BC OM-01166-02

January 21, 1981

Rev. C 06‐05‐2013

INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST

0 SERIES PUMP

MODEL

02K3-X2 1P

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
 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

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:

i
 TABLE OF CONTENTS
(continued)

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

ii
0 SERIES OM-01166

INTRODUCTION
Thank You for purchasing a Gorman‐Rupp pump. dures not addressed in this manual are performed
Read this manual carefully to learn how to safely only after establishing that neither personal safety
install and operate your pump. Failure to do so nor pump integrity are compromised by such prac­
could result in personal injury or damage to the tices.
pump.
The following are used to alert maintenance per­
This Installation, Operation, and Maintenance sonnel to procedures which require special atten­
manual is designed to help you achieve the best tion, to those which could damage equipment, and
performance and longest life from your Gorman‐ to those which could be dangerous to personnel:
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 explosion‐proof electric motor. The pump is de­
signed for handling clean liquids that do not con­ Immediate hazards which WILL result in
tain large entrained solids. The basic material of severe personal injury or death. These
construction is gray iron, with bronze impeller and instructions describe the procedure re­
stainless steel impeller shaft. quired and the injury which will result
from failure to follow the procedure.
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:
Hazards or unsafe practices which
The Gorman‐Rupp Company
COULD result in severe personal injury
P.O. Box 1217
or death. These instructions describe
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
the procedure required and the injury
or: which could result from failure to follow
Gorman‐Rupp of Canada Limited the procedure.
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870

Hazards or unsafe practices which COULD

For information or technical assistance on the mo­
result in minor personal injury or product
tor, contact the motor manufacturer's local dealer
or property damage. These instructions
or representative.
describe the requirements and the possi­
This manual will alert personnel to known proce­ ble damage which could result from failure
dures which require special attention, to those to follow the procedure.
which could damage equipment, and to those
which could be dangerous to personnel. However,
this manual cannot possibly anticipate and provide
NOTE
detailed precautions for every situation that might Instructions to aid in installation, operation, and
occur during maintenance of the unit. Therefore, it maintenance or which clarify a procedure.
is the responsibility of the owner/maintenance per­
sonnel to ensure that only safe, established main­
tenance procedures are used, and that any proce­

INTRODUCTION PAGE I - 1
0 SERIES OM-01166

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 pump is designed to handle petro­
This manual will alert personnel to leum products or other industrial liq­
known procedures which require spe­ uids that do not contain large entrained
cial attention, to those which could solids. Do not attempt to pump volatile,
damage equipment, and to those which corrosive, or flammable materials which
could be dangerous to personnel. How­ may damage the pump or endanger per­
ever, this manual cannot possibly pro­ sonnel as a result of pump failure.
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 This pump is designed to handle petro­
and/or maintenance personnel to en­ leum products or other industrial liq­
sure that applications and/or mainte­ uids that do not contain large entrained
nance procedures not addressed in this solids. All controls must meet industry
manual are performed only after estab­ standards and codes for use in an ex­
lishing that neither personal safety nor plosive atmosphere. Do not attempt to
pump integrity are compromised by pump liquids for which the pump and/or
such applications or procedures. controls have not been approved, or
which may damage the pump or endan­
ger personnel as a result of pump fail­
ure.

Before attempting to open or service the

pump:
1. Familiarize yourself with this man­ Be certain proper safety practices are
ual. followed before operating or servicing
2. Disconnect the incoming power to the pump. Provide adequate ventilation,
the motor and lock it out to ensure prohibit smoking, wear static‐resistant
that the pump will remain inopera­ clothing and shoes. Clean up all fuel
spills immediately after occurrence.
tive.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or Do not install and operate a non‐explo­
plugs. sion proof motor in an explosive atmo­
sphere. Install, connect, and operate
5. Close the suction and discharge
the motor in accordance with the Na­
valves. tional Electric Code and all local codes.
6. Vent the pump slowly and cau­ If there is a conflict between the instruc­
tiously. tions in the manual accompanying the
7. Drain the pump. unit and the National Electric Code or
SAFETY PAGE A - 1
OM-01166 0 SERIES

the applicable local code, the National

or local code shall take precedence.

Overheated pumps can cause severe

burns and injuries. If overheating of the
Because this pump is designed to han­ pump occurs:
dle volatile and/or flammable liquids, 1. Stop the pump immediately.
overheating may produce dangerous 2. Ventilate the area.
fumes. Take precautions to ensure the 3. Allow the pump to completely cool.
area surrounding the pump is ade­ 4. Check the temperature before
quately ventilated. Allow the pump to opening any covers, plates,
cool and use extreme caution when gauges, or plugs.
venting the pump, or when removing 5. Vent the pump slowly and cau­
covers, plates, plugs, or fittings. tiously.
6. Refer to instructions in this manual
before restarting the pump.

After the pump has been positioned,

make certain that the pump and all pip­
The electrical power used to operate
ing connections are tight, properly sup­
this pump is high enough to cause inju­
ported and secure before operation.
ry or death. Obtain the services of a qu­
alified electrician to troubleshoot, test
and/or service the electrical compo­
nents of this pump.
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 Use lifting and moving equipment in
low the pump to cool before servicing. 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.
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 Pumps and related equipment must be in­
to a boil, build pressure, and cause the stalled and operated according to all na­
pump casing to rupture or explode. tional, local and industry standards.

PAGE A - 2 SAFETY
0 SERIES OM-01166

INSTALLATION - SECTION B
Review all SAFETY information in Section A. specific application. Since the pressure supplied
to the pump is critical to performance and safety,
Since pump installations are seldom identical, this be sure to limit the incoming pressure to 50% of
section offers only general recommendations and the maximum permissible operating pressure as
practices required to inspect, position, and ar­ shown on the pump performance curve.
range the pump and piping.
For further assistance, contact your Gorman‐Rupp
Most of the information pertains to a standard
distributor or the Gorman‐Rupp Company.
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 Pump Dimensions

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
configuration, and priming must be tailored to the sions of this pump.

OUTLINE DRAWING

Figure 1. Pump Models 02K3-X2 1P

INSTALLATION PAGE B - 1
OM-01166 0 SERIES

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be­

fore shipment from the factory. Before installation, The electrical power used to operate
inspect the pump for damage which may have oc­ this pump is high enough to cause inju­
curred during shipment. Check as follows: ry or death. Obtain the services of a qu­
a. Inspect the pump and motor for cracks,
alified electrician to troubleshoot, test
dents, damaged threads, and other obvious and/or service the electrical compo­
damage. nents of this pump.

b. Check for and tighten loose attaching hard­

POSITIONING PUMP
ware. Since gaskets tend to shrink after dry­
ing, check for loose hardware at mating sur­
faces. Lifting

Pump unit weights will vary depending on the

c. Carefully read all warnings and cautions con­ mounting and drive provided. Check the shipping
tained in this manual or affixed to the pump, tag on the unit packaging for the actual weight, and
and perform all duties indicated. Note the di­ use lifting equipment with appropriate capacity.
rection of rotation indicated on the pump. Drain the pump and remove all customer‐installed
Check that the pump shaft rotates counter­ equipment such as suction and discharge hoses
clockwise when facing the impeller. or piping before attempting to lift existing, installed
units.

Only operate this pump in the direction in­ The pump assembly can be seriously
dicated by the arrow on the pump body damaged if the cables or chains used to lift
and on the accompanying decal. Refer to and move the unit are improperly wrapped
ROTATION in OPERATION, Section C. around the pump.
d. Check levels and lubricate as necessary. Re­
fer to LUBRICATION in the MAINTENANCE Mounting
AND REPAIR section of this manual and per­
form duties as instructed. Locate the pump in an accessible place as close as
practical to the liquid being pumped. Level mount­
ing is essential for proper operation.
e. If the pump and motor have been stored for
more than 12 months, some of the compo­ The intermediate is equipped with mounting foot
nents or lubricants may have exceeded their holes for mounting the pump to a base.
maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv­
ice. SUCTION AND DISCHARGE PIPING

If the maximum shelf life has been exceeded, or if Pump performance is adversely effected by in­
anything appears to be abnormal, contact your creased suction lift, discharge elevation, and fric­
Gorman‐Rupp distributor or the factory to deter­ tion losses. See the performance curve and oper­
mine the repair or updating policy. Do not put the ating range shown on Page E‐1 to be sure your
pump into service until appropriate action has overall application allows pump to operate within
been taken. the safe operation range.

PAGE B - 2 INSTALLATION
 0 SERIES OM-01166

Materials the source of the liquid being pumped; if the line

slopes down to the pump at any point along the
Either pipe or hose maybe used for suction and suction run, air pockets will be created.
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is Fittings
used in suction lines, it must be the rigid‐wall, rein­
forced type to prevent collapse under suction. Us­ Suction lines should be the same size as the pump
ing piping couplings in suction lines is not recom­ inlet. If reducers are used in suction lines, they
mended. should be the eccentric type, and should be in­
stalled with the flat part of the reducers uppermost
Line Configuration to avoid creating air pockets. Valves are not nor­
mally used in suction lines, but if a valve is used,
Keep suction and discharge lines as straight as install it with the stem horizontal to avoid air pock­
possible to minimize friction losses. Make mini­ ets.
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. Strainers

If a strainer is furnished with the pump, be certain

Connections to Pump to use it; any spherical solids which pass through a
strainer furnished with the pump will also pass
Before tightening a connecting flange, align it ex­ through the pump itself.
actly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or cou­ If a strainer is not furnished with the pump, but is
plings. installed by the pump user, make certain that the
total area of the openings in the strainer is at least
Lines near the pump must be independently sup­ three or four times the cross section of the suction
ported to avoid strain on the pump which could line, and that the openings will not permit passage
cause excessive vibration, decreased bearing life, of solids larger than the solids handling capability
and increased shaft and seal wear. If hose‐type of the pump.
lines are used, they should have adequate support
to secure them when filled with liquid and under This pump is designed to handle up to 3/8‐inch
pressure. (9,5 mm) diameter spherical solids.

Gauges Sealing

Most pumps are drilled and tapped for installing Since even a slight leak will affect priming, head,
discharge pressure and vacuum suction gauges. and capacity, especially when operating with a
If these gauges are desired for pumps that are not high suction lift, all connections in the suction line
tapped, drill and tap the suction and discharge should be sealed with pipe dope to ensure an air­
lines not less than 18 inches (457,2 mm) from the tight seal. Follow the sealant manufacturer's rec­
suction and discharge ports and install the lines. ommendations when selecting and applying the
Installation closer to the pump may result in erratic pipe dope. The pipe dope should be compatible
readings. with the liquid being pumped.

SUCTION LINES Suction Lines In Sumps

To avoid air pockets which could affect pump prim­ If a single suction line is installed in a sump, it
ing, the suction line must be as short and direct as should be positioned away from the wall of the
possible. When operation involves a suction lift, the sump at a distance equal to 1 1/2 times the diame­
line must always slope upward to the pump from ter of the suction line.

INSTALLATION PAGE B - 3
OM-01166 0 SERIES

If there is a liquid flow from an open pipe into the tance equal to at least 3 times the diameter of the
sump, the flow should be kept away from the suc­ suction pipe.
tion inlet because the inflow will carry air down into
the sump, and air entering the suction line will re­ Suction Line Positioning
duce pump efficiency.
The depth of submergence of the suction line is
If it is necessary to position inflow close to the suc­ critical to efficient pump operation. Figure 2 shows
tion inlet, install a baffle between the inflow and the recommended minimum submergence vs. veloc­
suction inlet at a distance 1 1/2 times the diameter ity.
of the suction pipe. The baffle will allow entrained
NOTE
air to escape from the liquid before it is drawn into
The pipe submergence required may be reduced
the suction inlet.
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
If two suction lines are installed in a single sump, reduce the inlet velocity. Calculate the required
the flow paths may interact, reducing the efficiency submergence using the following formula based
of one or both pumps. To avoid this, position the on the increased opening size (area or diameter).
suction inlets so that they are separated by a dis­

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES phoning action causing damage to the pump
could result.

Siphoning Valves

If a throttling valve is desired in the discharge line,

Do not terminate the discharge line at a level lower use a valve as large as the largest pipe to minimize
than that of the liquid being pumped unless a si­ friction losses. Never install a throttling valve in a
phon breaker is used in the line. Otherwise, a si­ suction line.

PAGE B - 4 INSTALLATION
 0 SERIES OM-01166

A check valve in the discharge line is normally rec­ ELECTRICAL CONNECTIONS

ommended, but it is not necessary in low dis­
charge head applications.
This pump is driven by an electric motor. Check
With high discharge heads, it is recommended that that the electrical service available matches the
a throttling valve and a system check valve be in­ motor requirements stamped on the motor name­
stalled in the discharge line to protect the pump plate before connecting the motor to the incoming
from excessive shock pressure and reverse rota­ power.
tion when it is stopped.

The electrical power used to operate the

If the application involves a high discharge pump is high enough to cause injury or
head, gradually close the discharge death. Obtain the services of a qualified
throttling valve before stopping the pump. electrician to make all electrical con­
nections.
Bypass Lines

If it is necessary to permit the escape of air to atmo­

sphere on initial priming or during the repriming
cycle, install an air bypass line ‐ sized so that it will
not affect the pump discharge capacity ‐ between Do not install and operate a non‐explo­
the pump and the discharge check valve. Since sion proof motor in an explosive atmo­
this pump does not use a suction check valve, the sphere. Install, connect, and operate
discharge end of the bypass line must be sub­ the motor in accordance with The Na­
merged in the liquid being pumped in order to tional Electric Code and all local codes.
maintain suction. If there is a conflict between the instruc­
tions in the manual accompanying the
NOTE unit and The National Electric Code or
The bypass line may clog frequently if the liquid the applicable local code, The National
contains solids and the valve remains closed. If this or local code shall take precedence.
condition occurs, either use a larger bypass line or
leave the shut‐off valve open during pumping. Refer to the following motor data before making
electrical connections.

MODEL VOLTAGE PHASE HP Hz RPM F.L. AMPS

02K3-X2 1P 115/230 1 2 60 3450 19.8/9.9

GROUNDING tight electrical connection with the rod and the

pump.
Because this pump is used to handle volatile or
flammable liquids, the unit must be grounded by
attaching a ground wire assembly to a ground rod
in order to eliminate electrostatic build‐up by the
liquid being pumped. Install the ground rod in ac­ Inspect and test the ground wire assembly
cordance with the National Electrical Codes and all for conductivity. Replace a broken or
local codes. Be sure the fastening device makes a frayed wire before resuming operation.

INSTALLATION PAGE B - 5
0 SERIES OM-01166

OPERATION - SECTION C

Review all SAFETY information in Section A. Add liquid to the pump casing when:
1. The pump is being put into service for the
Follow the instructions on all tags, labels and first time.
decals attached to the pump. 2. The pump has not been used for a consider­
able length of time.
3. The liquid in the pump casing has evapo­
rated.
Once the pump casing has been filled, the pump
This pump is designed to handle petro­ will prime and reprime as necessary.
leum products and other industrial liq­
uids that do not contain large entrained
solids. Do not attempt to pump volatile,
corrosive, or flammable liquids which
may damage the pump or endanger per­ After filling the pump casing, reinstall
sonnel as a result of pump failure. 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
under pressure could cause injury to
personnel.
Pump speed and operating conditions
must be within the performance range To fill the pump, remove the pump casing fill cover
shown on page E‐1. 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.
PRIMING
STARTING
Install the pump and piping as described in IN­
Consult the operations manual furnished with the
STALLATION. Make sure that the piping connec­
motor.
tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri­
cated (see LUBRICATION in MAINTENANCE
OPERATION
AND REPAIR).
Lines With a Bypass
This pump is self‐priming, but the pump should
Since this pump does not have a suction check
never be operated unless there is liquid in the
valve, the discharge end of the bypass line must be
pump casing.
submerged in order to maintain suction.

Close the throttling valve in the discharge line and

open the shut‐off valve in the bypass line so that
the pump will not have to prime against the weight
of the liquid in the discharge line. Start the motor.
Never operate this pump unless there is When the pump has primed and liquid is flowing
liquid in the pump casing. The pump will steadily through the bypass line, close the bypass
not prime when dry. extended operation of shut‐off valve and open the discharge throttling
a dry pump will destroy the seal assembly. valve.

OPERATION PAGE C - 1
OM-01166 0 SERIES

Lines Without a Bypass

Open all valves in the discharge line and start the

power source. Priming is indicated by a positive
reading on the discharge pressure gauge or by a Allow an over‐heated pump to com­
quieter operation. The pump may not prime imme­ pletely cool before servicing. Do not re­
diately because the suction line must first fill with move plates, covers, gauges, or fittings
liquid. If the pump fails to prime within five minutes, from an over‐heated pump. Liquid with­
stop it and check the suction line for leaks. in the pump can reach boiling tempera­
tures, and vapor pressure within the
After the pump has been primed, partially close the pump can cause parts being disen­
discharge line throttling valve in order to fill the line gaged to be ejected with great force. Af­
slowly and guard against excessive shock pres­ ter the pump completely cools, drain the
sure which could damage pipe ends, gaskets, liquid from the pump by removing the
sprinkler heads, and any other fixtures connected casing drain plug. Use caution when re­
to the line. When the discharge line is completely
moving the plug to prevent injury to per­
filled, adjust the throttling valve to the required flow
sonnel from hot liquid.
rate.
Strainer Check

If a suction strainer has been shipped with the

pump or installed by the user, check the strainer
Do not operate the pump against a regularly, and clean it as necessary. The strainer
closed discharge throttling valve for should also be checked if pump flow rate begins to
long periods of time. If operated against drop. If a vacuum suction gauge has been in­
a closed discharge throttling valve, stalled, monitor and record the readings regularly
pump components will deteriorate, and to detect strainer blockage.
the liquid could come to a boil, build
Never introduce air or steam pressure into the
pressure, and cause the pump casing to
pump casing or piping to remove a blockage. This
rupture or explode.
could result in personal injury or damage to the
equipment. If backflushing is absolutely neces­
Leakage
sary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
No leakage should be visible at pump mating sur­
on the pump performance curve.
faces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maxi­
Pump Vacuum Check
mum pump efficiency.

With the pump inoperative, install a vacuum gauge

Liquid Temperature And Overheating in the system, using pipe dope on the threads.
Block the suction line and start the pump. At oper­
The maximum liquid temperature for this pump is ating speed the pump should pull a vacuum of 20
160 F (71 C). Do not apply it at a higher operat­ inches (508,0 mm) or more of mercury. If it does
ing temperature. not, check for air leaks in the seal, gasket, or dis­
charge valve.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating Open the suction line, and read the vacuum gauge
against closed valves could bring the liquid to a with the pump primed and at operation speed.
boil, build pressure, and cause the pump to rup­ Shut off the pump. The vacuum gauge reading will
ture or explode. If overheating occurs, stop the immediately drop proportionate to static suction
pump and allow it to cool before servicing it. Refill lift, and should then stabilize. If the vacuum reading
the pump casing with cool liquid. falls off rapidly after stabilization, an air leak exists.

PAGE C - 2 OPERATION
0 SERIES OM-01166

Before checking for the source of the leak, check pump components will deteriorate, and
the point of installation of the vacuum gauge. the liquid could come to a boil, build
pressure, and cause the pump casing to
STOPPING rupture or explode.

After stopping the pump, disconnect the incoming Cold Weather Preservation
power to the motor and lock it out to ensure that the
pump will remain inoperative.
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
Do not operate the pump against a ing parts. If the pump will be idle for more than a
closed discharge throttling valve for few hours, drain the pump, and flush it thoroughly
long periods of time. If operated against with clean liquid. Operate the pump during the
a closed discharge throttling valve, draining process.

OPERATION PAGE C - 3
0 SERIES OM-01166

TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.

Before attempting to open or service the

pump:

1. Familiarize yourself with this manual.

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 open­
ing any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO Not enough liquid in casing. Add liquid to casing. See PRIM­
PRIME ING.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
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.

PUMP STOPS OR Air leak in suction line. Correct leak.

FAILS TO DELIVER
RATED FLOW OR Lining of suction hose collapsed. Replace suction hose.
PRESSURE Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leaking or worn seal or gasket.

TROUBLESHOOTING PAGE D - 1
OM-01166 0 SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP STOPS OR Strainer clogged. Check strainer and clean if neces­

FAILS TO DELIVER sary.
RATED FLOW OR
PRESSURE (cont.) Suction intake not submerged at Check installation and correct sub­
proper level or sump too small. mergence as needed.
Impeller or other wearing parts worn Replace worn or damaged parts.
or damaged. Check that impeller is properly
centered and rotates freely.
Impeller clogged. Free impeller of debris.

Suction lift or discharge head too high. Check piping installation and install
bypass line if needed. See INSTAL­
LATION.
Low or incorrect voltage. Measure control box voltage, both
when pump is running and when
shut off.

No voltage at line side of circuit Check power source for blown fuse,
breaker. open circuit breaker or control box,
broken lead, or loose connection.

PUMP REQUIRES Discharge head too low. Adjust discharge valve.

TOO MUCH
POWER Liquid solution too thick. Dilute if possible.

PUMP CLOGS Liquid solution too thick. Dilute if possible.

FREQUENTLY
Discharge flow too slow. Open discharge valve fully to in­
crease flow rate, and run power
source at maximum governed
speed.
EXCESSIVE NOISE Cavitation in pump. Reduce suction lift and/or friction
losses in suction line. Record vac­
uum and pressure gauge readings
and consult local representative or
factory.
Pumping entrained air. Locate and eliminate source of air
bubble.
Pump or drive not securely mounted. Secure mounting hardware.

Impeller clogged or damaged. Clean out debris; replace dam­

aged parts.

PAGE D - 2 TROUBLESHOOTING
0 SERIES OM-01166

PREVENTIVE MAINTENANCE equipped) between regularly scheduled inspec­

tions can indicate problems that can be corrected
Since pump applications are seldom identical, and before system damage or catastrophic failure oc­
pump wear is directly affected by such things as curs. The appearance of wearing parts should also
the abrasive qualities, pressure and temperature be documented at each inspection for comparison
of the liquid being pumped, this section is intended as well. Also, if records indicate that a certain part
only to provide general recommendations and (such as the seal) fails at approximately the same
practices for preventive maintenance. Regardless duty cycle, the part can be checked and replaced
of the application however, following a routine pre­ before failure occurs, reducing unscheduled down
ventive maintenance schedule will help assure time.
trouble‐free performance and long life from your
Gorman‐Rupp pump. For specific questions con­
For new applications, a first inspection of wearing
cerning your application, contact your Gorman‐
parts at 250 hours will give insight into the wear rate
Rupp distributor or the Gorman‐Rupp Company.
for your particular application. Subsequent inspec­
Record keeping is an essential component of a tions should be performed at the intervals shown
good preventive maintenance program. Changes on the chart below. Critical applications should be
in suction and discharge gauge readings (if so inspected more frequently.

Preventive Maintenance Schedule

Service Interval*
Item Daily Weekly Monthly Semi‐ Annually
Annually
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearing Lubrication I R
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V‐Belts (If So Equipped) I
Air Release Valve Plunger Rod (If So Equipped) I C
Front Impeller Clearance (Wear Plate) I
Rear Impeller Clearance (Seal Plate) I
Check Valve I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Bearings I
Bearing Housing I
Piping I
Driver Lubrication - See Mfgr's Literature

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-01166

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 MODELS 02K3-X2 1P

Based on 70 F (21 C) clear water (corrected to Contact the Gorman‐Rupp Company to verify per­
.80 specific gravity) at sea level with minimum suc­ formance or part numbers.
tion lift. Since pump installations are seldom identi­
cal, your performance may be different due to such
factors as viscosity, specific gravity, elevation, tem­
perature, and impeller trim.
Pump speed and operating condition
If your pump serial number is followed by an “N”, points must be within the continuous per­
your pump is NOT a standard production model. formance range shown on the curve.

MAINTENANCE & REPAIR PAGE E - 1

 OM-01166 0 SERIES

SECTION DRAWING
PARTS PAGE

Figure 1. Pump Models 02K3-X2 1P

PAGE E - 2 MAINTENANCE & REPAIR
0 SERIES OM-01166

PARTS LIST
Pump Models 02K3-X2 1P
(From S/N 312560 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 PART MAT'L

NO. PART NAME NUMBER CODE QTY

 1 PUMP CASING See Note Below

2 IMPELLER 10205 14000 1
3 MECHANICAL SEAL 25271-821 --- 1
 4 FILL PLUG ASSY 48271-060 --- 1
5 RD HD MACH SCREW X0402 14990 1
6 RD HD MACH SCREW X0405 14990 1
7 CASING GASKET 2958GB 20000 1
 8 STUD C0606 15991 8
9 HEX NUT D06 15991 8
10 INTERMEDIATE BRACKET 6367C 10010 1
11 STUD C0606 15991 4
12 HEX NUT D06 15991 4
13 LOCK WASHER J06 15991 4
14 1 PHASE MOTOR M33 --- 1
15 REDUCER COUPLING AE1612 15079 1
16 PIPE NIPPLE THA1206 15079 1
17 CONDUIT BOX 27144-124 --- 1
18 IMPELLER ADJUSTING SHIM SET 5889 17000 1
 19 CASING DRAIN PLUG P08 15079 1
20 VANE PLATE 10204 10010 1
 21 PIPE PLUG P04 15079 1
22 IMPELLER JAM NUT AT07S 15991 1
23 NAME PLATE 38818-020 13990 1
24 DRIVE SCREW BM#04-03 17000 4
25 VANE PLATE O‐RING S1487 --- 1

NOT SHOWN:
G‐R DECAL GR-03 --- 1
WARNING DECAL 2613FF --- 1
ROTATION DECAL 2613M --- 1
INSTRUCTION TAG 38817-027 --- 1
SUCTION STICKER 6588AG --- 1
PRIMING STICKER 6588AH --- 1
DISCHARGE STICKER 6588BJ --- 1

INDICATES PARTS RECOMMENDED FOR STOCK

 INCLUDED WITH REPAIR PUMP CASING ASSY 46471-213 --- 1

MAINTENANCE & REPAIR PAGE E - 3

OM-01166 0 SERIES

PUMP AND SEAL DISASSEMBLY 3. Allow the pump to completely cool

AND REASSEMBLY if overheated.
4. Check the temperature before
Review all SAFETY information in Section A.
opening any covers, plates, or
plugs.
Follow the instructions on all tags, label and decals 5. Close the suction and discharge
attached to the pump. valves.
6. Vent the pump slowly and cau­
This pump requires little service due to its rugged, tiously.
minimum‐maintenance design. However, if it be­ 7. Drain the pump.
comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional view (see Figure 1) and the accompa­
nying parts list.
Use lifting and moving equipment in
This manual will alert personnel to known proce­ good repair and with adequate capacity
dures which require special attention, to those to prevent injuries to personnel or dam­
which could damage equipment, and to those age to equipment.
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 Be certain proper safety practices are
sonnel to ensure that only safe, established main­ followed before operating or servicing
tenance procedures are used, and that any proce­ the pump. Provide adequate ventilation,
dures not addressed in this manual are performed prohibit smoking, wear static‐resistant
only after establishing that neither personal safety
clothing and shoes. Clean up all fuel
nor pump integrity are compromised by such prac­
spills immediately after occurrence.
tices.

Before attempting to service the pump, disconnect Pump Disassembly

the incoming power to the motor and lock it out to
Before attempting to service the pump, remove the
ensure that the pump will remain inoperative.
pump casing drain plug (19) and drain the pump.
Close all valves in the suction and discharge lines.
Clean and reinstall the drain plug.
For motor disassembly and repair, consult the liter­ To service the impeller (2), seal assembly (3), or va­
ature supplied with the motor, or contact your local ne plate (20), the pump housing (1) must be sepa­
motor representative. rated from the intermediate (10).

Remove the suction and discharge lines. Remove

the nuts (9) and use a suitable hoist and sling to
separate the pump casing and gasket (7) from the
intermediate. Remove the vane plate O‐ring (25).
Before attempting to open or service the
pump:
1. Familiarize yourself with this man­
ual.
2. Disconnect the incoming power to Use lifting and moving equipment in
the motor and lock it out to ensure good repair and with adequate capacity
that the pump will remain inopera­ to prevent injuries to personnel or dam­
tive. age to equipment. Suction and dis­
PAGE E - 4 MAINTENANCE & REPAIR
0 SERIES OM-01166

charge hoses and piping must be re­

moved from the pump before lifting.

Impeller Removal
Most cleaning solvents are toxic and
For access to the impeller (2), disengage the
flammable. Use them only in a well ven­
screws (5 and 6) and remove the vane plate (20).
tilated area free from excessive heat,
Immobilize the impeller by inserting a bar between sparks, and flame. Read and follow all
the impeller vanes, being careful not to damage precautions printed on solvent contain­
the vanes. Disengage the impeller nut (22). ers.
The seal is not normally reused because wear pat­
Immobilize the motor shaft by inserting a large flat
terns on the finished faces cannot be realigned
head screwdriver into the slot in the end of the shaft
during reassembly. This could result in premature
in the front end of the motor.
failure. If necessary to reuse an old seal in an emer­
gency, carefully wash all metallic parts in fresh
Unscrew the impeller from the shaft. Use caution
cleaning solvent and allow to dry thoroughly.
when removing the impeller; tension on the seal
spring will be released as the impeller is removed. Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
Remove the impeller adjusting shims (18). Tie and
finished faces; even fingerprints on the faces can
tag the shims or measure and record their thick­
shorten seal life. If necessary, clean the faces with a
ness for ease of reassembly.
non‐oil based solvent and a clean, lint‐free tissue.
Wipe lightly in a concentric pattern to avoid
Seal Removal and Disassembly scratching the faces.

Remove the spring retainer and spring. Apply oil to Inspect the seal components for wear, scoring,
the shaft and work it up under the rubber bellows. grooves, and other damage that might cause leak­
Slide the rotating portion of the seal off the shaft. age. If any components are worn, replace the com­
plete seal; never mix old and new seal parts.
Remove the hardware (12 and 13) securing the in­
If a replacement seal is being used, remove it from
termediate (10) to the motor (14). Slide the inter­
the container and inspect the precision finished
mediate off the shaft and use a suitably sized dowel
faces to ensure that they are free of any foreign
to press the seal stationary element and seat out of
matter.
the intermediate from the back side.
To ease installation of the seal, lubricate the bel­
Seal Reassembly and Installation lows with water or a very small amount of light lu­
bricating oil, and apply a drop of light lubricating oil
Clean the seal cavity and shaft with a cloth soaked on the finished faces. Assemble the seal as follows
in fresh cleaning solvent. (see Figure 2).

MAINTENANCE & REPAIR PAGE E - 5

OM-01166 0 SERIES

RETAINER
SPRING SEAL PLATE

IMPELLER
STATIONARY
ELEMENT
IMPELLER
SHIMS

IMPELLER
SHAFT

BELLOWS

DRIVE BAND
SPRING ROTATING
RETAINER ELEMENT STATIONARY
SEAT

Figure 2. Seal Assembly

Subassemble the rotating element into the retainer
and bellows. Lubricate the I.D. of the bellows with
water and slide this subassembly onto the shaft
until the polished faces contact. Install the seal
This seal is not designed for operation at spring and spring retainer.
temperatures above 160F (71C). Do not
use at higher operating temperatures. Impeller Installation

Lay the intermediate (10) on a flat surface with the Inspect the impeller and replace it if cracked or
impeller side facing up. Subassemble the station­ badly worn.
ary element into the stationary seat and use even
For maximum pump efficiency, the impeller should
pressure to press this subassembly into the inter­
be centered within the vane plate scroll.
mediate until it seats squarely against the shoulder
bore. To verify the impeller positioning, measure the
vane plate and impeller as shown in Figure 3. Use
Carefully slide the assembled intermediate and these measurements to calculate the required im­
stationary portion of the seal over the motor shaft. peller location (dimension E). Add or remove im­
Secure the intermediate to the motor with the hard­ peller adjusting shims (18) until dimension E is ob­
ware (12 and 13). tained.

PAGE E - 6 MAINTENANCE & REPAIR

0 SERIES OM-01166

C D

D
2

B
2 E
A B

Step 1 Step 2 Step 3

B - C+ D =E
A+
2 2

Figure 3. Centering Impeller Within Vane Plate Scroll

Install the correct thickness of impeller shims (18) Pump Reassembly
and screw the impeller onto the shaft until fully
seated. Install the vane plate O‐ring (25) onto the vane
plate shoulder. Install the casing gasket (7). Ease
the pump casing over the vane plate. Be careful
Apply “Loctite Threadlocker No. 242” or equivalent not to damage the O‐ring. Secure the casing to the
compound to the impeller shaft threads. Immobi­ intermediate bracket with the nuts (9).
lize the motor shaft by inserting a large flat head
screwdriver into the slot in the end of the shaft in Final Pump Assembly
the front end of the motor. Secure the impeller with
the impeller jam nut (22). Torque the nut to 15 ft. Install the suction and discharge lines and open all
lbs. (180 in lbs. or 2,07 m. kg.). valves. Make certain that all piping connections are
tight, properly supported and secure.

Fill the pump casing with clean liquid. Reinstall the

Clean all of the old adhesive from the vane plate
fill plug (4) and tighten it.
and its mating surface on the intermediate. Apply a
thin film of “3M Gasket Adhesive No. 847” or equiv­ Refer to OPERATION, Section C, before putting
alent compound to the vane plate and secure the the pump back into service.
vane plate to the intermediate bracket using the
machine screws (5 and 6).
LUBRICATION

NOTE Seal Assembly

After the vane plate has been installed, check for
free shaft rotation. Correct any scraping binding The seal assembly is lubricated by the medium be­
before further reassembly. ing pumped and no additional lubrication is re­
quired.

MAINTENANCE & REPAIR PAGE E - 7

For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
International: +1-419-755-1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty
or call:
519-631-2870

THE GORMAN‐RUPP COMPANY  MANSFIELD, OHIO

GORMAN‐RUPP OF CANADA LIMITED  ST. THOMAS, ONTARIO, CANADA