Gorman-Rupp Pumps 04B3-F4L User Manual

ACE

OM---01216---OE08

March 18, 2002

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

0SERIESPUMP

MODEL

04B3---F4L

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

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

ECopyright by the Gorman-Rupp Company

The engine exhaust from this
product contains chemicals
known to the State ofCaliforniato
cause cancer, birth defects or
other reproductive harm.

TABLE OF CONTENTS

INTRODUCTION PAGE I --- 1.................................................

SAFETY - SECTION A PAGE A --- 1............................................

IN S TA LLATIO N --- SE C TION B PA G E B --- 1....................................

Pump Dimensions PAGE B --- 1.....................................................

PREINSTALLATION INSPECTION PAGE B --- 1............................................

Battery Specifications And Installation PAGE B --- 2....................................

POSITIONING PUMP PA GE B --- 2.......................................................

Lifting PA GE B --- 2.................................................................

Alignment PA GE B --- 2.............................................................

Mounting PA GE B --- 2.............................................................

SUCTION AND DISCHARGE PIPING PAGE B --- 3.........................................

Materials PA GE B --- 3..............................................................

Line Configuration PAGE B --- 3......................................................

Connections to Pump PAGE B --- 3..................................................

Gauges PA GE B --- 3...............................................................

SUCTION LINES PAGE B --- 3...........................................................

Fittings PA GE B --- 3...............................................................

Strainers PA GE B --- 3..............................................................

Sealing PAGE B --- 3...............................................................

Suction Line Positioning PAGE B --- 4................................................

FLOAT SWITCHES PA GE B --- 4.........................................................

Installation PA GE B --- 4............................................................

DISCHARGE LINES PA GE B --- 5........................................................

Siphoning PAGE B --- 5.............................................................

Valves PA GE B --- 5................................................................

OP E R AT ION --- SEC T ION C PA G E C --- 1......................................

PRIMING PA GE C --- 1.................................................................

STARTING PA GE C --- 1................................................................

Manual Starting PAGE C --- 2........................................................

Automatic Starting PAGE C --- 2.....................................................

OPERATION PA GE C --- 3..............................................................

Lin es W ith a Bypa ss PA GE C --- 3....................................................

Lines Without a Bypass PAGE C --- 3.................................................

Leakage PAGE C --- 3..............................................................

Liquid Temperature And Overheating PAGE C --- 3.....................................

Strainer Check PAGE C --- 3.........................................................

Pump Vacuum Check PAGE C --- 3..................................................

STOPPING PA GE C --- 4................................................................

Manual Stopping PAGE C --- 4.......................................................

Automatic Stopping PAGE C --- 4....................................................

Safety Shutdown System PAGE C --- 4...............................................

OPERATIONINEXTREMEHEAT PAGEC---4............................................

BEARING TEMPERATURE CHECK PAGE C --- 5..........................................

Cold Weather Preservation PAGE C --- 5..............................................

i

TABLE OF CONTENTS

(continued)

TROU BLESH OOT I NG --- SE CTIO N D PA G E D --- 1..............................

PREVENTIVE MAINTENANCE PAGE D --- 3...............................................

PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E --- 1.................

STANDARD PERFORMANCE CURVE PAGE E --- 1........................................

PARTS LISTS:

Pump Model PA GE E --- 3..........................................................

Pump End Assembly PAGE E --- 5...................................................

Drive Assembly PAGE E --- 6........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 7.........................

Pump Disassembly PAGE E --- 7.....................................................

Impeller Removal P AGE E --- 8......................................................

Seal Removal and Disassembly PAGE E --- 8..........................................

Separating Intermediate and D rive Assembly From Engine PAGE E --- 8..................

Shaft and Bearing Removal and Disassembly PAGE E --- 8.............................

Shaft and Bearing Reassembly and Installation PAGE E --- 9............................

Securing Intermediate and Drive Assembly To Engine PAGE E --- 11......................

Seal Reassembly and Installation P AGE E - -- 11........................................

Impeller Installation P AGE E - -- 13.....................................................

Pump Reassembly PAGE E --- 13.....................................................

Final Pump Assembly PAGE E --- 14..................................................

LUBRICATION PA GE E --- 14.............................................................

Seal Assembly PAGE E --- 14.........................................................

Engine PA GE E --- 14................................................................

ii

0SERIES

OM--01216

INTRODUCTION

This Installation, Operation, and Maintenance
manual is designed to help you achieve the best
performance and longest life from your Gorman­Rupp pump.

Thispumpisan 0Series,closedimpeller,self-prim­ing centrifugal model, designed with straigh-in
suction, without a suction check valve. It is de­signed tohandleclearliquids containingspecified
entrained solids. The basic material of construc­tionforwettedparts isgray iron,withbronzeimpel­ler and gray iron wear rings.

The pump is close-coupledtoa four cylinder Deutz
dieselengine, modelF4L912D. Refer tothemanu­al accompanying the engine before installing or
operating the pump.

If there are any questions regarding t he pump or
its application which are not covered in this man­ual or in other literature accompanying this unit,
please contact your Gorman-Rupp distributor, or
write:

The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217

or

Gorman-Rupp of Canada Limited
70 Burwell Ro ad
St. Thomas, Ontario N5P 3R7

equipment must be installed and operated ac-
cording to all national, local and industry stan ­dards.

The following are used to alert maintenance per­sonnel toprocedureswhich require specialatten­tion, tothosewhichcoulddamage equipment, and
to those which could be dangerous to personnel:

Immediate hazards whichWILL result in
severe personal injury or death. These
instructions describe the procedure re­quired and the injury which will result
from failure to follow the procedure.

Hazards or unsafe practices which
COULDresult in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.

For information or technical assistance on the en­gine, contact the engine manufacturer’s local
dealer or representative.

Because pump installations are seldom identical,
this manual cannot possibly provide detailed in­structions and precautions for every aspect of
each specific application. Therefore, it is the re­sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety norpumpintegrity are com­promised by the installation. Pumps and related

HazardsorunsafepracticeswhichCOULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi­ble damagewhich could result from failure
to follow the procedure.

NOTE

Instructions to aid in installation, operation,and
maintenance, or which clarify a procedure.

PAGE I -- 1INTRODUCTION

0SERIES

OM--01216

SAFETY - SECTION A

This information applies to 0 Series en­gine driven pumps. Refer to the manual
accompanying the engine before at­tempting to begin operation.

Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre­cautions for each specific application.
Therefore, it is the owner/installer’s re­sponsibility to ensure that applications
not addressed in this manual are per­formed only after establishing that nei­ther operator safety nor pump integrity
are compromised by the installation.

Beforeattemptingto openorservicethe
pump:

1. Familiarize yourself with this man ­ual.

2. Switch off the engine ignition and
disconnect the positive battery
cable. Take precautions to ensure
that the pump will remain 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 cau­tiously.

7. Drain the pump.

vent injury during automatic operation.
Disconnect the positive battery cable
before performing any maintenance.
Failuretodosomayresultinserious
personal injury.

This pump is designed to handle clear
liquids containing specified entrained
solids.Donotattempttopumpvolatile,
flammable or corrosive materials, or
any liquids which may damage the
pumporendange r personnelas a result
of pump failure.

Use lifting and moving equipment in
good repair and with adequate capacity
toprevent injuriestopersonnelordam­age to equipment. Suction and dis­charge hoses and piping must be re­moved from the pump before lifting.

Afterthepumphasbeen installed,make
certain that the pump and all piping or
hose connections are tight, properly
supportedandsecurebeforeoperation.

Ifthe pump is equipped with the option­al automatic starting system, it is sub­ject to automatic restart. Keep hands
and clothing away from the unit to pre-

Do not operate the pump against a
closeddischarge valve for longperiods
oftime.Ifoperatedagainstacloseddis­charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.

PAGE A -- 1SAFETY

0SERIESOM--01216

Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over­heated pump. Vaporpressure withinthe
pump can cause parts being disen­gagedtobe ejectedwithgreat force.Al­low the pump to cool before servicing.

Do not operate an i n ternal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make ce r­tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color­less, tasteless, and odorless.

Fuel used by internal combustion en­gines presents an extreme explosion
and fire hazard. Make certain that all
fuel lines are securely connected and
free of leaks. Never refuel a hot or run­ning engine. Avoid overfilling the fuel
tank.Alwaysusethe correcttype offuel.

Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. The maximum continuous
operating speed for this pump is 2400
RPM.

PAGE A -- 2

SAFETY

0SERIES OM--01216

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.

Most of the information pertains to a standard
staticlift application where the pump ispositioned
above the free level of liquid to be pumped.

If installed ina flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line

OUTLINE DRAWING

configuration, and priming must be tailored to the
specific application. Since the pressure supplied
to the pump is critical to performance and safety,
besuretolimitthe incomingpressureto50%ofthe
maximum permissible operating pressure a s
shown on the pump performance curve.

Forfurtherassistance, contact yourGorman-Rupp
distributor or the Gorman-Rupp Company.

Pump Dimensions

SeeFigure1fortheapproximatephysicaldimen­sionsofthispump.

Figure 1. Pump Model 04B3--F4L

PREINSTALLATION INSPECTION

Thepump assemblywas inspectedandtested be­foreshipment from the factory. Before installation,
inspect the pump for damage which may haveoc ­curred during shipment. Check as follows:

a. Inspect the pump and engine for cracks,

dents, damaged threads, and other obvious
damage.

b. Check for and tighten loose attaching hard-

ware. Since gaskets tend to shrink after dry­ing, check for loose hardware at mating sur­faces.

c. Carefully read all tags, decals, and markings

onthepumpassembly,and performallduties
indicated.

d. Check levels and lubricate as necessary. Re-

fer to LUBRICATION in the MAINTENANCE

PAGE B -- 1INSTALLATION

OM--01216 0SERIES

AND REPAIR section of thismanualandper-

form duties as instructed.

e. If the pump and engine have been stored for

more than 12 months, some of the compo­nents or lubricants may have exceeded their
maximumshelflife.These mustbeinspected
or replaced to ensure maximum pump serv­ice.

If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman-Rupp distributor or the factory to deter­minethe repair or updating policy. Donotput the
pump into service until appropriate action has
been taken.

Battery Specifications And Installation

Unlessotherw ise specified on the pump order,the
engine battery wa s not included with the unit. Re­fer to the following specifications when selecting a
battery.

age to equipment. Suction and dis­charge hoses and piping must be re­moved from the pump before lifting.

Lifting

Use lifting equipment with a capacity of at least
7,650 pounds (3540 kg.). The pump weighs ap­proximately1,560pounds (708kg.), notincluding
the weight of any customer installed options.Cus­tomerinstalledequipmentsuchas suctionanddis­chargepipingmustbe removedbefore attempting
to lift.

Thepumpassemblycanbeseriously
damagedifthecablesorchainsused tolift
andmovetheunitare improperlywrapped
around the pump.

Alignment

Table 1. Battery Specifications

Voltage

12 Volts

Cold
Crank
Amps

@0

_ F

960 ---975

Reserve

Capacity

@80

_ F

(Minutes)

365

Amp/

Rating

175

Hr.

Approx.

Overall

Dims.

(Inches)

20.5L
x

8.75W
x

9.75H

Refer tothe information accompanyingthe battery
and/or electrolytesolutionfor activationandcharg­ing instructions.

Beforeinstalling thebattery,cleanthe positive and
negative cable connectors, and the battery termi­nals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
maybecoated with petroleumjellyto retard corro­sion. Connect and tighten the positive cable first,
then the negative cable.

POSITIONING PUMP

Use lifting and moving equipment in
good repair and with adequate capacity
toprevent injuriestopersonnelordam-

Thealignmentofthe pumpendand enginearecrit­ical for trouble-free performance. During repair of
thepumpend, refertoSecuring Intermediateand

Drive Assembly to Engine in MAINTENANCE
AND REPAIR, Section E for Details.

Mounting

Locatethepump inanaccessibleplaceascloseas
practicalto the liquidbeingpumped. Levelmount­ing is essential for proper operation.

The pump may have to be supported or shimmed
to provide for level operation or to eliminate vibra­tion.

If the pump has been mounted on a moveable
base,makecertainthebaseisstationarybysetting
the brakeandblocking thewheelsbefore attempt­ing to operate the pump.

To ensure sufficient lubrication and fuel supply to
the engine, do not position the pump and engine
morethan 15_ off horizontal for continuousopera­tion. The pump and engine may be positioned up
to 30_ off horizontal for intermittent operation
only;however,the enginemanufacturershouldbe
consulted for continuous operation at angles
greater than 15_.

PAGE B -- 2 INSTALLATION

0SERIES OM--01216

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in­creased suction lift, discharge elevation, and fric­tion losses. Contact the factory to be sure your
overall application allows pump to operate within
thesafeoperationrange.

Materials

Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatiblewiththe liquidbeingpumped. Ifhoseis
used in suction lines, it must be therigid-wall, rein­forcedtype to prevent collapseunder suction.Us­ing piping couplings in suction lines is not recom­mended.

Line Configuration

Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini­mum use of elbows and fittings, which substan­tiallyincreasefriction loss.If elbowsarenecessary,
use the long-radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it ex­actlywith the pump port. Never pulla pipe lineinto
place by tightening the flange bolts and/or cou­plings.

Lines near the pump must be independently sup­ported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type
linesare used,they shouldhaveadequatesupport
to secure them when filled with liquid and under
pressure.

Gauges

Most pumps are drilled and tapped for installing
discharge pressure and vacuum suction gauges.
If these gauges are desired for pumps that a re not
tapped, drill and tap the suction and discharge
lines not less than 18 inches from the suction and
discharge ports and install the lines. Installation
closer to the pump may result in erratic readings.

SUCTION LINES

Toavoidair pocketswhichcould affectpump prim­ing, thes uction line must be as short and direct as
possible.Whenoperationinvolvesasuctionlift,the
line must always slope upward to the pump from
the source of the liquid being pumped; if the line
slopes down to the pump at any point along the
suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be in­stalledwith the flat part of the reducers uppermost
to avoid creating air pockets. Valves are not nor­mally used in suction lines, but if a valve is used,
install it with the stem horizontal to avoid air pock­ets.

Strainers

If a strainer is furnished with the pump, be certain
touse it;any sphericalsolidswhichpassthrougha
strainer furnished with the pump will also pass
through the pump itself.

If a strainer is not furnished with the pump, but is
installed by the pump user, make certain that the
total area of the openings in the strainer is at least
three or four times the cross section of the suction
line,and that the openings willnot permit passage
of solids larger than the solids handling capability
of the pump.

Thispump isdesignedtohandle up to 1/2-inchdi­ameter spherical solids.

Sealing

Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an air­tight seal. Follow the sealant manufacturer’s rec­ommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sumpata distance equal to1 1/2 times the diame­ter of the suction line.

PAGE B -- 3INSTALLATION

OM--01216 0SERIES

If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc­tioninlet because theinflowwillcarryair downinto
the sump, and air entering the suction line will re­duce pump efficiency.

Ifitis necessary to positioninflowclose to the suc­tioninlet, installa bafflebetween theinflowandthe
suctioninlet at a distance 1-1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.

If two suction lines are installed in a single sump,
theflow pathsmay interact,reducing theefficiency
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a dis­tance equal to at least 3 times the diameter of the
suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is
critical toefficient pump operation. Figure 2 shows
recommended minimum submergence vs. veloc-

ity.

NOTE

The pipe submergence required may be reduced
by installing a standard pipe increaserfitting at the
endof the suctionline. The largeropening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

FLOAT SWITCHES

Installation

The standard pump is not furnished with a means
to automatically regulate liquid level. However, if
the unit is equipped with the optional auto-start
control system, the pump can be conformed to

PAGE B -- 4 INSTALLATION

start a nd stop as the liquid level in the wet well or
sump risesand falls. Theautostartoptionemploys
eitherasingle ordoublefloatswitch system,where
a bulb raises or lowers (floats) with the liquid level,
thus activating an enclosed miniature switch. The
floats are equipped with a socket type connector
that plugs into a matching receptacle on the auto ­start control box.