Gorman-Rupp Pumps 04B3-F4L User Manual

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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.

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..............................................

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................................................................

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

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

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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

_ 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

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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.

0SERIES OM--01216

Standard floatsare equipped with 50 feet(15,2m) of cable.

When installing the floats, note the following:

a. Be sure to provide sufficient room in the wet

well or sump so that floats do not get obstructedordrawn intothesuctionline.Ifaflexible suction hose is used, it may be extended tolayalongthebottomofthe wetwellorsump and the float can be attached to the hose abovethe point where it bends along the bottom. Direct the suction line toward the flow, and the float(s) away fromthe flow.If a standpipe is available, attach the float switch cable to the standpipe in the sump at the approximatedesiredliquidlevel.

ENGINE

CONTROL

BOX

(Emptying)

OFF

(Filling)

OPERATING

CABLE

TETHER

RANGE

(See Table Below)

POINT

OFF

(Emptying)

1.25” Pipe (Not Furnished)

(Filling)

b. In a single floatsystem, the cablecan be teth-

ered to the suction line or standpipeapproximately 6 inches (152 mm) above the float. This setting allows approximately 9 inches (229 mm) of liquid rise between pump start/ stop.The start/stopintervalmay beincreased by extending the float end of the cable. The liquid level in the sump will increase approximately8 inches (203mm) between start/stop intervals for every 6 inches (152 mm) of cable increase.

c. If a double float switch system is used, posi -

tion the “Start” float at the desired high water level in the sump, and the “Stop” float at the desired low water level in the pump.

d. Refer to Figure 3 for additional float switch

data.

3.0

(0.9)

2.5

(.76)

2.0

(0.6)

1.5

(.46)

1.0

(0.3)

0.5

(.15)

1.0

(0.3)

APPROXIMATEFREECORDLENGTHINFT.(M)

2.0

(0.6)

3.0

(0.9)

4.0

(1.2)

Figure 3. Float Switch Data

DISCHARGE LINES

Siphoning

Donot terminate the discharge lineat a level lower than that of the liquid being pumped unless a siphon breaker is used in the line. Otherwise, a siphoning action causing damage to the pump could result.

Valves

If a throttlingvalve is desired in the discharge line, useavalveaslargeasthelargestpipetominimize friction losses. Never install a throttling valve in a suction line.

Withhighdischarge heads,itis recommendedthat a t hrottling valve and a system check valve be installed in the discharge line to protect the pump from excessive shock pressure and reverse rotation when it is stopped.

Iftheapplicationinvolvesa highdischarge head, gradually close the discharge throttling valve before stopping the pump.

Bypass Lines

If a system check valve is used due to high discharge head, it may be necessary to vent trapped

PAGE B -- 5INSTALLATION

OM--01216 0SERIES

airfromthetop ofthepump duringtheprimingprocess.This maybeaccomplishedby installingabypass line from the top of the pump, back to the source of the liquid. The end of the bypass line must be submerged. The line must be large enough to prevent clogging, but not so large as to affect pump discharge capacity.

PAGE B -- 6 INSTALLATION

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OM--01216

OPERATION --- SECTION C

Review all SAFETY information in Section A. Follow the instructions on all tags, labels and

decals attached to the pump.

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

PRIMING

Install the pump and piping as described in INSTALLATION. Make sure that the piping connec-

tions are tight, and that the pump is securely mounted. Check that the pump is properly lubricated (see LUBRICATION in MAINTENANCE AND REPAIR).

notprimewhen dry.Extended operationof a dry pump willdestroythesealassembly.

Add liquid to the pump casing w hen:

1. The pump is being put into service for the first time.

2. Thepump has notbeenusedfora considerable length of time.

3. The liquid in the pump casing has evaporated.

When installed in a flooded suction application, simply open the system valves and permit the incoming liquid to evacuate the air. After the pump and piping system have completely filled, evacuate any remaining air pockets in the pump or suctionlineby looseningpipeplugoropeningbleeder valves.

Once the pump casing has been filled, the pump will prime and reprime as necessary.

After filling the pump casing, reinstall and tighten the fill plug. Do not attempt to operate the pump unless all connecting piping is securely installed. Otherwise, liquid in the pump forced out under pressure could cause injury to personnel.

Tofill the pump, remove the pump casing fill cover or fill plug in the top of the casing, and add clean liquid until the casing is filled. Replace the fillcover or fill plug before operating the pump.

This pump is self priming, but the pump should never be operated unless there is liquid in the pump casing.

STARTING

Ifthe pump is equipped with the optional automatic starting system, it is sub-

Never operate this pump unless there is liquid in the pump casing. The pump will

OPERATION PAGE C -- 1

ject to automatic restart. Keep hands and clothing away from the unit to pre-

OM--01216 0SERIES

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

Consult the operations manual furnished with the engine.

Manual Starting

On initial start-up, set the engine speed at the halfthrottleposition.Turnthe keyswitch on the control boxto the “START”positionuntil the enginestarts. Release the key and the switch will return to the “RUN” position.

After the engine starts and the unit is fully primed, adjust the engine RPM until the desired flow rateis achieved.

Pump speed and operating condition points must be within the continuous performance range shown on the curve on page E-1.

the keyswitch in the “AUTO START” position by pressing thewhite“MAN”button onthecontrol.The “Single Lightning Bolt” light on the control will illuminate in conjunction with an audible alarm before the unit starts. The unit can then be stopped manually by pressing the “OFF/SET” button.

In the auto-start mode, the “SingleLightningBolt” light will illuminate in conjunction with an audible alarm when the liquid level in the sump or wet well rises and activates the float(s). The light will blink and the alarm will sound for approximately 8 seconds before the unit starts.

Whentheliquidlevelinthesumpor wetwell issufficiently pumped down, the unit will automatically shut down.

NOTE

If the keyswitch is moved to the “OFF” position while in the auto-start mode, the engine will stop. However, the auto-start process will continue as soonas thekeyswitch is moved backtothe “AUTO START” position. Tocancel the auto-start process, press the “OFF/SET” button.

Automatic Starting

If the unit is equipped with the optional autostart control system, install the float(s) as described in INSTALLATION, Section B.

Followtheprocedures outlined formanual starting and throttle adjustment, then turn the key to the “AUTO START” position.

NOTE

For securitypurposes, thekey canbe removedwith the switch in the “AUTO START” position.

Press and hold the white “AUTO” button on the controlpanel untilthered “AUTO”lightilluminates. The auto-start system is now armed.

NOTE

The unit can continue to be started manually with

Thecontrolpanelisequipped with high oiltemperature, lowoil pressure, V-beltand start failure(3 attempts)safetyshutdowns. Ifanyoftheseproblems occur,the red “Double LightningBolt”lightwillilluminate to indicate a system fault. When the problemis corrected,pressthe“OFF/SET”buttontoreset the control.

NOTE

The “OFF/SET” button has dual functionality when in program mode. If necessary, consult the factory for details on programming functions.

The unit can be started manually with the keyswitch in the “AUTO START” position by pressing the white “MAN” button. The “Single Lightning Bolt” light will illuminatein conjunction with an audible alarm before the unit starts.

Stop the unit manually bypressing the “OFF/SET” button.

OPERATIONPAGE C -- 2

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OM--01216

OPERATION

Lines With a Bypass

Close the discharge throttling valve (if so equipped) so that the pump will not have to prime against the weight of the liquid in the discharge line. Air from the suction line will be discharged throughthe bypassline backto thew et wellduring the priming cycle. When the pump is fully primed andliquidisflowingsteadilyfromthebypassline, open the discharge throttling valve. Liquid will then continueto circulate through the bypass linewhile the pump is in operation.

Lines Without a Bypass

Open all valves in the discharge line and start the power source. Priming is indicated by a positive reading on the discharge pressure gauge or by a quieteroperation. The pump maynot primeimmediately because the suction line must first fill w ith liquid. If the pump fails toprimewithin fiveminutes, stop it and check the suction line for leaks.

Afterthepump hasbeen primed,partiallyclosethe discharge line throttling valve in order to fill the line slowly and guard against excessive shock pressure which could damage pipe ends, gaskets, sprinkler heads, and any other fixtures connected to the line. When the discharge line is completely filled,adjustthethrottlingvalve tothe requiredflow rate.

boil, build pressure, and cause the pump to rupture or explode. If overheating occurs, stop the pump and allow it to cool before servicing it. Refill the pump casing with cool liquid.

Strainer Check

If a suction strainer has been shipped with the pump or installed by the user, check the strainer regularly, and clean it as necessary. The strainer shouldalsobe checkedifpumpflowratebeginsto drop. If a vacuum suction gauge has been installed, monitor and record the readings regularly to detect strainer blockage.

Never introduce air or steam pressure into the pump casingor piping to removea blockage.This could result in personal injury or damage to the equipment. If backflushing is absolutely necessary,liquid pressuremustbe limited to50% oft he maximum permissible operating pressure. Since this pump is fitted with a Gorman-Rupp double grease lubricated seal, the maximum incoming pressure must be reduced to 10 p.s.i.

Leakage

No leakage should be visibleat pump mating surfaces, or at pump connections or fittings. Keep all lineconnectionsand fittingstight tomaintain maximum pump efficiency.

Liquid Temperature And Overheating

The maximum liquid temperature for this pump is 160_ F(71_C).Donotapplyitata higher operating temperature.

Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a

OPERATION PAGE C -- 3

Pump Vacuum Check

Withthe pump inoperative,installa vacuumgauge in the system, using pipe dope on the threads. Block the suction lineandstart thepump. At operating speed the pump should pull a vacuum of 20 inches (508,0 mm) or more of mercury. If it does not, check for air leaks in the seal, gask et, or discharge valve.

Openthe suctionline,andread thevacuum gauge with the pump primed and at operation speed. Shut offthe pump. The vacuumgaugereading will immediately drop proportionate to static suction lift,andshouldthenstabilize.Ifthevacuumreading falls off rapidly after stabilization, an air leak exists.

OM--01216 0SERIES

Before checking for the source of the leak, check the point of installation of the vacuum gauge.

STOPPING

Manual Stopping

In the manual mode, reduce the throttle speed slowly, and allow the engine to idle briefly before switching the HAND-OFF-AUTO switch to ‘OFF’.

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

Afterstoppingthe pump,switchoffthe engineignition and disconnect the positive battery cable to ensure that the pump will remain inoperative.

Automatic Stopping

In the automatic mode, the pump will stop when the liquid in the wet well or sump lowers and activatesthe“Off” floatswitch(s).Thepump willrestart automatically when the liquid rises and activates the “On” float switch(s).

Safety Shutdown System

The unit is equipped with a safety system to automaticallyshut down the engine under certain conditions. The engine will automatically shut down:

1. If the engine exceeds its safe operating temperature.

2. If the engine oil pressure drops below design limits.

3. Iftheenginefailstostartwithinapre-setperiod of time.

Shouldany oft he safety featurescausethe engine toshut down,the cause must bedeterminedand correctedbeforeputtingtheunitback intoservice. The engine will not restart until the HAND-OFFAUTOswitch has been returned to the ‘OFF’ position for at least 10 seconds.

Allsafetyshutdown features are pre-set at the factory for optimum performance and safety; do not attempt to adjust these settings.

Neverdisconnectanyofthe safetyshutdown features; this will void the warran-

and could result in serious damage to

ty theuni t and/orinjuryto personnel.Safety shutdown features are pre-set at the factory; do not

attempt to adjust any of the settings. Determine the cause of shutdown before putting the unit back into service. Consult the factory for additional information.

OPERATIONINEXTREMEHEAT

The safety shutdown system will automatically stop the unit if engine operating temperature exceeds design limits. If engine over-temperature shutdown occurs, allow the unit to cool before restarting.

If engine overheating continues, check the engine lubricant level and viscosity. Consult the engine operation manual for the recommended lubricant for operation in extreme heat.

If the unit is equipped with the optional auto-start control,the float(s)may need to be adjusted to allow shorter run and longer coolingperiods, ifpossible.

4. If the engine speed exceeds the safe operating range.

5. Iftheenginefanbeltbreaks.

Lights onthe control panelwillindicatewhich ofthe safety features has caused the engine to shut down.

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 prevent injury during automatic operation. Disconnect the battery before perform-

OPERATIONPAGE C -- 4

0SERIES

OM--01216

ing any maintenance. Failure to do so may result in serious personal injury.

BEARING TEMPERATURE CHECK

Bearingsnormallyrun at highert han ambient temperatures because of heat generated by friction. Temperatures up to 160_F(71_C) are considered normalforbearings, andthey canoperatesafelyto at least 180_F(82_C).

Checkingbearingtemperatures byhand isinaccurate. Bearing temperatures can be measured accurately by placing a contact-type thermometer against the housing. Record this temperature for future reference.

A sudden increase in bearing temperatures is a warning that the bearings are at the pointoffailing to operate properly.Make certain that the bearing lubricant is of the proper viscosity and at the correct level (see LUBRICATION in Section E). Bear-

ing overheating can also be caused by shaft misalignment and/or excessive vibration.

When pumps are first started, the bearings may seem to run at temperatures above normal. Con tinued operation should bring the temperatures down to normal levels.

Cold Weather Preservation

In below freezing conditions, drain the pump to preventdamagefrom freezing. Also,clean outany solids by flushing w ith a hose. Operate the pump for approximatelyone minute; this willremove any remaining liquid that could freeze the pump rotating parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids containing a large amount of solids, drain the pump, and flush it thoroughly with clean water .T oprevent large solids from clogging the drain port and preventing the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the liquid during the draining process. Clean out any remaining solids by flushing with a hose.

OPERATION PAGE C -- 5

0SERIES

OM--01216

TROUBLESHOOTING --- SECTION D

Review all SAFETY information in Section A.

Beforeattemptingto openorservicethe pump:

1. Familiarize yourself with this man ual.

2. Set the HAND-OFF-AUTO switch to ‘OFF’, and disconnect the positive battery cable 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.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

Not enough liquid in casing. Add liquid to casing. See PRIMING. Suction check valve contaminated Clean or replace check valve.

or damaged. Air leak in suction line. Correct leak. Lining of suction hose collapsed. Replace suction hose. Leaking or worn seal or pump gasket. Check pump vacuum. Replace

leakingorwornsealorgasket.

Suction lift or discharge head too high. Check piping installation and

install bypass line if needed. See INSTALLATION.

Strainer clogged. Check strainer and clean if

necessary.

Suction check valve or foot valve Clean valve. clogged or binding.

Air leak in suction line. Correct leak. Lining of suction hose collapsed. Replace suction hose.

Leaking or worn seal or pump gasket. Check pump vacuum. Replace

leakingorwornsealorgasket.

Strainer clogged. Check strainer and clean if

necessary.

TROUBLESHOOTING PAGE D -- 1

OM--01216

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

0SERIES

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.)

PUMP REQUIRES TOO MUCH POWER

PUMP CLOGS FREQUENTLY

Suction intake not submerged at Check installation and correct proper level or sump too small. submergence as needed.

Impellerorotherwearingpartsworn Replacewornordamagedparts. or damaged. Check that impeller is properly

centered and rotates freely. Impeller clogged. Free impeller of debris. Pump speed too s low. Check engine output; consult

engine operation manual. Suction lift or discharge head too high. Check piping installation and

install bypass line if needed. See

INSTALLATION. Pump speed too high. Check engine output.

Discharge head too low. Adjust discharge valve. Liquid solution too thick. Dilute if possible. Bearing(s) frozen. Disassemble pump and check

bearing(s). Liquid solution too thick. Dilute if possible.

Discharge flow too slow. Open discharge valve fully to in---

crease flow rate, and run power

source at maximum governed

speed.

EXCESSIVE NOISE

BEARINGS RUN TOO HOT

Discharge line clogged or restricted; Check discharge lines; straighten hose kinked. hose.

Suction check valve or foot valve Clean valve. clogged or binding.

Cavitation in pump. Reduce suction lift and/or friction

losses in suction line. Record

vacuum and pressure gauge

readings and consult local

representative or factory. Pumping entrained air. Locate and eliminate source of air

bubble. Pump or drive not securely mounted. Secure mounting hardware. Impeller clogged or damaged. Clean out debris; replace damaged

parts. Bearing temperature is high, but Check bearing temperature regu---

within limits. larly to monitor any increase. Loworincorrectlubricant Checkforpropertypeandlevel

of lubricant. Suction and discharge lines not Check piping installation for proper

properly supported. support. Drive misaligned. Align drive properly.

TROUBLESHOOTINGPAGE D -- 2

0SERIES

OM--01216

PREVENTIVE MAINTENANCE

Sincepump applicationsareseldomidentical,and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature oftheliquidbeingpumped, thissection isintended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however,following a routine preventive maintenance schedule will help assure trouble-free performance and long life from your Gorman-Rupp pump. For specific questions concerning your application, contact your GormanRupp distributor or the Gorman-Rupp Company.

Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so

equipped) between regularly scheduled inspections can indicate problems that can be corrected before system damage or catastrophic failure occurs.The appearanceof wearingpartsshouldalso bedocumented ateach inspectionfor comparison as well. Also, if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced beforefailureoccurs,reducing unscheduleddown time.

For new applications, a first inspection of wearing partsat250 hourswillgiveinsightintothewearrate foryourparticularapplication.Subsequentinspections should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

Loose Hardware, Etc.) I Pump Performance (Gauges, Speed, Flow) I Bearing Lubrication I R Seal Lubrication (And Packing Adjustment,

If So Equipped) I R V-Belts (If So Equipped) I Air Release Valve Plunger Rod (If So Equipped) I C Front Impeller Clearance (Wear Plate) I Rear Impeller Clearance (Seal Plate) I Check Valve I Pressure Relief Valve (If So Equipped) C Pump and Driver Alignment I Shaft Deflection I Bearings I Bearing Housing I Piping I Driver Lubrication --- See Mfgr’s Literature

Daily Weekly Monthly Semi-

Annually

Legend:

I = Inspect, Clean, Adjust, Repair or Replace as Necessary C= Clean R= Replace

* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.

Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.

TROUBLESHOOTING PAGE D -- 3

0SERIES OM--01216

PUMP MAINTENANCE AND REPAIR - SECTION E

MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE.

STANDARD PERFORMANCE FOR PUMP MODEL 04B3--F4L

Based on 70_ F(21_ C) clear water at sea level with minimumsuction lift.Since pump installations areseldomidentical,yourperformancemaybe difference due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.

Never tamper with the governor to gain more power. The governor establishes

If your pump serial number is followed by an “N”, your pump is NOT astandardproductionmodel. Contact the Gorman-Rupp Company to verifyperformance or part numbers.

MAINTENANCE & REPAIR PAGE E -- 1

safe operating limits that should not be exceeded. The maximum continuous operating speed for this pump is 2400 RPM.

SECTION DRAWING

0SERIESOM-- 01216

Figure 1. 04B3---F4L Pump Model Assembly

MAINTENANCE & REPAIRPAGE E -- 2

0SERIES OM--01216

PARTS LIST

Pump Model 04B3---F4L

(From S/N 1242057 Up)

Ifyourpump serialnumber is followedby an “N”,your pumpis NOT a standard production model. Contact the Gorman-Rupp Company to verify part numbers.

ITEM NO.

10 FUEL RETURN LINE 14294 24030 1 11 MUFFLER GUARD ASSY 42331---031 --- ------ 1 12 DEUTZ F4L 912D ENG 29217---043 --- --- --- 1 13 CAUTION DECAL 38816---169 --- - -- --- 1 14 BAT T E RY B O X A S S Y GR P 40 --- 08 C --- --- --- 1 15 ---HEX HD CAPSCREW B0607 15991 2 16 ---FLAT WASHER K06 15991 2 17 ---HEX NUT W/FLANGE 21765---314 --- ------ 2 18 ---GRND CABLE ASSY 47311---064 --- --- --- 1 19 ---BATT BOX LID ASSY 42113---012 24150 1

20 21 ---BATTERY TAG 38818- --506 ------ --- 1 22 ---BATTERY BOX ASSY 42431---030 24150 1 23 ---STUD MOUNT 24631---006 --- --- --- 4 24 ---FLANGED HEX NUT 21765---314 --- ------ 8 25 ---T TYPE LOCKWASHER BL06 15991 1 26 POS CABLE ASSY 47311---114 ------ --- 1 27 HEX HD CAPSCREW B1017 15991 2 28 LOCKWASHER J10 15991 2 29 HEX NUT D10 15991 2 30 OIL DRAIN ASSY 46342---007 --- - -- --- 1

PART NAME PART

NUMBER

1 P U MP E N D A S S Y 04B3 --- (SA E 4/ 1 0) --- --- --- 1 2 CONTROL PANEL 48122---501 --- --- --- 1 3 EXHAUST ELBOW 31912---023 15990 1 4 WEATHER CAP S1331 --- ------ 1 5 FUEL RETURN LINE 11308F ------ --- 1 6 HOSE CLAMP 26518---641 --- -- ---- 2 7 HOSE BARB FITTING 26523---443 --- ------ 1 8 MALE CONNECTOR 26523---382 ------ --- 1 9 REDUCER ELBOW Q0402 11999 1

---12V BATTERY SEE OPTION LIST REF

MAT’L CODE

QTY ITEM

NO. 31 HOSE INLET ASSY 46341---796 ------ --- 1

32 MALE CONNECTOR S1447 --- ------ 1 33 HEX HD CAPSCREW B1007 15991 4 34 LOCKWASHER J10 15991 4 35 HEX NUT D10 15991 4 36 FUEL TANK AND 46711---041 ------ --- 1

37 ---FUEL TANK ASSY 46711---042 ------ --- 1 38 ---FLANGED HEX NUT 21765---314 --- ------ 6 39 ---CARRIAGE BOLT AB0604 15991 6 40 ---FLAT WASHER K06 15991 6 41 ---TANK GRD ASSY 34851---178 15080 1 42 FLANGED HEX NUT 21765---314 --- ------ 10 43 FLAT WASHER K06 15991 10 44 HEX HD CAPSCREW B0604 15991 10 45 COMBINATION BASE 41566- --669 24150 1 46 HEX HD CAPSCREW B1010 15991 2 47 LOCKWASHER J10 15991 2 48 HEX NUT D10 15991 2

NOT SHOWN:

OPTIONAL:

PART NAME PART

NUMBER

GUARD ASSEMBLY

WARNING DECAL 2613FE ------ - -- 1

12V BATTERY 29331---506 --- ------ 1 WHEEL KIT GRP30---248F --- ------ 1 PRESSURE GAUGE 48312---012 --- --- --- 1 REPAIR MUFFLER 42331- --048 ------ --- 1 GUARD ASSEMBLY

MAT’L CODE

QTY

INDICATES PARTSRECOMMENDEDFOR STOCK

MAINTENANCE & REPAIR PAGE E -- 3

SECTION DRAWING

0SERIESOM-- 01216

Figure 2. 04B3---(SAE 4/10) Pump End Assembly

MAINTENANCE & REPAIRPAGE E -- 4

0SERIES OM--01216

PARTS LIST

04B3---(SAE 4/10) Pump End Assembly

ITEM NO.

10 RD HD MACH SCREW X0404 15991 2 11 12 LU B E F IT TING S1 91 --- --- --- 1

13 PIPE NIPPLE T0410 15079 1 14 PIPE COUPLING AE04 15079 1 15 CAP PLUG 25141---151 --- - -- --- 1 16 ALLEN HD SETSCREW GA0403 15990 1

17 18 19

20 INTERMEDIATE GUARD 42381---504 --- ------ 2 21 BEARING RET NUT 4329 10010 1 22 SPACER 13886 15990 1 23 RET AIN I N G R ING S2 1 5 --- --- --- 1

PART NAME PART

1 PUMP CASING 4820C 10010 1 2

IMPELLER 4803D 14000 1 SEAL ASSY 25271---207 --- ------ 1

3 4 DISCHARGE STICKER 6588BJ ------ --- 1 5 STUD C1010 15991 8 6 HEX NUT D10 15991 8 7

WEAR RING 3765A 10010 1 8 DISCHARGE FLANGE 1756 10010 1 9

DISCH FLANGE GASKET 1676GB 20000 1

BALL BEARING 23423---472 --- -- ---- 1

IMP ADJ SHIM SET 37J 17090 REF

SHAFT KEY N0607 15990 1

IMPELLER SHAFT 38517---517 1706H 1

NUMBER

MAT’L CODE

QTY ITEM

NO. 24 RET AIN I N G R ING S2 1 5 --- --- --- 1

25 INTERMEDIATE 7765D 10010 1 26

27 STUD C1010 15991 12 28 HEX NUT D10 15991 12 29 SEAL PLATE 5792 10010 1

30 31

32 NAME PLATE 38818---018 13990 1 33 DRIVE SCREW BM#04---03 17000 4 34 PIPE PLUG P06 15079 1 35 STUD C0807 15991 6 36 HEX NUT D08 15991 6 37 COVER PLATE 4822 10010 1

38 39 40 SUCTION FLANGE 1756 10010 1 41 HEX HD CAPSCREW B1005S 15991 1 42 T TYPE LOCKWASHER AK10 15991 1 43 IMPELLER WASHER 5718 15990 1 44 HEX HD CAPSCREW C1010 15991 8 45 HEX NUT D10 115991 8 46 DISCHARGE STICKER 6588AG --- --- --- 1 47 FILL PLUG ASSY 48271---065 --- ------ 1

PART NAME PART

NUMBER

WEAR RING 6902 10010 1

PUMP CASING GASKET 4820G 20000 1 IMPELLER KEY N0408 15990 1

COVER PLATE GASKET 4822G 20000 1 SUCT FLANGE GASKET 1676GB 20000 1

MAT’L CODE

QTY

INDICATES PARTSRECOMMENDEDFOR STOCK

MAINTENANCE & REPAIR PAGE E -- 5

SECTION DRAWING

0SERIESOM-- 01216

Figure 3. 04B3---(SAE 4/10) Drive Assembly

PARTS LIST

ITEM NO.

1 PILOT BUSHING ASSY 44144---003 ------ --- 1 2 COUPLING KIT 48112---001 --------- 1 3 ---BUSHING 24131---345 ------ --- 1 4 ---COUPLING ASSEMBLY 44165---011 --------- 1 5 ---LOCKWASHER 21171---536 --------- 8 6 ---SOCKET HD CAPSCREW 22644---220 --------- 8 7 HEX HD CAPSCREW 22645---164 --------- 12 8 LOCKWASHER 21171---511 --------- 12

PART NAME

PART NUMBER

MAT’L CODE

MAINTENANCE & REPAIRPAGE E -- 6

QTY

OM--012160SERIES

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.

Followtheinstructionson all tags,labeland de cals attached to the pump.

This pump requires little service due to its rugged, minimum-maintenance design. However, if it becomesnecessarytoinspect orreplacethe wearing parts, followthese instructionswhichare keyed to thesectionalviews(seeFigures 1,2 and3) andthe accompanying parts lists.

As described on the following pages, this manual willalert personnel toknown procedures which require special attention, to those which could dam age equipment, and to those which could be dangerousto personnel. However,this manualcannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenanceof theunit. Therefore,itis theresponsibilityof the owner/maintenance personnel to ensure that only safe, established maintenance proceduresare used, andthat anyproceduresnot addressedinthismanualareperformedonlyafterestablishingthat neitherpersonal safetynorpump integrity are compromised by such practices.

Before attempting to service the pump, switch off theengineignitionanddisconnect thepositivebatterycabletoensure thatthe pumpwill remaininoperative. Close all valves in the suction and dis charge lines.

Forengine disassembly and repair, consult the literature supplied with the engine, or contact your local engine representative.

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.

Pump Disassembly (Figure 2)

Beforeattemptingtoservicethepump, removethe pump casing drain plug (34) and drain the pump. Clean and reinstall the drain plug.

To service the wear ring (7), impeller (2), seal assembly (3), or seal plate (29), the pump casing (1) mustbe separatedfromthebase andintermediate (25).

Remove the suction and discharge lines. See Figure1,andremovethehardware(46, 47and 48)securing the casing to the base (45). Remove the nuts(28)and useasuitablehoistand slingtoseparatethe pumpcasingandgasket(30)fromtheseal plate and intermediate.

Tieand tagany levelingshims usedunder the casing feet to ease reassembly.

Beforeattemptingto openorservicethe pump:

1. Familiarize yourself with this man ual.

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

MAINTENANCE & REPAIR PAGE E -- 7

Inspect the wear ring (7) for excessive wear or scoring.The wear ring issecured in the pumpcasing by a press fit. If replacement is required, use a small bit to drill two holes through the ring horizontally, 180_ apart. Use a saw or chisel to complete the cuts through the ring, and remove it from the pump casing. Use caution not to damage the pump casing bore when removing the wear ring.

Use caution not to damage the pump casing bore when removing the wear ring.

0SERIESOM--01216

(Figure 3)

Support the intermediate using a hoist and sling, and remove the hardware (7 and 8) securing it to theenginebellhousing.Separatetheassemblies by pulling the intermediate straight away from the engine.

Impeller Removal (Figure 2)

To remove the impeller (2), disengage the hardware(41,42 and 43).Install3/8---16UNCby 4-inch longcapscrews inthetapped holesin the impeller. Use thecapscrewsanda suitablepuller toremove the impeller from the shaft. Use caution when removingthe impeller;tension on the sealspring will be released as the impeller is removed. Retain the impeller key (31).

Remove the impelleradjusting shims (17). Tie and tag the shims or measure and record their thickness for ease of reassembly.

Seal Removal and Disassembly (Figures 2 and 5)

Removethe spring. Apply oilto the shaft and work it up under the rubber bellows. Slide the rotating portionofthesealofftheshaft.

Remove the round head machinescrews (10) and slide the seal plate and stationary element off the impeller shaft as a unit. Press the stationary seal element and O-ring out of the seal plate from the back side.

Inspect the wear ring (26) for excessive wear or damage. If replacement is required, use a suitable puller to remove it from the seal plate.

As the assemblies separate, the flexible portionof the couplingassembly(4) will remain on the shaft. Toremovethe couplingfromt he shaft,unscrew the two allen head setscrews from the bushing (3). Screw one ofthe setscrews into the puller holeon the circumference of the bushing. As the coupling and bushing separate, remove the bushing, and slide the coupling off the shaft. Remove the shaft key (18, Figure 2).

It is not necessary to remove the outer ring of the coupling from the engine flywheel unless the couplingmust be replaced. To removethe ring, disengage the hardware (5 and 6) securing it to the flywheel.

Inspect t he pilot bushing (1) for excessive wear. If replacement is required, it can be easily removed from the engine flywheel by making a hydraulic ramfroma piece ofsteel bars tock. Turnthe ramto a diameter of 0.983 inch (25 mm).

Whenperforming the following procedure, grease can be ejected with great force. Wear safety glasses or goggles to prevent injury.

Completelypack the bore of the pilotbushingwith grease. Insert theendof the ram intothe I.D.of the bushing. Strike the ram sharply with a hammer, compressing the grease, and forcing the bushing out of the flywheel. Use additional grease as required, and continue to strike the ram until the bushing is completely free.

Separating Intermediate and Drive Assembly From Engine

(Figure 2)

To service the shaft (19), bearing (11) or drive assembly, the intermediate (25) must be separated from the engine.

Shaft and Bearing Removal and Disassembly (Figure 2)

When the pump is properly operated and maintained, the shaft and bearing should not require disassembly. Disassemble the shaft and bearing

only when there is evidence of wear or damage.

MAINTENANCE & REPAIRPAGE E -- 8

Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel.

After separating the intermediatefrom the engine, loosen the allen head setscrew (16) and unscrew thebearing retainernut (21) fromtheintermediate.

NOTE

There are no provisions for draining the grease fromtheintermediatecavity.Placea drip pan under theintermediatebeforeremovingtheshaftand bearing.

OM--012160SERIES

Cleanthebearingthoroughlyinfreshcleaningsolvent. Dry the bearing with filtered compressed air and coat with light oil.

Thebearingmustbekeptfreeofalldirtand foreign material. Failure to do so willgreatly shorten bearing life. Do not spin dry bearings. This may scratch the balls or races and cause premature bearing failure.

Rotatethe bearingbyhand tocheck forroughness or binding and inspect the bearing balls. If rotation is rough or the bearing balls are discolored, replace the bearing.

Place a block of wood against the impeller end of the shaft (19) and tap the shaft, spacer (22) and bearing (11) from the bearing bore.

Afterremoving theshaftand bearing, cleanandinspect the bearing in place as follows.

To prevent damage during removal from theshaft, it is recommendedthat thebearing be cleaned and inspected in place.It isstrongly recommended that thebearing bereplacedany time theshaftandbearing are removed.

Clean the intermediate, s haft and all component parts (except the bearing) with a soft cloths oaked in cleaning solvent. Inspect t he parts for wear or damage and replace as necessary.

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solventcontainers.

The bearing tolerances provide a tight press fit ontothe shaft and a snug slipfit into the intermediate. Replace the bearing, shaft, or intermediate if the proper bearing fit is not achieved.

Remove the inboard bearing retaining ring (24) andusing anarbor (orhydraulic)press removethe bearing (11) from the shaft. It is not necessary to remove the outboard bearing retaining ring (23) from the shaft unless replacement is required. Remove the bearing spacer (22).

Shaftand Bearing Reassembly and Installation

Clean and inspect the bearing as indicated in Shaft and Bearing Removal and Disassembly.

Inspect the shaft for distortion, nicks or scratches ordamage. D ress small nicks and burrswith a fine file or emery cloth. Replace the shaft if defective.

Installthe outboard bearing retaining ring (23) if it was removed. Replace the bearing spacer (22).

MAINTENANCE & REPAIR PAGE E -- 9

0SERIESOM--01216

NOTE

If ahot oil bathis used to heat thebearing, boththe oil and the container must be absolutely clean. If the oil has been previously used, it must be thor- oughly filtered.

Thebearing maybe heatedto ease installation.An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearing. Bearings should never be heated with a direct flame or directly on a hot plate.

NOTE

Positionthebearing ontheshaftas indicated inFigure 4.

BALL LOADING

DIRECTIONOF

THRUST

GROOVE POSITIONED AWAY FROM

LOADING GROOVE

IMPELLER

Heat the bearing to a uniform temperature no higher than 250_F (120_C), and slide the bearing

ontothe shaft until fullyseated against the bearing spacer. This should be done quickly, in one continuous motion, to prevent the bearing from cooling and sticking on the shaft.

Use caution when handling hot bear ings to prevent burns.

BALL LOADING

DIRECTIONOF

THRUST

GROOVE POSITIONED

TOWARD

LOADING GROOVE

IMPELLER

INSTALLATION OF NEW DEPARTURE OR

BCA/FEDERAL MOGAL 5300W SERIES BEARINGS

(OPEN OR ENCLOSED IMPELLERS)

Figure 4. Bearing Positioning

After the bearing has been installed and allowed to cool, check to ensure that it has not moved in shrinking. If movement has occurred, use a suitable sized sleeve and a press to reposition the bearing.

Ifheatingthebearingis notpractical,usea suitable sizedsleeveandan arbor(orhydraulic)press toinstall the bearing on the shaft.

When installing the bearing on the shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.

Packthe bearing by hand with No. 0 lithiumbased grease until the bearing balls are thoroughly lubri-

INSTALLATIONOF MRC/SKF5300M OR

FAFNIR 5300W SERIES BEARINGS

(OPEN OR ENCLOSED IMPELLERS)

cated. Secure the bearing on the shaft with the inboard bearing retaining ring (24).

Slide the shaft and assembled bearing into the intermediate bore from the drive end until the bearing seats squarely against the bore shoulder.

When installing the shaft and bearing into the bearing bore, push against the outer race. Never hit the balls or ball cage.

Installthe spacer(22)in theintermediate. Packthe intermediate w ith 2/3 lb. (0.3 kg.) of No. 0 lithium based grease (approximately 1/3 full).

Screw the bearing retaining nut (21) into the intermediate and check the shaft endplay. Adjust the bearing retaining nut to establish the correct

MAINTENANCE & REPAIRPAGE E -- 10

OM--012160SERIES

endplay,and secure the bearingretaining nutwith the setscrew (16).

NOTE

Impellershaftendplayshouldbe between.002and .010inch(0,05mmto0,25mm). Adjustthebearing retaining nut to obtain the correct endplay.

Securing Intermediate and Drive Assembly To Engine

(Figure 3)

Ifremoved,apply a thincoating of‘Never-Seez’(or equivalent) lubricant to the inside diameter of the replacement pilot bushing (1) and press it into the flywheel until fully seated.

Install the shaft key (18, Figure 2) in the shaft keyway.Position the flexible portion ofthecouplingassembly (4) on the shaft as shown in Figure 3.

NOTE

Theflexible portion ofthe coupling mustbeproperly positioned on the shaft. The heads of the capscrews in the center of the coupling must be posi- tioned toward the pump end of the shaft.

Align the keyway in the bushing (3) with the shaft key, and slide it onto the shaft to the dimension showninFigure3.

without pre-loading the bearing or pilot bushing.

Rotate the flexible portion of the coupling until the tappedholesforthetwosetscrewsalign withthose in the bushing, and install the setscrews.

With the flexible portion of the coupling and the bushing properly positioned on the shaft, tighten the two setscrews in an alternatingsequence until thebushing andcouplingare fullysecured.Torque thesetscrewsto175in.lbs.(2m.kg.).

If the complete coupling assembly is being replaced, apply ‘ Loctite Retaining Compound No. 242’ or equivalent compound to the threads of the hardware(5and 6),andsecure theouterringofthe coupling to the engine flywheel by torquing the hardwareto45ft.lbs.(540in.lbs.or6,2m.kg.).

Using a suitable lifting device, position the assembled intermediate and flexible portion of the couplingso thecouplingseatsinsidetheouterring attached to the engine flywheel.

NOTE

Toeaseinstallation,lightlylubricatetherubberportion of the coupling with a non-petroleum based lubricant suchasvegetableoilor glycerin,ora silicon-based lubricant such as“WD40”or equivalent. Donot usepetroleum-basedlubricants,oranyother substance which may soften or otherwise damage the rubber.

Secure the intermediate to the engine bellhousing with the previously removed hardware (7 and 8).

Make certain that the flexible portion of the coupling is mounted as shown in Figure 3.

Seal Reassembly and Installation (Figures 2 and 5)

Thisis critical. If the coupling is not prop-

erly positioned on the shaft, the coupling

Cleanthe seal cavityandshaft witha clothsoaked in fresh cleaning solvent.

parts may not fully engage, or a pre-load condition can cause premature bearing failure.

The flexible portion of the coupling, shaft key and bushing must be positioned on theshaft to thedimension shown inFigure

3. This will allow the two portions of the coupling to fullyengage when the intermediate is secured to the engine bellhousing,

MAINTENANCE & REPAIR PAGE E -- 11

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solventcontainers.

0SERIESOM--01216

The sealis not normallyreused because wear patterns on the finished faces cannot be realigned during reassembly. This could result in premature failure.Ifnecessary toreuse anoldsealinanemergency, carefully w ash all metallic parts in fresh cleaning solvent and allow to dry thoroughly .

Handlethe seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shortenseallife.Ifnecessary,cleanthefaceswitha non-oilbased solvent and a clean, lint-free tissue. Wipe lightly in a concentric pattern to avoid scratching the faces.

SPRING

RETAINER

IMPELLER

SHAFT

KEY

Inspect the seal components for wear, scoring, grooves,and otherdamage that mightcauseleakage.Ifany componentsareworn,replacethe complete seal; never mix old and new seal parts.

If a replacement seal is being used, remove it from the container and inspect the precision finished faces to ensure that they are free of any foreign matter.

To ease installation of the seal, lubricate the bellows and O-rings with water or a very small amount of light lubricating oil, and apply a drop of lightlubricatingoilonthe finishedfaces.Assemble thesealasfollows,(seeFigure5).

SEAL PLATE

O-RING

IMPELLER

SHAFT

BELLOWS

IMPELLER

SHIMS

DRIVE BAND

Figure 5. 25271--207 Seal Assembly

This seal is not designed for operation at temperatures above 160_F(71_C). Do not use at higher operating temperatures.

STATIONARY

SEAT

ROTATING

ELEMENT

plate untilit seatssquarelyagainst the bore shoulder.

Laythe seal plate (29)on a flat surface with the impeller side facing up. If the wear ring (26) was removed, press the replacement ring into the seal

The wear ring must seat squarely in the seal plate bore or binding and/or excessive wear will result.

MAINTENANCE & REPAIRPAGE E -- 12

OM--012160SERIES

Subassemble the O-ring onto the stationary element and use even pressure to press this subassembly into the seal plate until it seats squarely against the shoulder bore

Carefully slide the assembled seal plate and stationarysealelement overtheshaft.Securetheseal plate to the intermediate w ith the round head machine screws (10).

NOTE

It is recommended that a tapered sleeve be installedover the endof theimpellershaft to easeinstallation of the rotating seal components.

Subassemble the rotating element into theretainer and bellows. Lubricate the I.D. of the bellows with water,and slidethis subassemblyoverthetapered

sleeve and onto the shaft until the polished faces contact. Install the seal spring.

Impeller Installation (Figure 2)

Inspect the impeller, and replace it if cracked or badly worn.

Formaximum pump efficiency,the impellershould be centered within the volute scroll.

To verify the impeller positioning, measure the pump casing and impeller as shown in Figure 6. Usethese measurementstocalculatetherequired impeller location (dimension E). Add orremoveimpelleradjusting shims (17) untildimension E isobtained.

B 2

Figure 6. Centering Impeller Within Volute Scroll

Installthe correct thickness of impellershims, and install the impeller key (31) in the shaft keyway. Align the impeller keyway with the key, and slide the impeller onto the shaft until fully seated. M ake sure theseal s pring seats squarely over the shoulder on the back of the impeller.

NOTE

After the impeller has been properly positioned, check for free rotation. Correct any scraping binding before further reassembly.

D 2

Step 2Step 1 Step 3

---

Pump Reassembly (Figure 2)

If removed at disassembly, press the replacement wear ring (7) into the pump casing until it seats squarely against the shoulder bore.

The wear ring must seat squarely in the

When the impeller is properlypositioned, secure it with the hardware (41, 42 and 43).

MAINTENANCE & REPAIR PAGE E -- 13

casing bore or binding and/or excessive wear will result.

0SERIESOM--01216

Install the casing gasket (30) and secure the casingto the seal plateand intermediatewith the nuts (28). See Figure 1, reinstall any leveling shims under the casing mountingfeet, and secure the casing to the base (45) with the previously removed hardware (46, 47 and 48).

Final Pump Assembly

Be sure the pump and engine are securely

mounted to the base. Installthe suctionanddischarge linesand open all

valves. Makecertainthatallpiping connectionsare tight, properly supported and secure.

Be sure the pump, intermediate and engine have been properly lubricated, see LUBRICATION.

Fill the pump casing with clean liquid. Reinstall the fill plug (47) and tighten it.

Refer to OPERATION, Section C, before putting the pump back into service.

LUBRICATION

addthree shots ofNo. 0 lithiumbased greasefrom a grease gun through the grease fitting (12) after each 250 hours of operation or once each month, whichevercomesfirst.Do notover-lubricate. Overlubrication can cause the bearing to over-heat, resulting in premature bearing failure.

If grease is forced out around the shaft as newgreaseis added,the bearing cavity is full and should be disassembled and cleaned immediately.

There are no provisions in the bearing cavity to drainor flushthe lubricant.The pumpand intermediatemustbedisassembledtocompletelyclean and maintain this cavity.

Under normal conditions, change the grease after each5000 hoursofoperation, or at12 month intervals, whichever comes first. Change the grease more frequently if the pump is operated continuouslyor installedinanenvironment wherevariable hot and cold temperatures are common.

Seal Assembly

Theseal assemblyis lubricatedbythemediumbeing pumped a nd no additional lubrication is required.

Bearing (Figure 2)

The intermediate was fully lubricated when shipped fromthefactory.Undernormalconditions,

When lubricating a dry (overhauled) intermediate, fillthe cavity through the lubrication fitting with approximately 2/3 lb. (0.3 kg.) of grease (approximately 1/3 full).

Forcoldweather operation,consultthefactory ora lubricant supplier for the recommended grade of lubricant.

Engine

Consult the literature supplied with the engine, or contact your local Deutz engine representative.

MAINTENANCE & REPAIRPAGE E -- 14

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty

or call:

U.S.: 419−755−1280

International: +1−419−755−1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty

or call:

519−631−2870

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA

Gorman-Rupp Pumps 04B3-F4L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

INTRODUCTION

PAGE B -- 1INSTALLATION

OPERATION PAGE C -- 1

TROUBLESHOOTING PAGE D -- 1