GORMAN-RUPP PUMPS 06C1-GAR Application guide

OM-05688-OP01
July 20, 2004
Q
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
www.gormanrupp.com
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
eCopyright by the Gorman-Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
0SERIESPUMP
MODEL
06C1-GAR

TABLE OF CONTENTS
i
INTRODUCTION PAGE I --- 1.................................................
SAFETY - SECTION A PAGE A --- 1............................................
I N S T A L L A T I O N --- S E C T I O N B PA G E B --- 1....................................
Pump Dimensions PAGE B --- 1.....................................................
PREINSTALLATION INSPECTION PAGE B --- 1............................................
VEHICLEREQUIREMENTS PAGEB---2.................................................
Ta n k P r e p a r a t i o n PA G E B --- 2.......................................................
P OS I T I O N I NG P U M P PA G E B --- 2.......................................................
Lifting PA G E B --- 2.................................................................
ALIGNMENT PA G E B --- 3..............................................................
SUCTION AND DISCHARGE PIPING PAGE B --- 4.........................................
Typical System Installation PAGE B --- 4..............................................
Piping PA G E B --- 5................................................................
Sealing PA G E B --- 5...............................................................
Valves PA G E B --- 5................................................................
Siphoning PA G E B --- 6.............................................................
Eductors PA G E B --- 6..............................................................
O P E R A T I O N --- S E C T I O N C PA G E C --- 1......................................
PRIMING PA G E C --- 1.................................................................
GROUNDING PA G E C --- 1.............................................................
STARTING PA G E C --- 1................................................................
Rotation PA G E C --- 1..............................................................
Drive PA G E C --- 2.................................................................
OPERATION PA G E C --- 2..............................................................
Leakage PA G E C --- 2..............................................................
Liquid Temperature And Overheating PAGE C --- 2.....................................
Strainer Check PAGE C --- 2.........................................................
Pump Vacuum Check PAGE C --- 2..................................................
STOPPING PA G E C --- 3................................................................
Cold Weather Preservation PAGE C --- 3..............................................
GEARBOX TEMPERATURE CHECK PAGE C --- 3..........................................
T R O U B L E S H O O T I N G --- S E C T I O N D PA G E D --- 1..............................
PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E --- 1.................
P E R F O R M A N C E C U R V E PA G E E --- 1...................................................
PARTS LIST:
P u m p M o d e l PA G E 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 And Casing Wear Ring Removal PAGE E --- 5.................................
Seal Removal And Disassembly PAGE E --- 5.........................................

TABLE OF CONTENTS
(continued)
ii
Pump Casing Removal PAGE E --- 5.................................................
PUMP AND SEAL REASSEMBLY PAGE E --- 5............................................
Pump Casing And Wear Ring Installation PAGE E --- 6..................................
Seal Reassembly And Installation PAGE E --- 6........................................
Impeller 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 PA G E E --- 1 1.............................................................
Seal Assembly PAGE E --- 11.........................................................
Gearbox PA G E E --- 1 1..............................................................

0SERIES OM--05688
PAGE I -- 1INTRODUCTION
INTRODUCTION
This Installation, Operation, and Maintenance
manual is designed to help you achieve the best
performance and longest life from your Gorman-
Rupp pump.
This manual covers an 0 Series, enclosed impeller,
centrifugal model pump, with straight-in suction,
without a suction check valve. The pump is de-
signed for vehicular mounting in petroleum ser-
vice. The basic material of construction for wetted
parts for the pump is aluminum, with cast iron
wearing parts.
The pump is close-coupled to an integral 1900
RPM gearbox speed increaser with a 2.19:1 ratio.
Power is transmitted to the gearbox through a cus-
tomer-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 power source, contact the power source manufacturer’s local
dealer or representative.
The following are used to alert maintenance personnel to procedures which require special attention, 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.

0SERIES OM--05688
PAGE A -- 1SAFETY
SAFETY --- SECTION A
This information applies to 0 Series
power take-off driven pumps. Refer to
the manual accompanying the vehicle
before attempting to begin operation.
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
flammableliquids,becertainproper
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
oftime.Ifoperatedagainstacloseddis-
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.

0SERIES
OM--05688
PAGE A -- 2 SAFETY
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.
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 curve on Page E-1.
The gearbox provided on this pump is
designed for operation at 1900 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--056880SERIES
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.
Donottestoroperateyourpumpandin-
tegral gearbox before reading the in-
stallation and operation instructions in
this manual.
These pumps are self-priming centrifugal models
with an integral gearbox assembly. Each of the
pumps covered by this manual 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 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
SeeFigure1fortheapproximatephysicaldimen-
sionsofthispump.
OUTLINE DRAWING
Figure 1. Pump Model 06C1-- GAR

OM--05688 0SERIES
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.
Thepumpassemblycanbeseriously
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

OM--056880SERIES
PAGE B -- 3INSTALLATION
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 degrees (see Fig-
ure 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.

OM--05688 0SERIES
PAGE B -- 4 INSTALLATION
LUG ALIGNMENT
SHAFTS PARALLEL, ANGLES EQUAL
SHAFTS NOT PARALLEL, ANGLES EQUAL
LUGS MUST BE IN LINE, REGARDLESS
OF OPERATING ANGLE SHOWN BELOW
Figure 2. Proper Installation And Alignment of Universal Assembly
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
oftheaccessoriesareavailablefromGorman-
Rupp as optional equipment.
Refer to Figures 3 and 4 for illustrations of typical
piping systems for tank filling and dispensing.