GORMAN-RUPP PUMPS 0 Series Application guide

Q OM−03745−02

May 3, 1999

Rev. A 03-31-10

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

www.grpumps.com

GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

e1999 The Gorman-Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

0 SERIES PUMP

MODEL

04E1-GA

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

Pump Dimensions PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREINSTALLATION INSPECTION PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE REQUIREMENTS PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank Preparation PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POSITIONING PUMP PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION AND DISCHARGE PIPING PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical System Installation PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Eductors PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION − SECTION C PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GROUNDING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotation PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leakage PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature And Overheating PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainer Check PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEARBOX TEMPERATURE CHECK PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING − SECTION D PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PERFORMANCE CURVES PAGE E − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LIST:

Pump Model PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E − 4. . . . . . . . . . . . . . . . . . . . . . . . .

Removing Pump and Gearbox PAGE E − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Head and Wear Ring Removal PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal And Pump Casing Wear Ring Removal PAGE E − 5. . . . . . . . . . . . . . . . . . .

Seal Removal and Disassembly PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

(continued)

Pump Casing Removal PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL REASSEMBLY PAGE E − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing Installation PAGE E − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation PAGE E − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller And Pump Casing Wear Ring Installation PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Head and Wear Ring Installation PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Pump and Gearbox PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEARBOX DISASSEMBLY PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEARBOX REASSEMBLY PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0 SERIES OM−03745

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 pump is an 0 Series, enclosed impeller, cen-

trifugal model, with straight-in suction and without

a suction check valve. The pump is equipped with

Victaulic" suction and discharge fittings, and is

designed for vehicular mounting in water or petro-

leum service. The basic material of construction for

wetted parts is aluminum, with cast iron wearing

parts.

The pump is close-coupled to an integral speed in-

creaser with a 2.19:1 input ratio, with a maximum

input speed of 2250 RPM. Power is transmitted to

the gearbox through a customer-installed univer-

sal shaft assembly.

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.

For information or technical assistance on the pow-

er source, contact the power source manufactur-

er’s local dealer or representative.

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

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−03745

PAGE A − 1SAFETY

SAFETY − SECTION A

This information applies to 0 Series

power take-off pumps. Refer to the man-

ual accompanying the vehicle before at-

tempting to begin operation.

Because pump installations are seldom

identical, this manual cannot possibly

provide detailed instructions and pre-

cautions for each specific application.

Therefore, it is the owner/installer’s re-

sponsibility to ensure that applications

not addressed in this manual are per-

formed only after establishing that nei-

ther operator safety nor pump integrity

are compromised by the installation.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man-

ual.

2. Switch off the vehicle ignition and

remove the key to ensure that the

pump will remain inoperative.

3. Allow the pump to cool if over-

heated.

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 water or petroleum service.

Do not attempt to pump corrosive mate-

rials, 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.

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam-

age to equipment. Suction and dis-

charge hoses and piping must be re-

moved from the pump before lifting.

After the pump has been positioned,

make certain that the pump and all pip-

ing connections are tight, properly sup-

ported and secure before operation.

Do not operate the pump without the

guards in place over the rotating parts.

Exposed rotating parts can catch cloth-

ing, fingers, or tools, causing severe in-

jury to personnel.

Do not operate the pump against a

closed discharge valve for long periods

of time. If operated against a closed dis-

charge valve, pump components will

deteriorate, and the liquid could come

0 SERIES

OM−03745

PAGE A − 2 SAFETY

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

fitting.

Allow an overheated pump to cool be-

fore servicing. Do not remove plates,

covers, gauges, pipe plugs, or fittings

from an overheated pump. Liquid within

the pump can reach boiling tempera-

tures, and vapor pressure within the

pump can cause parts being disen-

gaged to be ejected with great force. Af-

ter the pump cools, drain the liquid from

the pump be removing the casing drain

plug. Use caution when removing the

plug to prevent injury to personnel from

hot liquid.

Never run this pump backwards. Be cer-

tain that rotation is correct before fully

engaging the pump.

After the vehicle is positioned for pump

maintenance, block the wheels and set

the emergency brake before attempting

to disconnect the drive shaft or remove

the pump. Be sure the pump is properly

reinstalled and secure before opera-

tion.

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 operation range as indicated

on the performance curves on Page E-1.

The gearbox provided on this pump is

designed for operation at 2250 RPM

maximum input speed. If operated at a

higher RPM, pump components may be

destroyed.

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.

OM−037450 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 your pump and in-

tegral gearbox before reading the in-

stallation and operation instructions in

this manual.

This pump is a self-priming centrifugal model with

an integral speed increasing gearbox assembly.

The pump is designed for vehicular mounting in

water or petroleum service, where the liquid is

supplied to the pump under pressure. Since the

pressure supplied to the pump is critical to per-

formance and safety, be sure to limit the incoming

pressure to 50% of the maximum permissible oper-

ating pressure as shown on the pump perform-

ance curve (see Section E, Page 1).

The integral gearbox is designed to be driven

through the vehicle transfer case by a customer-

supplied universal shaft assembly. The pump cas-

ing or gearbox may be rotated in 45_increments to

assist with alignment with the vehicle tank; howev-

er, if the gearbox is to be rotated, some modifica-

tions must be made to the gearbox to ensure ade-

quate lubrication. Consult the factory for details.

For further assistance, contact your Gorman-Rupp

distributor or the Gorman-Rupp Company.

Pump Dimensions

See Figure 1 for the approximate physical dimen-

sions of this pump.

OUTLINE DRAWING

Figure 1. Pump Model 04E1−GA

OM−03745 0 SERIES

PAGE B − 2 INSTALLATION

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be-

fore shipment from the factory. Before installation,

inspect the pump for damage which may have oc-

curred during shipment. Check as follows:

a. Inspect the pump and gearbox for cracks,

dents, damaged threads, and other obvious

damage.

b. Check for and tighten loose attaching hard-

ware. Since gaskets tend to shrink after dry-

ing, check for loose hardware at mating sur-

faces.

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated.Note the direction of rotation indi-

cated on the pump. Check that the pump

shaft rotates in the required direction.

Only operate this pump in the direction in-

dicated on the pump body and/or the ac-

companying decal. Reverse rotation of the

shaft will adversely effect pump perform-

ance, and the pump and/or gearbox could

be seriously damaged.

d. Check levels and lubricate as necessary. Re-

fer to LUBRICATION in the MAINTENANCE

AND REPAIR section of this manual and per-

form duties as instructed.

e. If the pump and gearbox have been stored for

more than 12 months, some of the compo-

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

or replaced to ensure maximum pump serv-

ice.

If the maximum shelf life has been exceeded, or if

anything appears to be abnormal, contact your

Gorman-Rupp distributor or the factory to deter-

mine the repair or updating policy. Do not put the

pump into service until appropriate action has

been taken.

VEHICLE REQUIREMENTS

The following instructions apply equally to new in-

stallations, rebuilds or retrofits.

Tank Preparation

It is essential that any tank scale, dirt, or other for-

eign material be removed from the tank and piping

prior to pump installation. Failure to do so could re-

sult in clogging or damage to the pump.

Damage to the pump resulting from debris

in the suction line will not be covered by

the pump warranty.

Before connecting the suction and dis-

charge piping, carefully check the storage

tank and piping for construction debris

such as nuts, bolts, wire, weld slag, and

other foreign material. Install a commer-

cially available 80 mesh screen in the suc-

tion line to prevent debris from entering the

pump.

POSITIONING PUMP

Lifting

Pump unit weights will vary depending on the

mounting and drive provided. Check the shipping

tag on the unit packaging for the actual weight, and

use lifting equipment with appropriate capacity.

Drain the pump and remove all customer-installed

equipment such as suction and discharge hoses

or piping before attempting to lift existing, installed

units.

The pump assembly can be seriously

damaged if the cables or chains used to lift

and move the unit are improperly wrapped

around the pump.

Due to the confined mounting location,

specialized equipment such as a transmis-

OM−037450 SERIES

PAGE B − 3INSTALLATION

sion jack with custom brackets should be

used to lift and position the pump and

gearbox.

NOTE

If the gearbox is rotated out of the standard position

shown in Figure 1, the oil fill and drain plugs must

be relocated. The magnetic drain plug must be re-

located to the lowest port, and the oil vent and el-

bow must be relocated to the highest port. Consult

the factory for correct positioning of the fill plug to

provide for proper lubrication of the gearbox.

ALIGNMENT

When installing and/or aligning univer-

sal shaft assemblies, switch off the ve-

hicle ignition and remove the key to en-

sure that the pump will remain inopera-

tive.

The alignment of the pump and its power source is

critical for trouble-free mechanical operation. Be-

fore checking alignment, make sure that the gear-

box mounting bolts are tight.

When connecting the universal joint drive shaft as-

sembly to a PTO unit, install, support, and align the

drive shaft in accordance with the manufacturer’s

instructions. The pump and the drive power source

are generally positioned so that shaft centerlines

are parallel and horizontal. The maximum operat-

ing angle should not exceed 15_(see Figure 2).

Check the direction of rotation of the PTO unit be-

fore starting the pump. The drive shaft must rotate

in the direction shown on the body of the pump,

gearbox, and/or decals, tags, and labels.

Do not operate the pump without the

guard in place over the rotating parts.

Exposed rotating parts can catch cloth-

ing, fingers, or tools, causing severe in-

jury to personnel.

After the power take-off has been aligned, block

the wheels of the external power source, engage

the braking system, or take other precautions to

ensure that the power source will remain station-

ary. Block the wheels on the unit to prevent creep-

ing.

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