GORMAN-RUPP 0 SERIES Bedienungsanleitung

OM‐03179‐OP02

June 6, 1995

Rev. E 03‐07‐13

THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO

www.grpumps.com

GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

1995 The Gorman‐Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

0 SERIES PUMPS

MODEL

06D1-GHH 06D3-GHH

06C3-GHH06C1-GHH

Gorman‐Rupp pump online at

www.grpumps.com

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....................................

PREINSTALLATION INSPECTION PAGE B - 1............................................

PUMP INSTALLATION PAGE B - 1......................................................

Pump Specifications PAGE B - 1....................................................

Pump Mounting Dimensions PAGE B - 2............................................

DIMENSIONAL DRAWING PAGE B - 3..................................................

VEHICLE REQUIREMENTS PAGE B - 4.................................................

Tank Preparation PAGE B - 4.......................................................

Brake Installation PAGE B - 4......................................................

Air Cylinder Pressure PAGE B - 4...................................................

POSITIONING PUMP PAGE B - 4.......................................................

Lifting PAGE B - 4.................................................................

Mounting Location PAGE B - 4.....................................................

Mounting Brackets PAGE B - 5.....................................................

Drive Flanges PAGE B - 6..........................................................

DRIVE SHAFT AND LINKAGE CONNECTIONS PAGE B - 6................................

Drive Shaft Alignment PAGE B - 6...................................................

Gear Shift Connections PAGE B - 7.................................................

SUCTION AND DISCHARGE PIPING PAGE B - 9.........................................

Typical System Installation PAGE B - 9..............................................

Piping PAGE B - 10................................................................

Valves PAGE B - 10................................................................

Eductors PAGE B - 11..............................................................

OPERATION - SECTION C PAGE C - 1......................................

PRIMING PAGE C - 1.................................................................

GROUNDING PAGE C - 1.............................................................

STARTING PAGE C - 2................................................................

OPERATION PAGE C - 2..............................................................

Operating Controls PAGE C - 2.....................................................

Shifting Sequence PAGE C - 3.....................................................

OPERATING CHECKS PAGE C - 3......................................................

Leakage PAGE C - 3..............................................................

Strainer Check PAGE C - 3.........................................................

Liquid Temperature And Overheating PAGE C - 3.....................................

Pump Vacuum Check PAGE C - 3..................................................

STOPPING PAGE C - 4................................................................

Cold Weather Preservation PAGE C - 4..............................................

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E - 1................

STANDARD PERFORMANCE CURVE PAGE E - 1........................................

PARTS LISTS:

Pump Model PAGE E - 3..........................................................

TABLE OF CONTENTS

(continued)

Gearbox Assembly PAGE E - 5.....................................................

Gearbox Assembly (Cont'd) PAGE E - 7.............................................

Cross Member Kit PAGE E - 9......................................................

PUMP AND SEAL DISASSEMBLY PAGE E - 10............................................

Removing Pump and Gearbox PAGE E - 10...........................................

Suction Head and Wear Ring Removal PAGE E - 11....................................

Impeller Removal PAGE E - 11......................................................

Seal Removal PAGE E - 11..........................................................

Pump Casing Removal PAGE E - 11.................................................

PUMP AND SEAL REASSEMBLY PAGE E - 11............................................

Pump Casing Installation PAGE E - 12................................................

Seal Reassembly and Installation PAGE E - 12........................................

Impeller Installation PAGE E - 14.....................................................

Suction Head and Wear Ring Installation PAGE E - 15..................................

Installing Pump and Gearbox PAGE E - 15............................................

Final Pump Assembly PAGE E - 15..................................................

GEARBOX DISASSEMBLY PAGE E - 15..................................................

Air Shift Cover Disassembly PAGE E - 16.............................................

Drive Flange Removal PAGE E - 16..................................................

Output Shaft Disassembly PAGE E - 16...............................................

Input Shaft Disassembly PAGE E - 16................................................

Idler Shaft Disassembly PAGE E - 17.................................................

Impeller Shaft Disassembly PAGE E - 17..............................................

Cleaning and Inspecting Bearings PAGE E - 17.......................................

GEARBOX REASSEMBLY PAGE E - 18...................................................

Impeller Shaft Reassembly PAGE E - 18..............................................

Idler Shaft Reassembly PAGE E - 18.................................................

Input Shaft Reassembly PAGE E - 19.................................................

Output Shaft Reassembly PAGE E - 20...............................................

Air Shift Cover Reassembly PAGE E - 20..............................................

Pressure Testing PAGE E - 20.......................................................

Drive Flange Installation PAGE E - 21................................................

LUBRICATION PAGE E - 21.............................................................

Seal Assembly PAGE E - 21.........................................................

Trunnion Bracket PAGE E - 21.......................................................

Gearbox Assembly PAGE E - 21.....................................................

Intermittent (Normal Refueler) Duty Cycle PAGE E - 21.................................

Continuous Pumping Duty Cycle PAGE E - 22.........................................

0 SERIES OM-03179

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 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.

These pumps are 0 Series, enclosed impeller, self‐

priming centrifugal models, with straight‐in suction

without a suction check valve. They are designed

for vehicular mounting in petroleum service.

The pumps are close‐coupled to an integral, 1750

RPM (06C) or 19000 RPM (06D) split‐shaft gearbox

speed increaser with a 2.56:1 ratio. Power is trans

mitted to the gearbox through a customer‐installed

universal shaft assembly.

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: (419) 755-1011

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2870

For information or technical assistance on the truck

chassis, contact the truck manufacturer's local

dealer or representative.

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-03179

PAGE A - 1SAFETY

SAFETY - SECTION A

This information applies to 0 Series

split‐shaft refueler pumps. Gorman‐

Rupp has no control over or particular

knowledge of the truck chassis which

will be used. Refer to the manual ac

companying the truck before attempt

ing 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, or take other ac

tion to ensure that the pump will re

main 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, or

any liquids which may damage the

pump or endanger personnel as a result

of pump failure.

If this pump is used with volatile and/or

flammable liquids, be certain proper

safety practices are followed before op

erating or servicing the pump. Provide

adequate ventilation, prohibit smoking,

wear static resistant clothing and

shoes. Clean up all fuel spills immedi

ately after occurrence.

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.

If this pump is used with volatile and/or

flammable liquids, overheating may

produce dangerous fumes. Take pre

cautions to ensure the area surrounding

the pump is adequately ventilated. Al

low the pump to cool and use extreme

caution when venting the pump, or

when removing covers, plates, plugs, or

fittings.

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

0 SERIES

OM-03179

PAGE A - 2 SAFETY

gaged to be ejected with great force. Al

low the pump to cool before servicing.

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.

Never tamper with the governor to gain

more power. The governor establishes

safe operating limits that should not be

exceeded. Limit the maximum input

speed and operating range as indicated

on the Performance Curve on Page E‐1.

The gearbox provided on this pump is

designed for operation at a maximum in

put speed of 1750 RPM (06C) or 1900

RPM (06D). If operated at a higher RPM,

pump or gearbox components may be

destroyed.

Decals and tags vital to pump operation

were shipped loose with the pump. Affix

these decals in a prominent place vis

ible to the pump operator.

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.

This pump has been shipped dry of gear

box lubrication, except for a residual coat

ing from the testing process of 90 weight

gear oil and Dow Corning “MolykoteM

Gear Guard” (an anti‐wear additive, con

sisting of molybdenum disulphide solid lu

bricants suspended in petroleum oil). The

gearbox must be lubricated before the

pump is operated (see LUBRICATION in

Section E).

OM-031790 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.

Do not test or operate this pump and in

tegral gearbox before reading the in

stallation and operation instructions in

this manual.

This pump is an 0 Series, semi‐enclosed impeller,

self‐priming centrifugal model with straight‐in suc

tion, and an integral split‐shaft gearbox assembly.

The pump is designed for vehicular mounting in

petroleum service, where the liquid is supplied to

the pump under pressure. The gearbox replaces a

part of the main drive shaft connecting the trans

mission to the rear axle.

This design permits full utilization of engine power

to selectively operate either the pump or the rear

driving wheels on the vehicle. Both cannot be op

erated at the same time.

For further assistance, contact your Gorman‐Rupp

distributor or the Gorman‐Rupp Company.

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 gearbox and/or the accom

panying 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.

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.

PUMP INSTALLATION

Pump Specifications

See Table 1 and 2 for the typical pump specifica

tions and gearbox data.

OM-03179 0 SERIES

PAGE B - 2 INSTALLATION

Table 1. Pump Specifications

Pump Type Self‐priming, centrifugal with enclosed impeller................................

Suction 6-inch “Victaulic” fitting....................................................

Discharge 4-inch petroleum flange................................................

Nominal Capacity See the Performance Curve, Page E-1.............................

Impeller Shaft Seal Mechanical self‐lubricated........................................

Gearbox (Air Shift)

Air Pressure Required at Shift Cylinder 70-140 psi (5,1-10,2 kg/cm@) through 1/4” line

Gear Ratio 2.56:1 Speed Increase..................................................

Input shaft Rotation Clockwise (when viewed from the trunnion end)....................

Maximum Input Speed (See the Performance Curve, Page E-1)......................

Input & Output Shaft Heavy‐duty 2-3/4 inch - 10 spline..............................

Input & Output Flanges “Dana” Heavy‐Duty 1810 Series...............................

Lubrication 68 U.S. ounces (2011 ml) - See LUBRICATION, Section E for SAE grade....

16 fl. oz. (18 ml) `MolykoteR M Gear Guard' (Dow Corning)

Approx. Net Weight (06C1-GHH) 384 pounds (174 kg)...................................

Approx. Net Weight (06C3-GHH) 434 pounds (197 kg)...................................

Approx. Net Weight (06D1-GHH) 384 pounds (174 kg)...................................

Approx. Net Weight (06D3-GHH) 434 pounds (197 kg)...................................

Table 2. Through Torque Capacity Based On Shaft and Spline Size

Type of Engine Transmission Max Through Torque

Ft. Lbs.

(M. Kg.)

Diesel Automatic 11,000

(1521)

Diesel Manual 10,000

(1383)

Gasoline Automatic 13,300

(1839)

Gasoline Manual 12,300

(1701)

Pump Mounting Dimensions

A 40-inch (1016 mm) cross member is provided

for mounting the output end of the gearbox, and a

trunnion mount is provided for the input end. This

design provides a flexible three‐point suspension.

The trunnion mount prevents the chassis frame

twist from being transmitted through the gearbox.

See Figures 1 on page B-3 for the physical dimen

sions of the pump.

OM-031790 SERIES

PAGE B - 3INSTALLATION

DIMENSIONAL DRAWING

TOP

MOUNTED AIR

SHAFT

7.25

(184,2)

5.56

(141,2)

23.02

(584,1)

3.625

(92,1)

6.44

(163,6)

INPUT FROM TRANSMISSION ‐ 2.75 (69,9)

DIAMETER ‐ 10 SPLINE SHAFT WITH 1800

SERIES COMPANION FLANGE.

.69

(17,5) DIA., 2 HOLES

12.75

(323,8)

.625‐11 UNC THREAD

4 MOUNTING HOLES

7.09

(180,1)

20.78

(527,8)

.46

(11,7)

2.25

(57,2)

1.38

(35,1)

2.75

(69,9)

4.31

(109,5)

6.56

(166,6)

4.00

(101,6)DIA. DISCHARGE

OUTPUT TO REAR AXLE

2.75 (69,9) DIA. - 10 SPLINE SHAFT

WITH 1800 SERIES COMPANION FLANGE.

2.25

(57,2)

DIA.

2.00

(50,8)

1.94

4.06

(101,6)

40.00

(1016,0)

20.00

(508,0)

FURNISHED LENGTH

FURNISHED

LENGTH

10.64

(270,2)

16.68

(423,7)

1.69

(42,9)

4.06

(103,1)

(49,3)

1.19

(30,2)

3.67

(93,2)

9.50

(241,3)

16.31

(414,3)

8.70

(221,0) 17.76

(451,1)

22.57

(573,3)

3.50

(88,9)

4.31

(109,5)

4.81

(122,2)

.375-16 UNC STUDS

A 5.88 (149,4) DIA. B.C.

.500 -13 UNC

THREAD

2 MOUNTING HOLES

1.00 (25,4) DEEP.

6.00

(152,4)VICTAULIC

SUCTION

2.00 NPT

DRAIN PLUG

CROSS

MEMBER

DIMENSIONS:

INCHES

(MILLIMETERS)

2.50

(63,5)

7.50

(190,5)

5.50

(139,7)

10.89

(276,6)

1.00

(25,4)

2.00

(50,8)

Figure 1. Pump Model 06C/D-GHH Pump Model Dimensions

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