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GORMAN-RUPP PUMPS 0 Series Installation, Operation, And Maintenance Manual With Parts List

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OM−03688−03
Q
August 29, 1995
Rev. C 03-31-10
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
0 SERIES PUMP
MODEL
04E1−GHH
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
D
GORMAN-RUPP OF CANADA LIMITED
ST. THOMAS, ONTARIO, CANADA
Printed in U.S.A.
e
1995 The Gorman-Rupp Company

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  • Page 1 OM−03688−03 August 29, 1995 Rev. C 03-31-10 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST 0 SERIES PUMP MODEL 04E1−GHH THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO www.grpumps.com GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A. 1995 The Gorman-Rupp Company...
  • Page 2 Register your new 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:...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..........PAGE I −...
  • Page 4 TABLE OF CONTENTS (continued) TROUBLESHOOTING − SECTION D ......PAGE D − 1 PREVENTIVE MAINTENANCE .

  • Page 5: Introduction

    Phone: (519) 631−2870 pump. The following are used to alert maintenance per- This pump is an 0 Series, enclosed impeller, cen- sonnel to procedures which require special atten- trifugal model, with straight-in suction and without tion, to those which could damage equipment, and a suction check valve.

  • Page 6: Safety − Section A

    0 SERIES OM−03688 SAFETY − SECTION A This information applies to 0 Series attempt to pump corrosive materials, or split-shaft refueler pumps. Gorman- any liquids which may damage the Rupp has no control over or particular pump or endanger personnel as a result knowledge of the truck chassis which of pump failure.
  • Page 7 0 SERIES OM−03688 After the vehicle is positioned for pump Decals and tags vital to pump operation maintenance, block the wheels and set were shipped loose with the pump. Affix the emergency brake before attempting these decals in a prominent place vis- to disconnect the drive shaft or remove ible to the pump operator.

  • Page 8: Installation − Section Bpage B

    Reverse rotation of the shaft will adversely effect pump perform- This pump is an 0 Series, self-priming centrifugal model with an integral split-shaft gearbox assem- ance, and the pump and/or gearbox could bly. The entire unit is designed for midship mount- be seriously damaged.

  • Page 9: Pump And Mounting Dimensions

    OM−03688 0 SERIES Table 1. Pump Specifications Pump Type ....... .
  • Page 10 0 SERIES OM−03688 DIMENSIONAL DRAWING Figure 1. Pump Model 04E1-GHH Dimensions INSTALLATION PAGE B − 3...

  • Page 11: Vehicle Requirements

    OM−03688 0 SERIES VEHICLE REQUIREMENTS low installation of the gearbox at the proper angle, ant that jumper hoses are long enough to allow a full turning radius. The following instructions apply equally to new in- stallations, rebuilds or retrofits. Brake Installation...

  • Page 12: Mounting Location

    0 SERIES OM−03688 Due to the confined mounting location, Figure 2). They must be heavy enough to support the weight of the pump assembly and provide easy specialized equipment such as a transmis- access for pump maintenance. sion jack with custom brackets should be used to lift and position the pump and gearbox.

  • Page 13: Drive Flanges

    OM−03688 0 SERIES The drive input end of the gearbox is fitted with a DRIVE SHAFT AND trunnion which prevents chassis frame twist from LINKAGE CONNECTIONS being transmitted through the gearbox. Mount the trunnion to the front cross member (not supplied) Drive Shaft Alignment to support the drive input end of the pump.

  • Page 14: Gear Shift Connections

    0 SERIES OM−03688 LUGS MUST BE IN LINE, REGARDLESS OF OPERATING ANGLE SHOWN BELOW LUG ALIGNMENT SHAFTS PARALLEL, ANGLES EQUAL SHAFTS NOT PARALLEL, ANGLES EQUAL Figure 3. Drive Shaft Alignment The alignment of the pump and its power source is The input and output shafts should be completely critical for trouble-free mechanical operation.

  • Page 15: Suction And Discharge Piping

    OM−03688 0 SERIES Proper operation of the gearbox air shift requires supplied shift indicator (mechanical, electrical, or air pressure of 70 to 140 psi (5,1 to 10,2 kg/cm@) air operated device) should be installed in this area and 1/4" air lines. The air line connection at the end to indicate shifter mode to the pump operator.

  • Page 16: Piping

    0 SERIES OM−03688 SCHEMATIC SYSTEM USING EDUCTOR FOR DISPENSING AND FILLING Figure 6. Typical Installation Using Eductor For Filling And Dispensing SCHEMATIC SYSTEM USING PUMP FOR DISPENSING AND FILLING Figure 7. Typical Installation Using Pump For Filling And Dispensing Piping Run the 4-inch suction piping from the tank sump to the pump inlet.

  • Page 17: Valves

    OM−03688 0 SERIES suction and discharge fittings as standard equip- the top of the chassis frame. It can easily be piped ment. to the filter inlet, discharge manifold, valves, etc. To avoid wracking, flexible connections or bellows A suction strainer was not furnished with this pump...

  • Page 18: Eductors

    0 SERIES OM−03688 11.0 0.44 DIA. HOLE [279,4] [11,2] 0.44 DIA.−12 HOLES ON [11,2] [127,0] 8.13 DIA B.C. BOTH [206,5] FLANGES 11.0 9.0 DIA. [152,4] [279,4] [228,6] 6.06 [139,7] DIA. [153,9] [139,7] 10.38 5.63 DIA. [143 [263,7] 0.44 DIA.−12 HOLES ON...

  • Page 19: Operation − Section C

    OM−03688 0 SERIES OPERATION − SECTION C Review all SAFETY information in Section A. PRIMING Install the pump and piping as described in IN- Follow the instructions on all tags, labels and STALLATION. Make sure that the piping connec- decals attached to the pump.

  • Page 20: Starting

    OM−03688 0 SERIES STARTING OPERATION Consult the operations manual furnished with the vehicle. Do not operate the pump against a Rotation closed discharge valve for long periods of time. If operated against a closed dis- charge valve, pump components will The correct direction of pump rotation is clockwise when facing the gearbox input shaft.

  • Page 21: Operating Checks

    OM−03688 0 SERIES The pump air cylinder must maintain air pressure could result in personal injury or damage to the of 70 to 140 psi (5,1 to 10,2 kg/cm@) at the gearbox equipment. If backflushing is absolutely neces- for air shift operation.

  • Page 22: Stopping

    OM−03688 0 SERIES Shut off the pump. The vacuum gauge reading will NOTE immediately drop proportionate to static suction For continuous duty operation (when the pumping lift, and should then stabilize. If the vacuum reading period exceeds 30 minutes without a 20 minute falls off rapidly after stabilization, an air leak exists.
  • Page 23 0 SERIES OM−03688 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. Switch off the vehicle ignition and re- move the key, or take other precau- tions to ensure that the pump will re- main inoperative.
  • Page 24 OM−03688 0 SERIES TROUBLE POSSIBLE CAUSE PROBABLE REMEDY Impeller or other wearing parts worn Replace worn or damaged parts. PUMP STOPS OR FAILS TO DELIVER or damaged. Check that impeller is properly cen- RATED FLOW OR tered and rotates freely.
  • Page 25 0 SERIES OM−03688 equipped) between regularly scheduled inspec- PREVENTIVE MAINTENANCE 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.
  • Page 26 OM−03688 0 SERIES PUMP MAINTENANCE AND REPAIR − SECTION E MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE. PERFORMANCE BASED ON WATER PERFORMANCE BASED ON PETROLEUM STANDARD PERFORMANCE FOR PUMP MODEL 04E1−GHH Based on 70_ F (21_ C) clear water at sea level, Contact the Gorman-Rupp Company to verify part corrected to 0.80 specific gravity, with minimum...
  • Page 27 OM−03688 0 SERIES SECTION DRAWING PARTS PAGE Figure 1. Pump Model 04E1−GHH PAGE E − 2 MAINTENANCE & REPAIR...
  • Page 28 OM−03688 0 SERIES PARTS LIST Pump Model 04E1−GHH (From S/N 1076270 Up) ITEM PART PART MAT’L NAME NUMBER CODE REPAIR PUMP CASING 38222−526 13000 IMPELLER 8375 1304R SEAL ASSEMBLY 25271−192 −−− DISCHARGE FLANGE O-RING 25154−244 −−− HEX HD CAPSCREW B0805...
  • Page 29 OM−03688 0 SERIES SECTION DRAWING Figure 2. 44161−146 Repair Gearbox Assembly PAGE E − 4 MAINTENANCE & REPAIR...
  • Page 30 OM−03688 0 SERIES PARTS LIST 44161−146 Repair Gearbox Assembly ITEM PART NAME PART MAT’L ITEM PART NAME PART MAT’L NUMBER CODE NUMBER CODE AIR SHIFT COVER ASSY 44231−501 −−− IDLER GEAR 38541−405 16000 −SHIFTER SHAFT ASSY 44231−502 −−− BALL BEARING S1088 −−−...
  • Page 31 OM−03688 0 SERIES SECTION DRAWING Figure 2A. 44161−146 Gearbox Assembly (Cont’d) PAGE E − 6 MAINTENANCE & REPAIR...
  • Page 32 OM−03688 0 SERIES PARTS LIST 44161−146 Gearbox Assembly (Cont’d) ITEM PART PART MAT’L NAME NUMBER CODE HEX HD CAPSCREW 21472−114 −−− HEX HD CAPSCREW 21472−099 −−− CERAMIC/MAG PLUG 22618−001 −−− WASHER 25123−041 −−− PIPE PLUG W/PATCH 25355−061 −−− OIL LEVEL PLATE 38816−233...
  • Page 33 OM−03688 0 SERIES SECTION DRAWING Figure 3. 48123−401 Cross Member Kit PAGE E − 8 MAINTENANCE & REPAIR...
  • Page 34 OM−03688 0 SERIES PARTS LIST 48123−401 Cross Member Kit ITEM PART PART MAT’L NAME NUMBER CODE CROSS MEMBER 34778−004 15020 HEX HD CAPSCREW B1004 15991 LOCKWASHER 15991 HEX HD CAPSCREW B0804 15991 LOCKWASHER 15991 BRACKET 34125−075 15020 HEX HD CAPSCREW...
  • Page 35 OM−03688 0 SERIES PUMP AND SEAL DISASSEMBLY Before attempting to service the pump,switch off the engine ignition and remove the key ensure that it will remain inoperative. Close all valves in the suc- Review all SAFETY information in Section A.
  • Page 36 OM−03688 0 SERIES specialized equipment such as a transmis- to damage the impeller. Remove the impeller nut (23). sion jack with custom brackets should be used to lift and position the pump and Install 1/4−20 UNC by 4-inch long capscrews in gearbox.
  • Page 37 OM−03688 0 SERIES If replacement is required, remove the hardware (5 With the stationary seal seat installed in the seal and 6), and separate the discharge flange and O- bore of the pump casing, lubricate the O-ring (12), ring (4 and 7) from the pump casing.
  • Page 38 OM−03688 0 SERIES precautions printed on solvent contain- Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak- ers. age. If any components are worn, replace the com- The seal is not normally reused because wear pat- plete seal;...
  • Page 39 OM−03688 0 SERIES NOTE If the pump casing was removed, install the casing Install a tapered sleeve (see Figure 5) over the shaft O-ring and gasket (12 and 18) on the pump casing keyway to ease installation of the rotating portion of studs.
  • Page 40 OM−03688 0 SERIES NOTE Install the hardware securing the input and output drive flanges (9 and 29) to the drive shafts. Install After the impeller has been properly positioned, the air lines from the air shift cylinder assembly on check for free rotation. Correct any scraping or the gearbox.
  • Page 41 OM−03688 0 SERIES used to lift and position the pump and gearbox. Refer to Removing Pump and Gearbox under The output shaft cannot be removed from PUMP AND SEAL DISASSEMBLY and remove the bearing retainer without first removing the pump and gearbox from the vehicle. Move the...
  • Page 42 OM−03688 0 SERIES Pull the outer race of the roller bearing (43) from the gearbox cavity using a suitable puller. Impeller Shaft Disassembly To prevent damage during removal, it is recommended that bearings be cleaned With the pump end disassembled (see PUMP and inspected in place.
  • Page 43 OM−03688 0 SERIES sparks, and flame. Read and follow all Inspect the shafts for distortion, damaged key- ways, nicks or scratches, or for damage on the im- precautions printed on solvent contain- peller or drive ends. Dress small nicks and burrs ers.
  • Page 44 OM−03688 0 SERIES gearbox housing on wooden blocks while in this Screw the pin in the bearing driver (G-R P/N position. Remove the bearing stop from the gear- 29511−909) into the tapped hole in the idler shaft. box housing. Use the driver to press the outer race of the bearing...
  • Page 45 OM−03688 0 SERIES kg.). Use caution not to damage the oil seal lip on Air Shift Cover Reassembly the shaft splines. Reinstall the shifter shaft O-ring (9) and oil seal (3). Be sure the lip of the oil seal is directed toward the Reposition the gearbox housing with the opening shifter fork.
  • Page 46 OM−03688 0 SERIES Use filtered compressed air to pressurize the gear- through the lubrication fitting (12) until grease es- box until it stabilizes at 6 psi (0,4 kg/cm@), then shut capes from the trunnion area. off the air flow and observe the pressure gauge. If...
  • Page 47 OM−03688 0 SERIES After the initial change, the lubricant should be ure. Monitor operation closely and sched- changed after every 500 hours of operation or ev- ule maintenance accordingly. ery 6 months, whichever comes first. The lubricant Continuous Pumping Duty Cycle...
  • Page 48 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 D MANSFIELD, OHIO GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA...

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