile, corrosive, or flammable materials, or any liquids which may damage the pump or endanger personnel as a result of pump failure.

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.

After filling the pump casing, reinstall and tighten the fill plug. Do not attempt to operate the pump unless all connect ing piping is securely installed. Other wise, liquid in the pump forced out un der pressure could cause injury to per sonnel.

To fill the pump, remove the pump casing fill cover or fill plug in the top of the casing, and add clean liquid until the casing is filled. Replace the fill cover or fill plug before operating the pump.

STARTING

Consult the operations manual furnished with the power source .

Rotation

The correct direction of pump rotation is counter clockwise when facing the impeller. If the pump is operated in the wrong direction, the impeller could become loosened from the shaft and seriously damage the pump.

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.

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

OPERATION

Only operate this pump in the direction in dicated by the arrow on the pump body and on the accompanying decal. Other wise, the impeller could become loosened from the shaft and seriously damage the pump.

PAGE C - 1

OM-01177 0 SERIES

Consult the operating manual furnished with the power source before attempting to start the power source.

If an electric motor is used to drive the pump, re move V‐belts, couplings, or otherwise disconnect the pump from the motor before checking motor rotation. Operate the motor independently while observing the direction of the motor shaft, or cool ing fan.

If rotation is incorrect on a three‐phase motor, have a qualified electrician interchange any two of the three phase wires to change direction. If rotation is incorrect on a single‐phase motor, consult the lit erature supplied with the motor for specific instruc tions.

OPERATION filled, adjust the throttling valve to the required 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.

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.

Lines With a Bypass

Close the discharge throttling valve (if so equipped) so that the pump will not have to prime against the weight of the liquid in the discharge line. Air from the suction line will be discharged through the bypass line back to the wet well during the priming cycle. When the pump is fully primed and liquid is flowing steadily from the bypass line, open the discharge throttling valve. Liquid will then continue to circulate through the bypass line while the pump is in operation.

Lines Without a Bypass

Open all valves in the discharge line and start the engine. Priming is indicated by a positive reading on the discharge pressure gauge or by a quieter operation. The pump may not prime immediately because the suction line must first fill with liquid. If the pump fails to prime within five minutes, stop it and check the suction line for leaks.

After the pump has been primed, partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pres sure which could damage pipe ends, gaskets, sprinkler heads, and any other fixtures connected to the line. When the discharge line is completely

PAGE C - 2

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.

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

OPERATION

0 SERIES OM-01177 maximum permissible operating pressure shown on the pump performance curve. (See Section E,

Page 1.)

Pump Vacuum Check

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.

Cold Weather Preservation

In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any remaining liquid that could freeze the pump rotat ing parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids con taining a large amount of solids, drain the pump, and flush it thoroughly with clean water. To prevent large solids from clogging the drain port and pre venting the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the liquid during the draining process. Clean out any remaining solids by flushing with a hose.

STOPPING

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.

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

After stopping the pump, lock out or disconnect the power source to ensure that the pump will re main inoperative.

BEARING TEMPERATURE CHECK

Bearings normally run at higher than ambient tem peratures because of heat generated by friction.

Temperatures up to 160 F (71 C) are considered normal for bearings, and they can operate safely to at least 180 F (82 C).

Checking bearing temperatures by hand is inaccu rate. Bearing temperatures can be measured ac curately by placing a contact‐type thermometer against the housing. Record this temperature for future reference.

A sudden increase in bearing temperatures is a warning that the bearings are at the point of failing to operate properly. Make certain that the bearing lubricant is of the proper viscosity and at the cor rect level (see LUBRICATION in Section E). Bear ing 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.

OPERATION PAGE C - 3

0 SERIES

TROUBLESHOOTING - SECTION D


OM-01177









TROUBLE

PUMP FAILS TO

PRIME

PUMP STOPS OR

FAILS TO DELIVER

RATED FLOW OR

PRESSURE

POSSIBLE CAUSE PROBABLE REMEDY

Not enough liquid in casing.

Suction check valve contaminated or damaged.

Air leak in suction line.

Lining of suction hose collapsed.

Add liquid to casing. See

Correct leak.

Replace suction hose.

PRIMING

Clean or replace check valve.

Leaking or worn seal or pump gasket.

Check pump vacuum. Replace leaking or worn seal or gasket.

Suction lift or discharge head too high.

Check piping installation and in stall bypass line if needed. See

INSTALLATION .

Strainer clogged.

Check strainer and clean if neces sary.

.

Air leak in suction line.

Lining of suction hose collapsed.

Correct leak.

Replace suction hose.

Leaking or worn seal or pump gasket.

Check pump vacuum. Replace leaking or worn seal or gasket.

Strainer clogged.

Check strainer and clean if neces sary.

Suction intake not submerged at proper level or sump too small.

Check installation and correct sub mergence as needed.

TROUBLESHOOTING PAGE D - 1

OM-01177 0 SERIES

TROUBLE

PUMP STOPS OR

FAILS TO DELIVER

RATED FLOW OR

PRESSURE (cont.)

POSSIBLE CAUSE

Impeller or other wearing parts worn or damaged.

Impeller clogged.

Pump speed too slow.

Discharge head too high.

Suction lift too high.

PUMP REQUIRES

TOO MUCH

POWER

PUMP CLOGS

FREQUENTLY

EXCESSIVE NOISE

BEARINGS

RUN TOO HOT

Pump speed too high.

Discharge head too low.

Liquid solution too thick.

Bearing(s) frozen.

Liquid solution too thick.

Discharge flow too slow.

Suction check valve or foot valve clogged or binding.

Cavitation in pump.

Pumping entrained air.

Pump or drive not securely mounted.

Impeller clogged or damaged.

Bearing temperature is high, but within limits.

Low or incorrect lubricant.

Suction and discharge lines not properly supported.

Drive misaligned.

PROBABLE REMEDY

Replace worn or damaged parts.

Check that impeller is properly centered and rotates freely.

Free impeller of debris.

Check driver output; check belts or couplings for slippage.

Install bypass line.

Measure lift w/vacuum gauge. Re duce lift and/or friction losses in suction line.

Check driver output; check that sheaves or couplings are cor rectly sized.

Adjust discharge valve.

Dilute if possible.

Disassemble pump and check bearing(s).

Dilute if possible.

Open discharge valve fully to in crease flow rate, and run power source at maximum governed speed.

Clean valve.

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.

Clean out debris; replace dam aged parts.

Check bearing temperature regu larly to monitor any increase.

Check for proper type and level of lubricant.

Check piping installation for proper support.

Align drive properly.

PAGE D - 2 TROUBLESHOOTING

0 SERIES

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

OM-01177 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-01177

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 03A52-B

Based on 70 F (21 C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be dif ference 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-01177

PARTS PAGE

SECTION DRAWING

0 SERIES

PAGE E - 2

Figure 1. Pump Model 03A52-B

MAINTENANCE & REPAIR

0 SERIES OM-01177

PARTS LIST

Pump Model 03A52-B

(From S/N 1327255 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.

PART NAME PART

NUMBER

MAT'L

CODE

1 PUMP CASING

2 IMPELLER

See Note Below

4170D 10010

3 MECH SEAL ASSY

4 DISCHARGE FLANGE

5 STUD

6 HEX NUT

25285-855

1753A

C1009

D10

7 DISCH FLANGE GASKET 1674GB

---

10010

15991

15991

20000

8 PUMP CASING GASKET 4156GA

9 IMP ADJ SHIM SET

10 SEAL PLATE

11 HEX HD CAPSCREW

12 LOCKWASHER

13 SHAFT SLEEVE

14 SLINGER RING

2X

5349A

B0604

J06

2146F

2352

15 OIL SEAL

16 PIPE PLUG

17 PEDESTAL

18 BALL BEARING

19 BEARING CAP

20 SHAFT KEY

21 IMPELLER SHAFT

S29

S1703

7639C

N0610

5343A

20000

17090

10010

15991

15991

16000

19120

---

---

10010

S375 ---

38324-407 10010

15990

15010

22 OIL SEAL

23 RETAINING RING

24 HEX HD CAPSCREW

25 LOCKWASHER

26 GASKET/SHIM SET

27 PIPE PLUG

28 SIGHT GAGE

29 PIPE PLUG

30 BALL BEARING

31 BEARING CAP

S1465

S442

B0605

J06

---

---

15991

15991

48211-043 ---

P06 15079

26714-011 ---

P06 15079

S1088

7622

---

10010

QTY

1

4

4

1

1

1

1

1

1

1

1

1

1

1

4

4

1

1

1

1

1

1

1

1

1

1

1

1

4

4

ITEM

NO.

PART NAME PART

NUMBER

MAT'L

CODE

QTY

32 HEX HD CAPSCREW

33 LOCKWASHER

34 STUD

35 HEX NUT

36 PIPE PLUG

37 WASHER

38 CAP SCREW

39 LOCKWASHER

40 WEAR RING

41 CVR PLATE GASKET

42 COVER PLATE

43 STUD

44 HEX NUT

45 STUD

46 HEX NUT

47 SUCTION FLANGE

48 FLANGE GASKET

49 FILL PLUG ASSY

50 IMPELLER KEY

NOT SHOWN:

ROTATION DECAL

NAME PLATE

DRIVE SCREW

G‐R DECAL

LUBE DECAL

INSTRUCTION TAG

INSTRUCTION TAG

SUCTION STICKER

PRIMING STICKER

DISCHARGE STICKER

B0403

J04

C0807

D08

P04

6750A

BT0804S

J08

4158A

4635GA

4635

C0606

D06

C1009

D10

1753A

20000

10010

15991

15991

15991

15991

10010

1674GB 20000

48271-062 ---

N0407-3/4 15990

15991

15991

15991 12

15991 12

4

4

15079

17000

1

1

15991

15991

10010

1

1

1

4

4

1

4

4

1

1

1

1

1

2613M ---

38818-018 13990

BM#04-03 17000

GR-03 ---

38816-079 ---

38817-011 ---

38817-028 ---

6588AG

6588AH

6588BJ

---

---

---

4

1

1

1

1

1

1

1

1

1

INDICATES PARTS RECOMMENDED FOR STOCK

INCLUDED WITH REPAIR PUMP CASING ASSY 46471-255 --1


OM-01177 0 SERIES

PUMP AND SEAL DISASSEMBLY

AND REASSEMBLY


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 Figure 1) and the accom panying parts list.

This manual will alert personnel to known proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices.

Before attempting to service the pump, switch off the power source to ensure that the pump will re main inoperative. Close all valves in the suction and discharge lines.

For power source disassembly and repair, consult the literature supplied with the power source, or contact your local power source representative.





Pump Casing and Wear Ring Removal

Before attempting to service the pump, remove the hex nuts (44) securing the cover plate (42) and drain the pump. Clean and reinstall the cover plate.

To service the wear ring (40), impeller (2), seal as sembly (3), or seal plate (10), the pump casing (1) must be separated from the base and pedestal

(17).

Remove the suction and discharge lines. Remove the nuts (35) and use a suitable hoist and sling to separate the pump casing and gasket (8) from the seal plate and pedestal.


Tie and tag any leveling shims used under the cas ing feet to ease reassembly.

Inspect the wear ring (40) for excessive wear or scoring. The wear ring is secured in the pump cas ing by a press fit. If replacement is required, use a small bit to drill two holes through the ring horizon tally, 180 apart. Use a saw or chisel to complete the cuts through the ring, and remove it from the pump casing. Use caution not to damage the pump casing bore when removing the wear ring.





PAGE E - 4

Use caution not to damage the pump cas ing bore when removing the wear ring.


0 SERIES OM-01177

Impeller Removal

To remove the impeller (2), block impeller rotation and disengage the hardware (37, 38 and 39). In stall 3/8-16 UNC by 4‐inch long capscrews in the tapped holes in the impeller. Use the capscrews and a suitable puller to remove the impeller from the shaft. Use caution when removing the impeller; tension on the seal spring will be released as the impeller is removed. Retain the impeller key (50).

Remove the impeller adjusting shims (9). Tie and tag the shims or measure and record their thick ness for ease of reassembly.

Seal Removal and Disassembly

(Figures 1 and 2)

Remove the seal spring. Slide the shaft sleeve (13) and rotating portion of the seal off the shaft as a unit.

Apply oil to the sleeve and work it up under the rub ber bellows. Slide the rotating portion of the seal off the shaft sleeve.

Remove the hardware (11 and 12) and slide the seal plate and stationary element off the impeller shaft as a unit. Press the stationary seal element and O‐ring out of the seal plate from the back side.

Shaft And Bearing Removal And Disassembly

When the pump is properly operated and main tained, the pedestal should not require disassem bly. Disassemble the shaft and bearings only when there is evidence of wear or damage.

cap (31) and oil seal (15) off the shaft. Press the oil seal from the bearing cap.

Disengage the hardware (24 and 25) and slide the assembled bearing cap (19) and oil seal (22) off the shaft. Tie and tag bearing gasket/shim set (26) for ease of reassembly. Press the oil seal from the bearing cap.

Place a block of wood against the impeller end of the shaft and tap the shaft (21) and assembled bearings (18 and 30) from the bearing housing.

After removing the shaft and bearings, clean and inspect the bearings in place as follows.

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 bearing housing, shaft and all compo nent parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary.

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.

Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel.

Remove the pedestal drain plug (27) and drain the lubricant. Clean and reinstall the drain plug.

Remove the slinger ring (14). Disengage the hard ware (32 and 33) and slide the assembled bearing


Bearings must be kept free of all dirt and foreign material. Failure to do so will great ly shorten bearing life. Do not spin dry bearings. This may scratch the balls or

PAGE E - 5

OM-01177 0 SERIES races and cause premature bearing fail ure.

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 shaft and a snug slip fit into the pedestal.

Replace the bearings, shaft, or pedestal if the proper bearing fit is not achieved.

If bearing replacement is required, remove the out board bearing retaining ring (23) and use a suit able bearing puller to remove the bearings from the shaft.

Shaft And Bearing Reassembly And

Installation

Clean the pedestal, shaft and all component parts

(except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or dam age as necessary.


Inspect the shaft for distortion, nicks or scratches, or for thread damage on the impeller end. Dress small nicks and burrs with a fine file or emery cloth.

Replace the shaft if defective.

Position the oil seal (15) in the bearing cap (31) with the lip positioned as shown in Figure 1. Press the oil seal into the bearing cap until the face is just flush with the interior surface of the bearing cap.

Apply a thin film of “Loctite No. 515 Gasket Elimina tor” (or equivalent compound) to the face of the bearing cap (31) and secure the cap to the pedes tal with hardware (32 and 33).

PAGE E - 6

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.

The bearings may be heated to ease installation.

An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bear ings 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 the bearings onto the shaft, one at a time, until they are fully seated. This should be done quickly, in one con tinuous motion, to prevent the bearings from cool ing and sticking on the shaft.

After the bearings have been installed and allowed to cool, check to ensure that they have not moved away from the shaft shoulders in shrinking. If movement has occurred, use a suitably sized sleeve and a press to reposition the bearings against the shaft shoulders.

If heating the bearings is not practical, use a suit ably sized sleeve and an arbor (or hydraulic) press to install the bearings on the shaft.

When installing the bearings onto the shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.

Secure the outboard bearing to the shaft with the retaining ring (23).

Lubricate the lip seal area of the shaft, and slide the shaft and assembled bearings into the pedestal


0 SERIES OM-01177 until the inboard bearing seats against the inboard bearing cap. Use caution not to roll or cut the lip of the oil seal (15).

When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage.

Install the complete set of gasket/shims (26) on the pedestal side of the bearing retaining ring with the split at the 12:00 position.

Press the oil seal (22) into the bearing cap (19) with the lip positioned as shown in Figure 1. The face of the oil seal should be flush with the outside of the bearing cap.

Secure the bearing cap to the pedestal with the hardware (24 and 25). Be careful not to damage the oil seal lip on the shaft keyway.

Install the slinger ring (14).

Lubricate the bearing housing as indicated in LU

BRICATION .

Seal Reassembly and Installation

(Figures 1 and 2)

Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.


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. If any components are worn, replace the com plete 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. Discard the spring centering washer in cluded with the seal. It is not used in this applica tion.

To ease installation of the seal, lubricate the bel lows and O‐rings with water or a very small amount of light lubricating oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as follows, (see Figure 2).


OM-01177

SPRING

RETAINER

0 SERIES

ROTATING

ELEMENT

O‐RING

STATIONARY

SEAT

IMPELLER

IMPELLER

ADJUSTING

SHIMS

IMPELLER

SHAFT

SHAFT

SLEEVE

SEAL

PLATE

BELLOWS temperatures above 160 F (71

Figure 2. Seal Assembly sleeve until the seal face is just flush with the under cut end of the sleeve.

This seal is not designed for operation at

C). Do not use at higher operating temperatures.

Lay the seal plate (10) on a flat surface with the im peller side facing up.

Slide the assembled shaft sleeve and rotating por tion of the seal and onto the shaft until the polished faces contact. Continue to push the sleeve through the seal until it is fully seated against the shaft shoulder.

Install the seal spring.

Subassemble the O‐ring onto the stationary ele ment and use even pressure to press this subas sembly into the seal plate until it seats squarely against the shoulder bore.

Carefully slide the assembled seal plate and sta tionary seal element over the shaft. Use caution not to nick or damage the stationary seat. Secure the seal plate to the pedestal with the hardware (11 and 12).

Subassemble the rotating element into the retainer and bellows. Lubricate the I.D. of the bellows with water, and slide this subassembly over the shaft

PAGE E - 8

Impeller Installation

Inspect the impeller and replace it if cracked or badly worn.

For maximum pump efficiency, the impeller should be centered within the volute scroll.

To verify the impeller positioning, measure the pump casing and impeller as shown in Figure 3.

Use these measurements to calculate the required impeller location (dimension E). Add or remove im peller adjusting shims (9) until dimension E is ob tained.


0 SERIES OM-01177

C

D

2

D

A

B

2

B

E

Step 1

A+

B

2

Step 2

-

C+

D

2

= E

Step 3

Figure 3. Centering Impeller Within Volute Scroll

Install the correct thickness of impeller shims and install the impeller key (20) in the shaft keyway.

Align the impeller keyway with the key and slide the impeller onto the shaft until fully seated.

Final Pump Assembly

Be sure the pump and power source are securely mounted to the base.

NOTE

After the impeller has been properly positioned, check for free rotation. Correct any scraping bind ing before further reassembly.

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, pedestal and power source have been properly lubricated, see LUBRICA

TION .

When the impeller is properly positioned, secure it with the hardware (37, 38 and 39).

Fill the pump casing with clean liquid. Reinstall the fill plug (49) and tighten it.

Pump Reassembly Refer to OPERATION , Section C, before putting the pump back into service.

If removed at disassembly, press the replacement wear ring (40) into the pump casing until it seats squarely against the shoulder bore.

LUBRICATION

Seal Assembly

The seal assembly is lubricated by the medium be ing pumped and no additional lubrication is re quired.

The wear ring must seat squarely in the casing bore or binding and/or excessive wear will result.

Install the casing gasket (8) and secure the casing to the seal plate and pedestal with the nuts (35).

Reinstall any leveling shims under the casing mounting feet, and secure the casing to the base with the previously removed hardware.


Bearings

The pedestal was fully lubricated when shipped from the factory. Check the oil level regularly through the sight gauge (28) and maintain it at the middle of the gauge. When lubrication is required,

PAGE E - 9

OM-01177 0 SERIES add SAE No. 30 non‐detergent oil through the hole for the air vent (16). Do not over‐lubricate. Over‐lu brication can cause the bearings to over‐heat, re sulting in premature bearing failure.

NOTE

The white reflector in the sight gauge must be posi tioned horizontally to provide proper drainage.

tinuously or installed in an environment with rapid temperature change.

Under normal conditions, drain the bearing hous ing once each year and refill with clean oil. Change the oil more frequently if the pump is operated con

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.

For cold weather operation, consult the factory for the recommended grade of oil.

PAGE E - 10 MAINTENANCE & REPAIR

For Warranty Information, Please Visit www.grpumps.com/warranty or call:

U.S.: 419-755-1280

Canada: 519-631-2870

International: +1-419-755-1352

GORMAN‐RUPP PUMPS

Gorman-Rupp Pumps 03A52-B 1327255 and up User Manual 30 Pages

Gorman-Rupp Pumps 03A52-B 1327255 and up User Manual

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

0 SERIES PUMP

MODEL

03A52-B