GORMAN-RUPP PUMPS 60 Series Installation guide

OM−01465−02

October 16, 1992

Rev. B 09-26-11

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

www.grpumps.com

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

e1992 The Gorman-Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

60 SERIES PUMP

MODEL

66C3−GE (HYD)

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

VEHICLE REQUIREMENTS PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank Preparation PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

ALIGNMENT PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION AND DISCHARGE PIPING PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical System Installation PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Eductors PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 CURVE 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 PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

TABLE OF CONTENTS

(continued)

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

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

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

Impeller Installation PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Head and Wear Ring Installation PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

60 SERIES OM−01465

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 a 60 Series, enclosed impeller, cen-

trifugal model, with straight-in suction, without a

suction check valve. It is designed for vehicular

mounting in petroleum service. The basic material

of construction for wetted parts is ductile iron, with

bronze impeller and wearing parts.

The pump is close-coupled to an integral 2050

RPM gearbox speed increaser with a 2.19:1 ratio.

Power is transmitted to the gearbox through a cus-

tomer-installed hydraulic motor and coupling.

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.

If there are any questions regarding the pump or its

application which are not covered in this manual or

in other literature accompanying this unit, please

contact your Gorman-Rupp distributor, or the Gor-

man-Rupp Company:

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 pow-

er source, contact the power source manufactur-

er’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.

60 SERIES OM−01465

PAGE A − 1SAFETY

SAFETY − SECTION A

This information applies to 60 Series hy-

draulic motor driven pumps. Refer to

the manual accompanying the vehicle

before attempting 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 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.

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

60 SERIES

OM−01465

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.

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over-

heated pump. Vapor pressure within the

pump can cause parts being disen-

gaged to be ejected with great force. Al-

low the pump to cool before servicing.

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.

The gearbox provided on this pump is

designed for operation at a maximum in-

put speed of 2050 RPM. If operated at a

higher RPM, pump components may be

destroyed. Limit the maximum input

speed and operation range as indicated

on the performance curve on Page E-1.

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−0146560 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 gearbox assembly. It is designed for ve-

hicular mounting in petroleum service, where the

liquid is supplied to the pump under pressure.

Since the pressure supplied to the pump is critical

to performance and safety, be sure to limit the in-

coming pressure to 50% of the maximum permissi-

ble operating pressure as shown on the pump per-

formance curve (see Section E, Page 1).

The integral gearbox is designed to be driven

through the vehicle transfer case by a customer-

supplied hydraulic motor and coupling. The pump

casing or gearbox may be rotated in 30_incre-

ments to assist with alignment with the vehicle

tank; however, if the gearbox is to be rotated, some

modifications must be made to the gearbox to en-

sure adequate lubrication. Consult the factory for

details.

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 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.

OM−01465 60 SERIES

PAGE B − 2 INSTALLATION

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-

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

Because this pump is designed to be driven by a

close-coupled motor, it is imperative that the user

make certain that the motor drive shaft is parallel

and concentric with the gearbox drive shaft.The

alignment of the gearbox and motor is critical for

trouble-free mechanical operation. Before check-

ing alignment, make sure that the gearbox mount-

ing bolts are tight.

To check coupling alignment, use a feeler gauge or

taper gauge between the coupling halves every

90_. The coupling is in alignment when the hubs

are the same distance apart at all points.

To check parallel adjustment, lay a straightedge

across both coupling halves at the top, bottom and

sides. The horizontal parallel adjustment is correct

when the straightedge rests evenly on both halves

of the coupling at all points. Use a feeler gauge be-

tween the coupling to measure any misalignment.

SUCTION AND DISCHARGE PIPING

Typical System Installation

Tank filling and dispensing operations require a

system utilizing flow-directing (FDF) valves, educ-

tors, related piping and safety accessories. Some

of the accessories are available from Gorman-

Rupp as optional equipment.

Refer to Figures 2 and 3 for illustrations of typical

piping systems for tank filling and dispensing.

OM−0146560 SERIES

PAGE B − 3INSTALLATION

SCHEMATIC SYSTEM USING EDUCTOR FOR DISPENSING AND FILLING

Figure 2. Typical System Installation Using Educator For Filling And Dispensing

SCHEMATIC SYSTEM USING PUMP FOR DISPENSING AND FILLING

Figure 3. Typical Installation Using Pump For Filling And Dispensing

Piping

All piping material must be compatible with the liq-

uid being pumped. If hose is used in suction lines,

it must be the rigid-wall, reinforced type to prevent

collapse under suction. Using piping couplings in

suction lines is not recommended.

A suction strainer was not furnished with this pump

since it is not designed to handle liquids containing

solids. However, to protect the pump from acciden-

tal damage a commercially available 80 mesh

screen should be installed in the suction line. Make

certain that the total open area of the screen is at

least three or four times the cross section of the

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