GORMAN-RUPP PUMPS 02K3-E2 1P Application guide

OM-01164-01
January 21, 1981
Rev. B 06‐05‐2013
C
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
1981 The Gorman‐Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
0 SERIES PUMP
MODEL
02K3-E2 1P

Register your new
Gorman‐Rupp pump online at
www.grpumps.com/register.
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
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 - 2............................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................
Materials PAGE B - 3..............................................................
Line Configuration PAGE B - 3......................................................
Connections to Pump PAGE B - 3..................................................
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 - 4................................................
DISCHARGE LINES PAGE B - 4........................................................
Siphoning PAGE B - 4.............................................................
Valves PAGE B - 4................................................................
Bypass Lines PAGE B - 5..........................................................
ELECTRICAL CONNECTIONS PAGE B - 5...............................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
OPERATION PAGE C - 1..............................................................
Lines With a Bypass PAGE C - 1....................................................
Lines Without a Bypass 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..............................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...........................................
PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E - 1................
PERFORMANCE CURVE PAGE E - 1...................................................
PARTS LIST:

TABLE OF CONTENTS
(continued)
ii
Pump Model PAGE E - 3..........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 4.........................
Pump Disassembly PAGE E - 4.....................................................
Impeller Removal PAGE E - 4......................................................
Seal Removal and Disassembly PAGE E - 5..........................................
Seal Reassembly and Installation PAGE E - 5........................................
Impeller Installation PAGE E - 6.....................................................
Pump Reassembly PAGE E - 7.....................................................
Final Pump Assembly PAGE E - 7..................................................
LUBRICATION PAGE E - 7.............................................................
Seal Assembly PAGE E - 7.........................................................

0 SERIES OM-01164
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, self‐
priming centrifugal model with straight‐in suction,
without a suction check valve and close‐coupled to
an electric motor. The pump is designed for han
dling clean liquids that do not contain large en
trained solids. The basic material of construction is
gray iron, with bronze impeller and stainless steel
impeller shaft.
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: [phone]
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
For information or technical assistance on the mo
tor, contact the motor manufacturer's local dealer
or representative.
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.
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-01164
PAGE A - 1SAFETY
SAFETY - SECTION A
This information applies to 0 Series
electric motor driven pumps. Refer to
the manual accompanying the motor
before attempting to begin operation.
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 pro
vide detailed instructions and precau
tions for each specific application or for
every situation that might occur during
maintenance of the unit. Therefore, it is
the responsibility of the owner, installer
and/or maintenance personnel to en
sure that applications and/or mainte
nance procedures not addressed in this
manual are performed only after estab
lishing that neither personal safety nor
pump integrity are compromised by
such applications or procedures.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Disconnect the incoming power to
the motor and lock it out to ensure
that the pump will remain inopera
tive.
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 to handle clean
liquids that do not contain large en
trained solids. Do not attempt to pump
volatile, corrosive, or flammable materi
als which may damage the pump or en
danger personnel as a result of pump
failure.
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 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 cool before servicing.
Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed dis
charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.
Do not install and operate a non‐explo
sion proof motor in an explosive atmo
sphere. Install, connect, and operate
the motor in accordance with the Na

0 SERIESOM-01164
PAGE A - 2 SAFETY
tional Electric Code and all local codes.
If there is a conflict between the instruc
tions in the manual accompanying the
unit and the National Electric Code or
the applicable local code, the National
or local code shall take precedence.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a qu
alified electrician to troubleshoot, test
and/or service the electrical compo
nents of this pump.
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.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.

OM-011640 SERIES
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.
Most of the information pertains to a standard
static lift application where the pump is posi
tioned above the free level of liquid to be pumped.
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
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.
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 Models 02K3-E2 1P

OM-01164 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 motor 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 warnings and cautions con
tained in this manual or affixed to the pump,
and perform all duties indicated. Note the di
rection of rotation indicated on the pump.
Check that the pump shaft rotates counter
clockwise when facing the impeller.
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 motor 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.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a qu
alified electrician to troubleshoot, test
and/or service the electrical compo
nents of this 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
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.
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 intermediate is equipped with mounting foot
holes for mounting the pump to a base.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in
creased suction lift, discharge elevation, and fric
tion losses. See the performance curve and oper
ating range shown on Page E‐1 to be sure your
overall application allows pump to operate within
the safe operation range.

OM-011640 SERIES
PAGE B - 3INSTALLATION
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
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 (457,2 mm) 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
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
(9,5 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.