Whale Gusher 30 Series Assembly Instructions

Thank you for purchasing this Whale® product.
For over 60 years Whale® has led the way in the design and manufacturer of water and waste systems
including:- plumbing, faucets, showers and pumps for low voltage applications. The company and its products have
built a reputation for quality, reliability and innovation backed up by excellent customer service.
For information on our full product range visit: www.whalepumps.com
CONTENTS
1. Principles of Operation
2. Specification
3. Application
4. Warnings
5. Parts List
6. Optional Extras
7. Installation
8. Plumbing
9. Maintenance
10. Trouble Shooting
11. Winterising
12. Service Support Details
13. EU Declaration of Conformity
14. Patents and Trademarks
15. Warranty
LIST OF IMAGES
Fig. 1 Through-deck installation
Fig. 2 Incorrect installation
Fig. 3 Typical installation diagram
Fig. 4 Underdeck installation
Fig. 5 Exploded diagram
Read the following carefully before installation
To the Fitter:
Check that the product is suitable for the intended application. Follow these installation instructions and ensure all
relevant personnel read the points listed below. Also ensure that these operating instructions are passed on to the
end user. The manufacturer cannot be held responsible for claims arising from incorrect installation, unauthorised
modification or misuse of the product.
To the User:
Read the following instructions carefully.
Whale Gusher®30 Pump BP3000 / BP3010 / BP3020
INSTALLATION & USER INSTRUCTIONS
1

This bilge pump is designed to exhaust standing water only. The double acting pump chamber design of the
Gusher® 30 ensures highly efficient throughput with an easy pumping action. Full even strokes will obtain the best
results. The detachable handle is fitted with a lanyard and should be safely secured close to the pump.
This bilge pump is suitable as a primary bilge pump on boats equal to or greater than 12m (40ft). Output capacity
depends on installation, conditions during use and pumping rate. Users should be aware that capacity may not be
sufficient to cope with rapid influx of water. If it is intended for any other purpose or for use with any other liquid, it is
the user’s responsibility to ensure that the pump is suitable for the intended use and, in particular, that the materials
are fully compatible with the liquids to be used.
• The pump is designed to evacuate standing bilge water only. Bilge pump capacities may not be sufficient to
prevent flooding from rapid accumulation of water due to storms, rough weather and/ or rapid leaks created
by hull damage and or unsafe navigational conditions.
• Fitting an inlet strainer will ensure the maximum efficiency of the pump.
• This pump must not be mounted below the water line when connected to an intake or outlet unless the
system has a vented loop (next page see Fig 3 - Typical installation diagram).
•Not suitable for pumping flammable liquids, diesel, chemicals etc. Suitable for bilge water only.
• With all applications, it is important that a system of safe working practice is applied to installation, use and
maintenance. Ensure the waste water system is drained before installation. In order to securely fasten the
1. PRINCIPLES OF OPERATION
4. WARNINGS
2. SPECIFICATION
Model On Deck On Bulkhead Thru Deck Only
Product Code BP3000 BP3010 BP3020
Hose Connections 38 mm (1 1/2”) Hose Connections
Weight 5.05 kg (11.1 lbs) 5.9 kg (13lbs)
Materials
Pump Body: Marine Grade LM6 Aluminium Alloy (epoxy coated).
Diaphragm: Neoprene, Brushes: Acetal, Handwheels: Nylon,
Fasteners: Stainless Steel
Materials In Contact With Fluid Marine Grade LM6 Aluminium Alloy (epoxy coated).
Neoprene, Stainless Steel
Service Kit
AK3051 - Service Kit for Gusher®30
Contains: Diaphragms, Valves, Gasket
AK3020 - Thru Deck Conversion Kit
(for BP3000 includes DP3804 and bridge section)
AS3725 - Gaiter Kit for use with BP3020
AS3016 - Handwheel / Stud Kit
AS3015 - Lever Assembly
Accessories AS3095 Spare Handle
DP3804 Deckplate, AS3020 Deckplate Conversion Kit
Maximum Suction Lift 4 m (13.5ft)
Maximum Discharge Head 4 m (13.5ft)
45 Strokes per Minute 75 ltrs (20 US gals) 71 ltrs (19 US gals) 71 ltrs (19 US gals)
70 Strokes per Minute 117 ltrs (31 US gals) 111 ltrs (29 US gals) 111 ltrs (29 US gals)
3. APPLICATION
2

unit, ensure that the mounting surface is a minimum thickness of 18mm (⁄") as shown in Fig. 4
•NOTE Do not screw directly to the hull - must be mounted on a bulkhead or on an additional board.
BP3000 / BP3010 / BP3020
1 x Gusher® 30 pump
1 x Stainless steel handle
AK3020 - Through Deck Conversion Kit for all 3 models (BP3000 / BP3010 / BP3020)
(BP3000 includes DP3804 and Underdeck Bracket)
SF5425 - 1 1/2” (38mm) Plastic Skinfitting
SB5865 / SB4222 - Top or Side Entry Strainer / Strumbox
DV5606 - 1 1/2” (38mm) 2 Way Diverter Valve
AK3051 - Service Kit (contains diaphragms, valves and gasket)
Please note that incorrect installation may invalidate the warranty.
The Gusher® 30 is designed for mounting on deck or through deck (BP3000), or on deck (BP3010) or through bulk-
head (BP3020).
N.B. The pump must be installed above the waterline.
Choose a position to mount the pump that is dry and away from standing water and is free from obstacles, where the
pump can be operated efficiently and comfortably. Ensure that the pump is installed to allow easy access for servic-
ing.
Avoid installation locations which require a cockpit locker to be opened in order to operate the pump.
To minimise pumping effort, site the pump halfway (in height) between the strumbox / strainer and hull outlet. Mount
in a position with the shortest run lengths possible.
To ensure good priming and flow, avoid sharp bends in pipework and fit a Whale strumbox /
strainer (Part number SB3422 / SB4222 / SB5865 (incorporating a non-return valve)) in order to
prevent the end of the hose sucking against a flat surface and therefore allowing the water level to be reduced to a
minimum.
7.A. For Mounting On Deck/Bulkhead:
1. Use pump as a template, mark off and drill four ¼” (6mm) holes. (Note. if replacing a Gusher® 25 the
mounting holes are the same).
2. Secure the pump with ⁄” (8mm) bolts.
3. Attach either 1½” (38mm) smooth bore reinforced hose with stainless steel worm drive hose clips. Ensure
tight connections. NOTE: Do not overtighten screws or hoseclips.
4. It is recommended that the outlet is mounted above the water line and anti-syphon loops are fitted where
applicable.
6. OPTIONAL EXTRAS
AS3015 - Lever Assembly Service Kit
AS3725 - Gaiter Kit (for BP3020)
AS3016 - Handwheel/Stud Kit
YP6114 - 1 1/2” (38mm) Y Piece
AS3020 - Deckplate Conversion Kit
AS3095 - Spare Handle
DP3804 - Metal Deckplate & Lid
5. PARTS LIST
Fig. 2 Incorrect installation
Fig. 1 Through deck installation
7. INSTALLATION
Fig 3 - Typical installation diagram
3

5. Check the installation for air leaks, correct priming and discharge.
7.B. For Mounting Underdeck or Thru Bulkhead:
1. Using template mark off the four holes for the deck-plate and cut out the hole for the pump handle.
2. The deck thickness must be a minimum of 18mm (⁄”). For thinner decks use a backing plate 8” (200mm)
square of suitable thickness so that the backing plate plus the deck is at least the minimum thickness (stated
above). Bond this to the deck (see Fig. 4).
3. Position pump under deck and check flow direction. Work the rubber gaiter up through the hole until its
flange rests on the deck. Secure the six ¼” (6mm) countersunk mounting screws provided.
4. As points 3 - 5 of Section 7.A.
Use 38mm (1½") smooth bore reinforced pipework to connect to the pump.
Secure the pipework on inlet and outlet with worm drive hose clip.
This Whale Gusher® 30 is designed to only require minimal maintenance.
WARNING: Before servicing pump, drain water from the system.
Inspection:
The diaphragms and inlet valves are held in place by the groove in the pump body and cover. Following inspection,
ensure that they are seated properly in the grooves before tightening the covers in place. Regular inspection of the
pump is recommended. Access to the pump chamber is quick and easy, requiring no tools. Rubber components
should be replaced if worn or every three years regardless of condition.
During periodic shipboard inspections, the bilge pump should be visually inspected to confirm parts are in good
condition, especially rubber parts and mounting arrangements. The pump should be operated to show that it pumps
water efficiently.
Annual Checks
• Whale advises that the boat's plumbing system is checked annually for leaks and obstructions.
Optimal Performance
• Ensure this product is clear of debris.
Replacement components and Service Kits (AK3051) are available from your local chandlery. It is recommended a
service kit is kept on-board.
Changing the Inlet Valves
1. Unscrew the two hand wheels and remove the cover to expose the diaphragm and valves.
2. Remove the inlet valve.
3. Replace with new valve and make sure it is sealed properly before replacing the cover.
4. Repeat for the other side.
Changing the Outlet Valves
1. Remove both covers.
2. Release 4 screws on outlet and inlet ports, remove ports and gaskets.
3. The outlet valves are moulded as 1 unit. Loosen the 2 screws in the centre of the valves and remove the
valves.
9. MAINTENANCE
Fig. 4 Underdeck installation
8. PLUMBING
4
(¼“)
(12¹/“)

4. Keep valve retainers (one located in inlet valve chamber and the other in between the outlet valves).
5. Note that the 2 holes on the valves are not evenly spread. Match these with the large holes on the valve
retainer.
6. Pass the 2 screws through the 2 large holes in the valve retainer and valves, then place resulting assembly
in outlet chamber - located on side of pump.
7. Position valves in the centre of the chamber and pass screws through the pump body.
8. Position second valve retainer in the inlet chamber so the screws are aligned with the smaller holes and then
tighten the screws.
9. Reassemble ports and covers.
Changing the Diaphragm
1. Remove cover and remove clamping screw and plates to release the diaphragms
2. Place new diaphragm in position between the two clamping plates, attach clamping screw and tighten.
3. Repeat for the other side.
To convert a deck mounting model (BP3000) to a bulkhead model (BP3010)
1. Remove covers and diaphragms.
2. Remove the fulcrum bolt by unscrewing the nyloc nut.
3. Remove the lever assembly and re-fit through the alternative aperture in the pump body.
4. Reposition fulcrum bolt, nyloc nut and tighten.
5. Reassemble diaphragms and covers.
Hand wheel nut
DP3804
Deckplate kit
Underdeck bracket
Buffer
2” (50mm) Port
Valve chamber gasket
Valve retainer
Outlet valve
Hand wheel nut
M10 Nylon washer
Clamping plate
M6 Washer Lever assembly
Handle assembly
Cover
M6 Nut
Diaphragm
Body
M8 Nyloc nut
Valve chamber gasket
Clamping plate
1 1/2” (38mm) Port
M6 x 20 Hex. Hd. Screw
M6 x 20 Ch. Hd. Screw
Buffer
Stud
Inlet valve & gasket
M10 Nylon washer
M6 x 20 Ch. Hd. Screw
1 1/2” (38mm) Port
Inlet valve & gasket
2” (50mm) Port
Fig. 5 Exploded diagram
5

Note: Annually at the end of the season, fully drain all water in the pipework and pump chamber. Whale® cannot
guarantee warranty if the system is not fully drained for winterising.
Service kits available: AK3051 (Full Spare Kit) and AS3095 (Spare Handle etc)
For installation or service advice please contact Whale® Customer Support:
Tel: [phone]
Email: [email protected]
www.whalepumps.com
This product complies with all relevant European directives and standards. Please contact Whale® if further details
are required
Manufacturer’s Declaration
We hereby declare, under our sole responsibility, that the enclosed equipment complies the international standard
EN ISO 15083. Also approved by Lloyds (MSCA) and USCG for use in lifeboats and rescue boats or as an
emergency fire pump in accordance with BS ISO 18813 Sections 4.3.2.2 and 4.3.2.3.
Engineering Director
WHALE® and GUSHER® are registered trademarks of Munster Simms Engineering Limited, Bangor, Northern
Ireland trading as Whale and Whale Seaward Inc.
This Whale® product is covered by a 5 year warranty. Please see the enclosed document for details of our
Statement of Limited Warranty.
©Copyright Whale® 2014 - All rights reserved.
Whale’s policy is one of continuous improvement and we reserve the right to change specifications without prior
notice. Illustrations are for guidance purposes only. Please note that by contacting Whale® Support you will be
indicating your consent to receiving product updates, recall information, help guides and appropriate marketing
messages from us via post, email or telephone unless you indicated an objection to receiving such messages.
11. WINTERISING
10. TROUBLE SHOOTING
14. PATENTS AND TRADEMARKS
15. WARRANTY
Fails to prime
Inlet hose fault Check inlet hose connection is airtight, free from blockages and does not
collapse during suction stroke
Diaphragm failure If damaged replace all rubber parts (Part No. AK3051)
Debris in the body
of the pump
May not prevent its operation, but should be removed to prevent
damage
Inlet and/or
outlet valve failure Inspect and remove any debris. If damaged replace (Part No. AK3051)
USA Tel: [phone]
USA Fax: [phone]
Email USA: [email protected]
www.whalepumps.com
12. SERVICE SUPPORT DETAILS
13. DECLARATION OF CONFORMITY, STANDARDS AND APPROVALS
6

7

Munster Simms Engineering Ltd.
2 Enterprise Road, Bangor, N. Ireland BT19 7TA
Tel: [phone]
whalepumps.com [e-mail]
Ref No: db_jw_G30_181.17_v7_0314