GORMAN-RUPP 0 SERIES User manual

OM‐03179‐OP02
June 6, 1995
Rev. E 03‐07‐13
Q
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

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:

TABLE OF CONTENTS
i
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)
ii
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: [phone]
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
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
ON
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