Bosworth guzzler ge-0401x User manual

Doc M-PR-09-32.120115
O’M
..
G® GE‐0401ø GE‐0501øD P
for use as Maple Sap Vacuum pumps
GE‐0401D GE‐0401N
GE‐0501D GE‐0501N
Copyright©2015 The Bosworth Company

Guzzler GE-0401xPump Exploded View
1 Doc M-09-32-120115
The Bosworth Company
Note:
GE‐0401N is pictured.
GE‐0401D has gray Body, Flanges, Buons and Intermediate Ring.
Item
#
Part Name
1 Inlet Flange
2 Outlet Flange
3A Top Buon & Stainless Steel
Washer
3B Boom Buon & Stainless Steel
Washer
4B Connecng Rod & Screw
5 Body
6B Intermediate Ring
7C Motor Mounng Plate
12 Miscellaneous Hardware (10‐24
Screws & Nuts)
12C TH1/4‐20x1/2 (1) Diaphragm
Screw
13 Diaphragm
14 Flapper Valves
15 Umbrella Valves (Umbrella
valves (2), Valve Stops (2), O‐
rings (4), Screws & Nuts)
16 Duckbill Valves
18 Rod End Bearing with Nut
18A Rod End Bolt with Washers (2) &
Spacer
19A Crank Arm (18 mm) with 1/4‐20
Set Screws (2)
19B Crank Arm (5/8 in) with 1/4‐20
Set Screws (2)
20 Motor Mounng Bracket
21 GearMotor
22 Switch Box w/On/OffToggle
Switch
22A Motor‐Switch Box Cord with
connectors
22B Power Cord
23 Pump Guard

Guzzler GE-0501xPump - Exploded View
2
The Bosworth Company
Doc M-09-32-120115
Note:
GE‐0501N is pictured
GE‐0501D has white Body, Flanges, Buons and Intermediate Ring.
Item
#
Part Name
1 Inlet Flange
2 Outlet Flange
3A Top Buon & Stainless Steel
Washer
3B Boom Buon & Stainless Steel
Washer
4B Connecng Rod & Screw
5 Body
6B Intermediate Ring
7C Motor Mounng Plate
12 Miscellaneous Hardware (10‐24
Screws & Nuts)
12C TH1/4‐20x1/2 (1) Diaphragm
Screw
13 Diaphragm
14 Flapper Valves
15 Umbrella Valves (Umbrella
valves (2), Valve Stops (2), O‐
rings (4), Screws & Nuts)
16 Duckbill Valves
18 Rod End Bearing with Nut
18A Rod End Bolt with Washers (2) &
Spacer
19A Crank Arm (18 mm) with 1/4‐20
Set Screws (2)
19B Crank Arm (5/8 in) with 1/4‐20
Set Screws (2)
20 Motor Mounng Bracket
21 GearMotor
22 Switch Box w/On/OffToggle
Switch
22A Motor‐Switch Box Cord with
connectors
22B Power Cord
23 Pump Guard

Guzzler GE-0401x/ -0501xPump Installation & Safety Information
The Bosworth Company
3 Doc M-09-32-120115
Your Guzzler pump ships fully assembled and ready to operate.
The pump on/off switch is located on the side of the switch box.
(Figure 1)
You can test the pump’s operation by plugging it into a 115 VAC
outlet and turning it on using the on/off switch. Carefully place
your hand over the inlet port (the shorter of the two pump ports)
of the pump. You will feel the pump sucking your hand toward
the port. Take your hand away and now place it over the outlet
port of the pump. You will feel the pump’s exhaust pushing your
hand away from the port. When you can feel the vacuum creat-
ed at the inlet port and the positive exhaust pressure generated
at the outlet port, the pump is operating properly.
The Guzzler should be securely mounted to a mounting surface prior to
operation. The four pump feet have mounting holes that can accommo-
date a 1/4 in (6.4 mm) diameter bolt or screw. The holes are arranged on
a square, 4-5/16 in (109.5 mm) on a side, inscribed on a bolt circle of di-
ameter 6-1/8 in (155.6 mm). (Figure 2) We recommend countersinking
holes on the bottom of a mounting surface and inserting mounting bolts
up through those holes and through the pump feet. Secure the end of the
bolt with a nut.
Your Guzzler pump has a range of different inlet and outlet ports available
to accommodate a range of different connections to your sap lines and
collection tank tubing. We recommend the use of Quick Connect Cou-
plers so that the pump can be easily disconnected from and reconnected
to your lines.
The pump should be protected from the weather. If it is placed in an en-
closure, be sure to allow adequate airflow around the motor for cooling.
Your Guzzler pump requires 115 VAC power. If power is not readily available, it can be provided from a generator
that supports a minimum 200 running waoutput. (The motor is rated for 1.44 amps at full load.) Be sure that
the generator is actually delivering 115 VAC, however, as deviaons from this voltage – lower or higher – will re-
sult in improper motor operaon.
IMPORTANT SAFETY INFORMATION
NEVER OPERATE YOUR GUZZLER PUMP WITHOUT THE PUMP GUARD PROPERLY IN-
STALLED ON THE PUMP.
NEVER REACH INSIDE THE PUMP OR INSERT ANY OBJECTS INTO THE PUMP WHILE THE
PUMP IS OPERATING. SERIOUS INJURY OR DAMAGE TO THE PUMP WILL RESULT.
ALWAYS CONNECT THE PUMP TO A PROPERLY GROUNDED CIRCUIT. OPERATING THE
PUMP WITHOUT CONNECTION TO A PROPERLY GROUNDED CIRCUIT CAN CREATE A SERI-
OUS RISK OF ELECTRICAL SHOCK.
Mounng holes on pump feet.
Figure 2
6-1/8 in
4-5/16 in
4-5/16 in
On/offswitch located on side of pump.
Figure 1

Pump Installation and Operating Information
4
The Bosworth Company
Doc M-09-32-120115
Your Guzzler Pump is capable of developing 22 in. of Hg vacuum (0.7 bar), but it is a low‐cfm (cubic feet of air per
minute) pump. This means that even very small leaks can prevent the pump from delivering its rated vacuum.
Maintain your tap lines to keep your system tight and address problems that can cause vacuum leaks.
It is best to install your Guzzler at or above collection tank level to avoid shortening diaphragm life. This will re‐
duce the output pressure on the diaphragm, thus reducing mechanical stress on the diaphragm.
When installing your Guzzler Pump, we recommend that you install a shut‐offvalve and a vacuum gauge – in
that sequence – “in front of” the pump; i.e., just before your connecon to the pump’s inlet port. (Figure 3)
If you experience a loss of vacuum in your system – as registered in the gauge near the pump – slowly turn the
shut‐offvalve to isolate the pump from your mainline. DO NOT SHUT THE VALVE SUDDENLY, AS PUMP DAMAGE
MAY RESULT. If the gauge begins to return to normal operang vacuum, then the pump is working properly and
the source of the leak is somewhere in your sap lines or taps. If, on the other hand, the pump fails to recover
normal vacuum, then the pump is the source of the problem, and you should inspect the pump diaphragm and/
or valves for any holes or tears. In the case of the valves, check for any material that may have entered the
pump and lodged in the valve body, prevenng the valve from proper opening and closing.
The motor on your Guzzler Pump has a built‐in cooling fan to keep from overheating. Ensure that the motor has
adequate airflow during operation or it will overheat. Even with adequate ventilation, you may notice that the
motor becomes uncomfortably hot to touch during pump operation. This is normal. The surface temperature of
the motor can become as hot as 175°F (~80°C) during pump operation. If the motor overheats, an internal ther‐
mal sensor will shut the motor off. Should this happen, allow the motor to cool before attempting to restart the
pump.
If there is a risk of freezing conditions, we recommend that you disconnect the pump from your sap lines when
the pump is not running and drain any excess sap from the pump. Sap can freeze within the pump bodies or
lines. If this happens and the pump is turned on, it will result in damage to various pump components, including
pump bodies, valves and diaphragms. We recommend flushing the pump (i.e., letting it pull a full volume of wa‐
ter) and then draining any remaining water from the pump to help prevent freezing.
To shut the pump down and disconnect it from the mainline, first turn the pump off. Then, close the shut‐off
valve to isolate and maintain some vacuum in the mainline. Then disconnect the pump from the mainline, using
Quick Couplers if you have used these for your pump‐to‐mainline connection. Turn the pump back on briefly to
flush any remaining sap from it. Finally, tilt the pump to drain any remaining sap.
Schemac showing recommended shut‐offvalve and vacuum gauge
installed on inlet side of pump.
Figure 3

Maintenance - Changing the Diaphragm
The Bosworth Company
5 Doc M-09-32-120115
Over time, the elastomer components of the pump (i.e., the diaphragm and valves) will fail. Diaphragms tend to
develop a hole or tear. If the diaphragm fails, the pump will continue to operate, but will be unable to create or
maintain a vacuum. Additionally, you will notice sap leaking from the diaphragm and out around the pump
guard. Your Guzzler pump ships with a spare diaphragm. Additional replacement diaphragms can be purchased
through your local maple sap equipment dealer and directly from our
website (www.thebosworthco.com). Note that the GE‐0401x and the GE‐
0501x pumps use the same size diaphragm.
When replacing the diaphragm, close aenon should be paid to the ori‐
entaon of various parts. The use of witness marks may be helpful during
the reassembly.
Remove pump body from aluminum
mounng plate.
Figure 4
1. Disconnect the power.
2. Turn the pump upside down so that it is resng on the pump guard
and motor. With a pencil, mark the side of the mounng plate
next to the pump inlet (the shorter of the two ports).
3. Remove the 10 screws holding the pump body to the aluminum
mounng plate. (Figure 4)
4. Remove the pump body to expose the diaphragm screw aaching
the plasc “buon” (a plasc support plate) to the diaphragm.
5. Remove the sloed head screw, washer, buon and diaphragm
from the aluminum connecng rod. (Figure 5)
6. Ensure the top buon (rounded edge side toward diaphragm) and
stainless steel washer are properly seated on the connecng rod,
and then place the new diaphragm onto the top buon. Reinstall
the boom buon (rounded edge side toward diaphragm) and
stainless steel washer onto the diaphragm and secure all with the
diaphragm screw. Note: Be sure to place the diaphragm on the
connecng rod so that the ridge running along the diaphragm’s
circumference is facing toward you. (The other side of the dia‐
phragm’s outer edge is flat.) Be sure the screw is ght. We recom‐
mend using blue Locte on the screw to help ensure it does not
come loose during pump operaon.
7. Place the pump body up against the diaphragm and align it with
the holes on the Intermediate Ring and Mounng Plate. Be sure
that the diaphragm’s outer lip sits in the groove running around
the circumference of the pump body. (Figure 6) (Note: Ensure
the pump body is installed in the correct orientaon, with the
inlet next to the mounng plate witness mark made in Step 2.)
8. Fasten the pump body to the mounng plate using the 10 screws
and nuts. Start all screws and nuts before ghtening them
down. Tighten to a maximum of 30 in‐lbs of torque. Tighten
screws evenly (crisscross paern). Do not completely ghten
screws unl everything is aligned.
Outer lip of diaphragm fits into groove on
pump body.
Figure 6
Remove diaphragm screw.
Figure 5

Maintenance - Changing Pump Valves
6
The Bosworth Company
Doc M-09-32-120115
There are two valves in each Guzzler pump. One valve is located between the pump body and the inlet port; the
other, between the pump body and the outlet port. Your Guzzler pump may be equipped with either duckbill
valves or umbrella valves, depending on the pump options chosen.
The duckbill valve is shaped like a bird’s beak. When pressure is placed on the outside of the beak, it forces it to
close; when pressure is placed on the other end of the valve, it forces the beak to open so that fluid may pass.
(Figure 7A‐B) The duckbill valve on the GE‐0501x series pumps is slightly larger than that on the GE‐0401x pumps.
The other kind of valve available for your pump is an
umbrella valve. The umbrella valve features a rubber
valve with a flat round disk held under tension against a
plastic plate (the “valve stop”) that contains a number
of holes or “pores”. (Figure 8)
When pressure is applied to one side of the valve stop,
it pushes the rubber disk away from the holes, like an
umbrella turning inside out. (Figure 9A‐B) When this
happens, fluid or air can pass through the holes. When
the pressure is reversed, the rubber disk is forced
against the holes, making a tight seal to prevent any
fluid or air from passing.
Either kind of valve can be fouled by material in the sap (e.g., wood shavings from taps, plastic shavings from tub‐
ing, etc.) that is too large to pass through the valve. When this happens, the diaphragm will be unable to develop
any vacuum. However, unlike the case of a diaphragm failure, valve malfunction will not result in any sap leaking
from the pump. If you were to disconnect the pump from your tap lines and perform the simple pump check
described on page 3, you would feel no vacuum pulling from the inlet port. To correct the problem the valve
should be removed, inspected and cleaned. Several of the steps involved in doing this are the same as the steps
required to change a valve. (Instructions on changing valves are provided on page 7.)
GE‐0401x Duckbill valve (le: Closed; right: Open)
Figure 7A
GE‐0401x umbrella valve (le: Closed; right:
Open)
Figure 9A
GE‐0501x umbrella valve (le: Closed; right:
Open)
Figure 9B
Figure 8
Umbrella valve stop on GE‐
0401x pump. Four mounng
holes on periphery. Valve
stem retaining hole in cen‐
ter. Six valve “pores” to
admit air/fluid flow.
Umbrella valve. Stem
“snaps” into center valve
stop retaining hole.
GE‐0501x Duckbill valve (le: Closed; right: Open)
Figure 7B

Maintenance - Changing Pump Valves
The Bosworth Company
7 Doc M-09-32-120115
In the case of the umbrella valve, material may become lodged in the umbrella valve pores, preventing the rub-
ber umbrella valve from sealing tightly against the valve stop. The duckbill valve is generally better able to pass
fluid containing some debris or material. Nonetheless, it is also possible for material to become lodged in the
valve, preventing it from properly closing, resulting in loss of vacuum. If there is a loss of vacuum, inspect the
valves and remove any foreign material that may be obstructing valve function.
Valves are typically replaced in pairs; i.e., the inlet and outlet valve of a given pump body are replaced at the
same Ɵme. The process of valve replacement is similar whether your pump contains duckbill valves or umbrella
valves. Care must be taken to install the valves in the proper orientaƟon.
Duckbill valves must be installed so that their pointed edge points in the direcƟon of fluid flow. (Figure 10A)
On the inlet side, the duckbill valve points into the pump body; on the outlet port, it points away from the pump
body.
Umbrella valves have a flat side and a side with a valve stem. Umbrella valves must be installed so that their
valve stems point in the opposite direcƟon to fluid flow. (Figure 10B) On the inlet side, the umbrella valve stem
points away from the pump body; on the outlet port, the stem points toward the pump body.
Changing Pump Valves
1. Disconnect the power.
2. For ease of access, turn the pump upside down so
that it is resƟng on the pump guard and motor.
3. Remove the screws holding the inlet flange to the
pump body. (Figure 11) (GE-0401x pump has 4
screws; GE-0501x has 6 screws.) The valve is located
between this flange and the pump body.
Pointed edge of duckbill valves point along the direcƟon of
fluid flow. (Example shown for GE-0401x pump)
Figure 10A
Remove screws holding flange to pump body.
Figure 11
NOTE: When replacing a pair of pump valves, it is best that only one valve is removed and replaced before
aƩempƟng to remove and replace the other valve.
Valve stem of umbrella valve points in opposite direcƟon of
fluid flow. (Example shown for GE-0401x pump.)
Figure 10B
Fluid flow Fluid flow

Maintenance - Changing Pump Valves
The Bosworth Company
Doc M-09-32-120115
8
4.Inspectthevalveforanytears.Removeanydirtormaterialthat
mayhavebecomelodgedinthevalve.Forumbrellavalves,in-
spectO-ringsinvalvestopforanysignofwearandreplaceas
necessary.Ensurethattheyarecorrectlyinstalledinthevalve
stopgrooves.(Figure 12)
5.Toreplaceanumbrellavalve,useapairofplierstograsptheflat
poronoftheoldumbrellavalveandpulltheenrevalve
throughthevalvestopcenterretaininghole.(Figure 13) Insert
thestemofthenewvalveintothevalvestopretainingholeso
thattheflatporonofthevalveisonthesamesideofthevalve
stopastheoldvalve.Useplierstograspthestemofthevalve
ontheothersideandpullitcompletelythroughunlitsnaps
intoplace.
6.Posionthenewvalve(ortheinspectedandcleanedold
valve)betweenthepumpbodyandthepumpinlet
flange,takingcaretoorientthevalveasshowninFigure
10onpage7.Fastenthepumpflangeand,forumbrella
valves,thevalvestoptothepumpbodyusingtheflange
screws.
7.Repeatsteps3-6,thismewiththeoutletsideofthe
pump.Be sure to install the outlet valve so it is oriented
as shown in Figure 10.
UmbrellavalvestopwithO-ringinstalledin
grooves.(ExampleshownforGE-0401x
pump.)
Figure 12
Useplierstoremoveoldumbrellavalvefromvalve
stop.(ExampleshownforGE-0401xpump.)
Figure 13
NOTE: IF THE VALVES ARE NOT ORIENTED CORRECTLY IN THE PUMP
FLANGES, THE PUMP WILL NOT FUNCTION PROPERLY AND COULD BE
DAMAGED UPON OPERATION.

Maintenance - Rod End Bearing Lubrication; Replacement Parts
The Bosworth Company
9 Doc M-09-32-120115
The rod end bearing of your Guzzler GE‐0n01x pump has a grease fitting that should be used to periodically lubri‐
cate the bearing. We recommend that the bearing be lubricated every 400 hours of operation or, more fre‐
quently, if operating conditions are such that the bearing begins to make a squeaking noise.
The fitting can be accessed by removing the screw that attaches the front of the pump guard to the back of the
guard plate. (Figure 14) Slide the front of the pump guard off the plate to reveal the grease fitting. (Figure 15)
The fitting can be lubricated with standard multi‐purpose NLGI Grade 2 lithium grease.
Screw aaching front of pump guard to back of guard plate.
Figure 14
Grease fing located on rod end bearing.
Figure 15
Your Guzzler pump comes with a replacement diaphragm. The Bosworth Company sells a full line of replacement
parts for your pump, including replacement diaphragms and valves.
You can order replacement parts directly through your distributor or by going on our website at
www.thebosworthco.com
Replacement Parts