Gormann-Rupp Pumps 0 Series Application guide

QOM−03688−03
August 29, 1995
Rev. C 03-31-10
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 PUMP
MODEL
04E1−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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Through Torque Capacity PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump and Mounting Dimensions PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Dimensions PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE REQUIREMENTS PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank Preparation PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Configuration 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 − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Controls PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shifting Sequence PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX TEMPERATURE CHECK PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COLD WEATHER PRESERVATION PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS
(continued)
ii
TROUBLESHOOTING − SECTION D PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREVENTIVE MAINTENANCE PAGE D − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP MAINTENANCE AND REPAIR − SECTION E PAGE E − 1. . . . . . . . . . . . . . . .
PERFORMANCE CURVE PAGE E − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LISTS:
Pump Model PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Assembly PAGE E − 5 & 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 − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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−03688
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. It is designed for vehicular
mounting in petroleum service. The basic material
of construction is aluminum, with cast iron wear
rings.
The pump is close-coupled to an integral, 1950
RPM split-shaft gearbox speed increaser with a
2.56:1 ratio. Power is transmitted to the gearbox
through a customer-installed universal shaft as-
sembly.
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−03688
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.
Be certain proper safety practices are
followed before operating or servicing
the pump. Provide adequate ventilation,
prohibit smoking, wear static-resistant
clothing and shoes. Clean up all fuel
spills immediately 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.
Overheating may produce dangerous
fumes. Take precautions to ensure the
area surrounding the pump is ade-
quately ventilated. Allow 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-
gaged to be ejected with great force. Al-
low the pump to cool before servicing.

0 SERIES
OM−03688
PAGE A − 2 SAFETY
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 (1950 RPM) and performance 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 1950 RPM. If operated at a
higher RPM, pump or gearbox compo-
nents 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.
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−036880 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 arrange
the pump and piping.
Do not test or operate this pump and in-
tegral gearbox before reading the in-
stallation and operation instructions on
this manual.
This pump is an 0 Series, self-priming centrifugal
model with an integral split-shaft gearbox assem-
bly. The entire unit is designed for midship mount-
ing between the frame members of a petroleum
handling vehicle, 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. The gearbox assembly was shipped dry of
lubricant. Refer to LUBRICATION in the
MAINTENANCE AND REPAIR section of this
manual and perform 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 for the typical pump specifications and
gearbox data.

OM−03688 0 SERIES
PAGE B − 2 INSTALLATION
Table 1. Pump Specifications
Pump Type Self-priming, centrifugal with enclosed impeller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction 4-inch Victaulic" fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge 4-inch Victaulic" fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 1950 RPM (See the Performance Curve, Page E-1). . . . . . . . . . . . . .
Input & Output Shaft Heavy-duty 2-3/4 inch - 10 spline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input & Output Flanges Dana" Heavy-Duty 1800 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 68 U.S. ounces (2011 ml) - See LUBRICATION, Section E for SAE grade. . . . .
6 fl. oz. (18 ml) ‘MolykoteM Gear Guard’ (Dow Corning)
Approx. Net Weight (pump and gearbox) 285 pounds (129,3 kg). . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2. Through Torque Capacity Based On Shaft and Spline Size
Type of Engine Transmission Max Through Torque (ft.-lbs.)
Diesel Automatic 11,000
Manual 10,000
Gasoline Automatic 13,300
Manual 12,300
Pump and 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 Figure 1 on page B−3 and Figure 2 on page
E−4 for the physical dimensions of the pump.

OM−036880 SERIES
PAGE B − 3INSTALLATION
DIMENSIONAL DRAWING
Figure 1. Pump Model 04E1-GHH Dimensions

OM−03688 0 SERIES
PAGE B − 4 INSTALLATION
VEHICLE REQUIREMENTS
The following instructions apply equally to new in-
stallations, rebuilds or retrofits.
After installation, do not attempt to test run
or operate the pump and integral gearbox
before reading OPERATION, Section B.
The gearbox was shipped dry of lubrica-
tion, except for a residual coating from the
testing process of Dow Corning
‘MolykoteM Gear Guard’ (an anti-wear
additive, consisting of molybdenum disul-
phide solid lubricants suspended in petro-
leum oil). Lubricate the gearbox as in-
structed in LUBRICATION, Section E be-
fore attempting to operate the pump.
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.
Vehicle Configuration
If the pump is to be used in tractor-trailer or
straight-truck plus trailer service, either a liquid fifth
wheel or jumper hoses are required. Be sure the
drive line of the tractor-trailer is long enough to al-
low installation of the gearbox at the proper angle,
ant that jumper hoses are long enough to allow a
full turning radius.
Brake Installation
When shifting from vehicle drive to pump
mode, or vice versa, input shaft rotation
must be limited to no less than 2 RPM or
no more than 15 RPM at the time of the
shift. Stopping the input shaft entirely may
cause a butt-shift" condition, which will
prevent the shift from occurring. Shaft rota-
tion in excess of 15 RPM causes raking of
the gears. Either of these conditions can
damage gears, resulting in premature
gearbox failure.
Vehicles with automatic transmissions should be
equipped with a brake on the transmission shaft to
slow, but not stop, shaft rotation during shifting.
Air Cylinder Pressure
For proper operation of the gearbox, the air shift
device requires air pressure of 70 to 140 psi (482 to
965 kPa). See Gear Shift Connections for further
information.
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.

OM−036880 SERIES
PAGE B − 5INSTALLATION
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.
Mounting Location
The following factors must be considered when se-
lecting a mounting location for the pump.
a. Mounting brackets
b. Universal joint angles
c. Shift linkage
d. Piping
e. Ground clearance
f. Accessibility of pump and gearbox for service..
Any damage to the pump or gearbox resulting from
improper mounting and installation is not covered
by the Gorman-Rupp Warranty.
Mounting Brackets
The customer must furnish two cross members
which fit between the vehicle chassis side rails (see
Figure 2). They must be heavy enough to support
the weight of the pump assembly and provide easy
access for pump maintenance.
Secure the rear cross member rigidly to the pump
and gearbox using a fabricated mounting bracket
(customer-furnished). The mounting bracket must
fasten to the threaded holes located in the pump
casing above the pump suction, and in the top of
the gearbox housing. The bracket and cross mem-
ber must not obstruct pump operation or impede
removal of the pump casing during maintenance.
The rear cross member or mounting
bracket must not interfere with movement
of the air shift indicator shaft (located on
top of the gearbox). If necessary, drill a
1-inch (25,4 mm) diameter hole through
the cross member or bracket to provide
clearance.
AIR SHIFT COVER
TRUNNION BRACKET
DRIVE INPUT FROM
TRANSMISSION
FRONT CROSS MEMBER
(SUPPLIED BY CUSTOMER)
REAR CROSS MEMBER
(SUPPLIED BY CUSTOMER)
OUTPUT TO REAR AXLE
(SHOWN WITHOUT FLANGES)
1" [25,4 mm] DIA.
HOLE FOR AIR
SHIFT POSITION
INDICATOR SHAFT
RUBBER MOUNTED
BY CUSTOMER
16.31"* [414,3 mm] APPROX.
ROAD CLEARANCE
29" * [736,6 mm] APPROX.
ROAD CLEARANCE
NOTE: DIMENSIONS MARKED WITH AN ASTERISK (*) MAY BE
ALTERED TO FACILITATE INSTALLATION OF UNIT
INPUT ROTATION FOR PUMP
Figure 2. Typical Pump Mounting on Vehicle Chassis

OM−03688 0 SERIES
PAGE B − 6 INSTALLATION
The drive input end of the gearbox is fitted with a
trunnion which prevents chassis frame twist from
being transmitted through the gearbox. Mount the
trunnion to the front cross member (not supplied)
to support the drive input end of the pump. When
mounting the trunnion, make certain that it will not
interfere with the input drive flange. The trunnion
mounting foot must be directed toward the input
flange.
Position the cross members and mounted pump
on the side rails of the chassis. The cross members
must be mounted with rubber or other vibration-
dampening material when secured to the side
rails.
Do not secure the cross members to the side rails
before establishing the exact location and position
of the air shift rod and shift indicator connections.
Be careful not to put the pump in a bind from front
to rear during mounting. Improper alignment could
result in bearing or gear failure, or gearbox break-
age (see Drive Shaft Alignment).
Drive Flanges
The input and output shafts on the gearbox (2-3/4
inch, 10-spline) are equipped with heavy-duty
Dana 1800 Series flanges. The shaft splines are
designed to produce a tight interference fit with the
drive flange. This fit is intentional to eliminate fret-
ting corrosion.
For instructions on installing or removing drive
flanges and universal joints, see the specific areas
in MAINTENANCE AND REPAIR, Section E.
DRIVE SHAFT AND
LINKAGE CONNECTIONS
Drive Shaft Alignment
To promote maximum universal joint and bearing
life, the universal joint angles must be kept to a
minimum. A joint angle of 1is required for proper
needle bearing circulation, but excessive angles
cause accelerated wear and require a lower maxi-
mum operating speed (see Table 3).
Table 3. Joint Angle/Maximum RPM
JOINT
ANGLE
MAXIMUM
SPEED
55000 RPM
6, 30’ 4000 RPM
83000 RPM
Align the gearbox with the transmission and the
rear axle to obtain the optimum universal joint
angles. See Figure 3 for drive shaft alignment.
Be certain the rear axle position when the
vehicle is empty or fully loaded will not
cause excessive universal joint angles, or
cause the drive shaft slip joints to bottom
out.
When installing and/or aligning univer-
sal shaft assemblies, shut off the ve-
hicle ignition and remove the key to en-
sure that the pump will remain inopera-
tive.

OM−036880 SERIES
PAGE B − 7INSTALLATION
LUG ALIGNMENT
SHAFTS PARALLEL, ANGLES EQUAL
SHAFTS NOT PARALLEL, ANGLES EQUAL
LUGS MUST BE IN LINE, REGARDLESS
OF OPERATING ANGLE SHOWN BELOW
Figure 3. Drive Shaft Alignment
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.
Make sure the horizontal and vertical joints are
equal. Limit the angles to 1 to 3using a short
coupled joint, and less than 8with a double joint
assembly. The maximum operating angle should
not exceed 15(see Figure 3).
NOTE
Install a short coupled slip joint on the input side
and a double joint with slip on the output side of the
gearbox to attain the prescribed angles and elimi-
nate tensile stress on the shaft.
The input and output shafts should be completely
subassembled and checked for straightness and
balance before installation. Also check the univer-
sal joint yokes for proper alignment.
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.
Gear Shift Connections
After the pump is mounted to the chassis, hook up
the air shift rod to the proper control stations.
Decals and tags vital to pump operation
were shipped loose with the pump.
These decals must be affixed in a promi-
nent place visible to the pump operator.

OM−03688 0 SERIES
PAGE B − 8 INSTALLATION
Proper operation of the gearbox air shift requires
air pressure of 70 to 140 psi (5,1 to 10,2 kg/cm)
and 1/4" air lines. The air line connection at the end
cap of the air cylinder is for vehicle operation, and
the air line connection at the top of the air shifter
cover is for pump operation. Seal all hose fittings
with Permatex" or equivalent compound.
When activated, the shifter rod travels through a
hole in the rear cross member. A customer-
supplied shift indicator (mechanical, electrical, or
air operated device) should be installed in this area
to indicate shifter mode to the pump operator. A
tapped hole is provided in the shaft for conve-
nience.
See Figures 4 and 5 for the approximate shaft trav-
el and hole size. See Figure 4, Section E for Air Shift
Kit parts.
Figure 4. Air Shifter Shaft Detail
Figure 5. Optional Manual Shifter
SUCTION AND DISCHARGE PIPING
Typical System Installation
Most petroleum handling vehicles perform both
fueling and defueling operations. This requires 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 6 and 7 for illustrations of typical
piping systems used on refueling vehicles.

OM−036880 SERIES
PAGE B − 9INSTALLATION
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
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.
Run the 4-inch suction piping from the tank sump
to the pump inlet. The suction lines should be as
short and straight as possible to minimize friction
loss.
NOTE
This pump is fitted with straight-in Victaulic" type

OM−03688 0 SERIES
PAGE B − 10 INSTALLATION
suction and discharge fittings as standard equip-
ment.
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
suction line to ensure an adequate supply of liquid
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.
The pump discharge is a 4-inch Victaulic" type fit-
ting. The discharge should be mounted just below
the top of the chassis frame. It can easily be piped
to the filter inlet, discharge manifold, valves, etc.
To avoid wracking, flexible connections or bellows
must be installed in the pump suction and dis-
charge.
Do not tighten connecting flanges unless they are
properly aligned. Never pull a pipe into place by
tightening the flange bolts.
Valves
Gorman-Rupp manufactures several sizes of flow-
diverting (FDF) valves for use in truck-mounted
pumping applications. The valves are designed to
reverse the flow of liquid with only the turn of a han-
dle. This allows the same pump to fill or dispense
from the tank.
The FDF valve is designed for directing
flow only. It will not serve as a positive shut-
off or throttling valve.
See Figures 8 and 9 illustrating the installation di-
mensions and theory of operation for a typical FDF
valve. Consult the factory for further assistance or
other sizes.

OM−036880 SERIES
PAGE B − 11INSTALLATION
11.0
11.0
[279,4]
[279,4]
5.5
[139,7]
6.0
[152,4]
9.0 DIA.
[228,6]
0.44 DIA. HOLE
[11,2] DIA.−12 HOLES ON
[11,2]
DIA B.C.
[206,5] BOTH
0.44
8.13
6.06
[153,9] DIA.
10.38
[263,7]
5.5
[139,7]
5.63
[143
]
DIA.
3.06
[77,7] DIA.
DIA.−12 HOLES ON
[11,2]
DIA B.C.
[124,0] BOTH
0.44
4.88
FLANGES
FLANGES
5.0
[127,0]
DIMENSIONS:
INCHES
[MILLIMETERS]
Figure 8. Typical FDF Valve Installation Dimensions
When the center web of the valve is aligned with the
6-inch ports (fueling position), the flow passes
straight through. When the handle is turned to the
defueling position, the web blocks the straight flow
and opens two paths of flow through the 6-inch and
3-inch ports.
FILL
POSITION
DISPENSE FILLTOP VIEW
DISPENSING
POSITION
Figure 9. FDF Valve Theory of Operation
Eductors
An eductor may be used in conjunction with an
FDF valve to increase dispensing rates and im-
prove efficiency. An eductor may also be used to
collapse the tank service hose after the tank has
been filled or emptied.
Contact the Gorman-Rupp Company or an author-
ized distributor for specifications and performance
data on eductors or FDF valves.

OM−03688
0 SERIES
OPERATION PAGE C − 1
OPERATION − SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to the pump.
Whether new installation or rebuild of re-
fueler, the following requirements apply:
1. It is essential that tank scale, dirt, and
any other foreign elements be re-
moved from the tank and piping prior
to pump installation.
2. The gearbox was shipped dry of lu-
bricant. Lubrication must be added
before any operation.
3. The pump must not be run dry of
product at any time.
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.
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. The gearbox provided on
this pump is designed for operation at a
maximum input speed of 1950 RPM. If
operated at a higher RPM, pump or
gearbox components may be de-
stroyed.
PRIMING
Install the pump and piping as described in IN-
STALLATION. Make sure that the piping connec-
tions are tight, and that the pump is securely
mounted. Check that the pump and gearbox are
properly lubricated (see LUBRICATION in MAIN-
TENANCE AND REPAIR).
This pump is not self-priming, and should never be
operated unless there is liquid in the pump casing.
Never operate this pump unless there is
liquid in the pump casing. The pump will
not prime when dry. Extended operation of
a dry pump will destroy the seal assembly.
When installed in a flooded suction application,
simply open the system valves and permit the in-
coming liquid to evacuate the air. After the pump
and piping system have completely filled, evacu-
ate any remaining air pockets in the pump or suc-
tion line by loosening a pipe plug or opening
bleeder valves.
Once the pump casing has been filled, the pump
will prime as long as positive suction head is avail-
able.
GROUNDING
To eliminate electrostatic build-up by the liquid be-
ing pumped, the pump must be grounded by at-
taching a ground wire to a ground rod (grounding
is not required if pumping water). Install the ground
rod in accordance with the National Electrical
Code and all local codes. Be sure the clamp or fas-
tener has made a tight electrical connection with
the rod.
Inspect and test the ground wire assembly
for conductivity. Replace broken or frayed
wire before resuming operation.

OM−03688 0 SERIES
OPERATIONPAGE C − 2
STARTING
Consult the operations manual furnished with the
vehicle.
Rotation
The correct direction of pump rotation is clockwise
when facing the gearbox input shaft. The pump
could be damaged and performance adversely af-
fected by incorrect rotation. If pump performance
is not within the specified limits (see the curve on
page E-1), check the direction of rotation before
further troubleshooting.
Only operate the input shaft in a clockwise
direction when facing the input shaft.
Otherwise, pump performance will be ad-
versely affected, and the pump and/or
gearbox could be seriously damaged.
Drive
The pump and gearbox assembly are designed to
be mounted midship between the chassis frame
members. The gearbox split shaft replaces a part
of the vehicle drive shaft connecting the transmis-
sion to the rear axle.
The gearbox assembly has a ratio of 2.56:1, and is
designed for operation at a maximum input speed
of 1950 RPM. Do not operate at a higher input
speed.
The gearbox provided on this pump is
designed for operation at a maximum in-
put speed of 1950 RPM. If operated at a
higher RPM, pump or gearbox compo-
nents may be destroyed.
OPERATION
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.
The split drive shaft of the pump gearbox provides
for selective operation of either the pump or the ve-
hicle; both cannot be operated at the same time.
Operating Controls
Since Gorman-Rupp has no control over the actual
installation, it is the obligation of the tank builder or
the installer to devise controls to safely operate the
pump from inside the cab, or from a remote control
panel. All instructions and operational procedures
for the pump and system must be provided to the
pump operator.
Decals and tags vital to pump operation
were shipped loose with the pump.
These decals must be affixed in a promi-
nent place visible to the pump operator.
The shift mode indicator must be visible to the op-
erator.
Shifting Sequence
In shifting to vehicle operation, the air shift rod link-
age is activated to engage the output shaft and
provide direct drive (1:1 ratio) through the gearbox
to the rear axle of the vehicle.
In shifting to pump operation, activate the air shifter
to disengage the gearbox drive output shaft, and to
engage the drive input shaft to the gear train which
operates the pump. Never shift from drive" to
pump" unless the vehicle is completely stopped.