GORMAN-RUPP PUMPS 0 Series Application guide

OM‐03756-02
January 11, 1993
Rev. C 09‐27‐19
GORMAN‐RUPP PUMPS
www.grpumps.com
e1993 Gorman‐Rupp Pumps Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
0 SERIES PUMP
MODEL
03H1-GR /S2

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Please record your pump model and serial number in the
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needs this information when you require parts or service.
Pump Model:
Serial Number:

TABLE OF CONTENTS
i
INTRODUCTION PAGE I - 1.................................................
SAFETY SECTION A PAGE A - 1...........................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................
Materials PAGE B - 2..............................................................
Line Configuration PAGE B - 2......................................................
Connections to Pump PAGE B - 2..................................................
Gauges PAGE B - 3...............................................................
SUCTION LINES PAGE B - 3...........................................................
Fittings PAGE B - 3...............................................................
Strainers PAGE B - 3..............................................................
Sealing PAGE B - 3...............................................................
Suction Lines In Sumps PAGE B - 3.................................................
Suction Line Positioning PAGE B - 3................................................
DISCHARGE LINES PAGE B - 4........................................................
Siphoning PAGE B - 4.............................................................
Valves PAGE B - 4................................................................
ALIGNMENT PAGE B - 4..............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 5.........................................
Typical System Installation PAGE B - 5..............................................
Piping PAGE B - 6................................................................
Sealing PAGE B - 7...............................................................
Valves PAGE B - 7................................................................
Siphoning PAGE B - 8.............................................................
Eductors PAGE B - 8..............................................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
Rotation PAGE C - 1..............................................................
Drive PAGE C - 1.................................................................
OPERATION PAGE C - 2..............................................................
Leakage PAGE C - 2..............................................................
Liquid Temperature And Overheating PAGE C - 2.....................................
Strainer Check PAGE C - 2.........................................................
Pump Vacuum Check PAGE C - 2..................................................
STOPPING PAGE C - 3................................................................
Cold Weather Preservation PAGE C - 3..............................................
GEARBOX TEMPERATURE CHECK PAGE C - 3..........................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................

TABLE OF CONTENTS
(continued)
ii
PUMP MAINTENANCE AND REPAIR SECTION E PAGE E - 1.................
PERFORMANCE CURVE PAGE E - 1...................................................
PARTS LIST:
Pump Model PAGE E - 3..........................................................
Gear Box Assembly PAGE E - 5....................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 6.........................
Removing Pump and Gearbox PAGE E - 6...........................................
Pump Casing and Wear Ring Removal PAGE E - 7....................................
Impeller Removal PAGE E - 7......................................................
Seal Removal and Disassembly PAGE E - 7..........................................
PUMP AND SEAL REASSEMBLY PAGE E - 7............................................
Seal Reassembly and Installation PAGE E - 8........................................
Impeller Installation PAGE E - 9.....................................................
Pump Casing and Wear Ring Installation PAGE E - 9..................................
Installing Pump and Gearbox PAGE E - 10............................................
GEARBOX DISASSEMBLY PAGE E - 10..................................................
GEARBOX REASSEMBLY PAGE E - 11...................................................
LUBRICATION PAGE E - 13.............................................................
Seal Assembly PAGE E - 13.........................................................
Gearbox PAGE E - 13..............................................................

0 SERIES OM‐03756
PAGE I - 1INTRODUCTION
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, cen
trifugal model, with straight‐in suction and without
a suction check valve. The basic material of con
struction for wetted parts is aluminum. The pump is
close‐coupled to an integral, 1000 RPM gearbox
speed increaser with a 4.09:1 ratio that is rotated
180_from the standard position. Power is trans
mitted to the gearbox through a customer‐installed
universal shaft assembly.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety nor pump integrity are com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
If there are any questions regarding the pump or
its application which are not covered in this man
ual or in other literature accompanying this unit,
please contact your Gorman‐Rupp distributor, or
write:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: [phone]
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
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.

0 SERIES OM‐03756
PAGE A - 1SAFETY
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.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Switch off the vehicle ignition and
remove the key to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
This pump is designed for vehicular
mounting in petroleum service. Do not
attempt to pump corrosive materials
which may damage the pump or endan
ger personnel as a result of pump fail
ure.
Be certain proper safety practices are
followed before operating or servicing
the pump. Provide adequate ventilation,
prohibit smoking, wear static‐resistant
clothing and shoes. Clean up all fuel
spills immediately after occurrence.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting.
After the pump has been positioned,
make certain that the pump and all pip
ing connections are tight, properly sup
ported and secure before operation.
Do not operate the pump without the
shields and/or guards in place over the
rotating parts. Exposed rotating parts
can catch clothing, fingers, or tools,
causing severe injury to personnel.
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

0 SERIESOM-03756
PAGE A - 2 SAFETY
to a boil, build pressure, and cause the
pump casing to rupture or explode.
Overheating may produce dangerous
fumes. Take precautions to ensure the
area surrounding the pump is ade
quately ventilated. Allow the pump to
cool and use extreme caution when
venting the pump, or when removing
covers, plates, plugs, or fitting.
Overheated pumps can cause severe
burns and injuries. If overheating of the
pump occurs:
1. Stop the pump immediately.
2. Ventilate the area.
3. Allow the pump to completely cool.
4. Check the temperature before
opening any covers, plates,
gauges, or plugs.
5. Vent the pump slowly and cau
tiously.
6. Refer to instructions in this manual
before restarting the pump.
After the vehicle is positioned for pump
maintenance, block the wheels and set
the emergency brake before attempting
to disconnect the drive shaft or remove
the pump. Be sure the pump is properly
reinstalled and secure before opera
tion.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to completely cool before
servicing.
The gearbox provided on this pump is
designed for operation at 1000 RPM
maximum input speed. If operated at a
higher RPM, pump components may be
destroyed.
Never run this pump backwards. Be cer
tain that rotation is correct before fully
engaging the pump.
Never run the pump dry of pumping me
dium. There must be a supply of liquid to
the pump at all times to prevent destruction
of the shaft seal faces.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.

0 SERIES OM-03756
PAGE B - 1INSTALLATION
INSTALLATION - SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and ar
range the pump and piping.
Do not test or operate your pump and in
tegral gearbox before reading the in
stallation and operation instructions in
this manual.
This pump is a self‐priming centrifugal model with
an integral gearbox assembly. It is designed for ve
hicular mounting in petroleum service, where the
liquid is supplied to the pump under pressure.
Since the pressure supplied to the pump is critical
to performance and safety, be sure to limit the in
coming pressure to 50% of the maximum permissi
ble operating pressure as shown on the pump per
formance curve (see Section E, Page 1).
The integral gearbox is designed to be driven
through the vehicle transfer case by a customer‐
supplied universal shaft assembly. The pump cas
ing or gearbox may be rotated in 45_increments to
assist with alignment with the vehicle tank; howev
er, if the gearbox is to be rotated, some modifica
tions must be made to the gearbox to ensure ade
quate lubrication. Consult the factory for details.
For further assistance, contact your Gorman‐Rupp
distributor or the Gorman‐Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimen
sions of this pump.
OUTLINE DRAWING
Figure 1. Pump Model 03H1‐GR /S2

OM-03756 0 SERIES
PAGE B - 2 INSTALLATION
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.
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.
Before operation, remove the shipping
plug (6) and replace with the reducing
bushing (5) and air vent (4), which are
shipped loose. The air vent must be
installed to prevent the gearbox from over
heating during operation.
The gearbox assembly was lubricated and
tested before it was shipped from the fac
tory; however, the lubricant level must be
checked before putting the pump into ser
vice.
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.
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.
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

0 SERIES OM-03756
PAGE B - 3INSTALLATION
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 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.
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
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 7/16 inch
(11,1 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.
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