Gorman-Rupp Pumps 06C1-GAR User Manual
Q
OM-05688-OP01
July 20, 2004
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH P ARTS LIST
0SERIESPUMP
MODEL
06C1-GAR
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
www.gormanrupp.com
GORMAN-RUPP OF CANADA LIMITED
eCopyright by the Go rman-Rupp Company
D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
TABLE OF CONTENTS
INTRODUCTION PAGE I --- 1.................................................
SAFETY - SECTION A PAGE A --- 1............................................
I N S T A L L A T I O N --- S E C T I O N B PA G E B --- 1....................................
Pump Dimensions PAGE B --- 1.....................................................
PREINSTALLATION INSPECTION PAGE B --- 1............................................
VEHICLEREQUIREMENTS PAGEB---2.................................................
Ta n k P r e p a r a t i o n PA G E B --- 2.......................................................
P O S I T I O N I N G P U M P PA G E B --- 2.......................................................
Lifting PA G E B --- 2.................................................................
ALIGNMENT PA G E B --- 3..............................................................
SUCTION AND DISCHARGE PIPING PAGE B --- 4.........................................
Typical System Installation PAGE B --- 4..............................................
Piping PA G E B --- 5................................................................
Sealing PA G E B --- 5...............................................................
Valves PA G E B --- 5................................................................
Siphoning PA G E B --- 6.............................................................
Eductors PA G E B --- 6..............................................................
O P E R A T I O N --- S E C T I O N C PA G E C --- 1......................................
PRIMING PA G E C --- 1.................................................................
GROUNDING PA G E C --- 1.............................................................
STARTING PA G E C --- 1................................................................
Rotation PA G E C --- 1..............................................................
Drive PA G E C --- 2.................................................................
OPERATION PA G E C --- 2..............................................................
Leakage PA G E C --- 2..............................................................
Liquid Temperature And Overheating PAGE C --- 2.....................................
Strainer Check PAGE C --- 2.........................................................
Pump Vacuum Check PAGE C --- 2..................................................
STOPPING PA G E C --- 3................................................................
Cold Weather Preservation PAGE C --- 3..............................................
GEARBOX TEMPERATURE CHECK PAGE C --- 3..........................................
T R O U B L E S H O O T I N G --- S E C T I O N D PA G E D --- 1..............................
PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E --- 1.................
P E R F O R M A N C E C U R V E PA G E E --- 1...................................................
PARTS LIST:
P u m p M o d e l PA G E E --- 3..........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 4.........................
Removing Pump And Gearbox PAGE E --- 4...........................................
Suction Head And Wear Ring Removal PAGE E --- 5...................................
Impeller And Casing Wear Ring Removal PAGE E --- 5.................................
Seal Removal And Disassembly PAGE E --- 5.........................................
i
TABLE OF CONTENTS
(continued)
Pump Casing Removal PAGE E --- 5.................................................
PUMP AND SEAL REASSEMBLY PAGE E --- 5............................................
Pump Casing And Wear Ring Installation PAGE E --- 6..................................
Seal Reassembly And Installation P AGE E -- - 6........................................
Impeller Installation P AGE E -- - 8.....................................................
Suction Head And Wear Ring Installation PAGE E --- 9..................................
Installing Pump And Gearbox PAGE E - -- 9............................................
GEARBOX DISASSEMBLY PAGE E --- 9..................................................
GEARBOX REASSEMBLY PAGE E --- 10...................................................
LUBRICATION PA G E E --- 1 1.............................................................
Seal Assembly PAGE E --- 11.........................................................
Gearbox PA G E E --- 1 1..............................................................
ii
0SERIES
OM-- 05688
INTRODUCTION
This Installation, Operation, and Maintenance
manual is designed to help you achieve the best
performance and longest life from your GormanRupp pump.
This manual covers an 0 Series, enclosed impeller,
centrifugal model pump, with straight-in suction,
without a suction check valve. The pump is designed for vehicular mounting in petroleum service. The basic material of construction for w etted
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217
Phone: (419) 755 --1011
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631 --2870
parts for the pump is aluminum, with cast iron
wearing parts.
The p ump is close-coupled to an integral 1900
RPM gearbox speed increaser with a 2.19:1 ratio.
Power is transmitted to the gearbox through a customer-installed universal shaft assembly.
If there are any questions regarding the 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:
or:
For information or technical assistance on the power source, contact the power source manufacturer’s local
dealer or representative.
The following are used t o alert maintenance personnel to procedures which require special attention, to
those which could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure required and the injury which will result
from failure to follow the procedure.
Hazards or unsafepractices whichCOULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possible damage which could result from failure
to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
NOTE
the procedure required and the injury
which could result from failure to follow
the procedure.
PAGE I -- 1INTRODUCTION
0SERIES OM-- 05688
SAFETY --- SECTION A
This information applies to 0 Series
power take-off driven pumps. Refer to
the manual accompanying the vehicle
before attempting to begin operation.
Before attempting to open or servic e the
pump:
1. Familiarize yourself with this manual.
2. Switch off the vehicle ignition and
remove the key to ensure that the
pump will remain inoperative.
3. Allow the pump to cool if 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.
erating or servicing the pump. Provide
adequate ventilation, prohibit smoking,
wear static-resistant clothing and
shoes. Clean up all fuel spills immediately after occurrence.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equi pment. Suction and discharge hoses and piping must be removed from the pump before lifting.
After the pump has been positioned,
make certain that the pump and all piping connecti ons are tight, properly sup ported and secure before operation.
This pump is designed for vehicular
mounting in petroleum servic e . Do not
attempt to pump corrosive materials, or
any liquids which may damage the
pump or endanger personnel as a result
of pump failure.
If thi s pump is used with volatile and/or
flammableliquids,becertainproper
safety practices are followed before op-
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to personnel.
Do not operate the pump against a
closed discharge valve for long periods
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
OM-- 05688
If thi s pump is used with volatile and/or
flammable liquids, overheating may
produce dangerous fumes. Take pre cautions to ensure the area surrounding
the pump is ade quately ventilated. Allow the pump to cool and use extre m e
caution when venting the pump, or
when removing covers, plates, plugs, or
fitting.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an overheated pump. Vapor pressure within the
pump can cause parts being disengaged to be ejected with great force. Allow the pump to cool before servicing.
0SERIES
the pump. Be sure the pump is properly
reinstalled and secure before operation.
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. Limit the maximum input
speed and operation range as indicated
on the performance curve on Page E-1.
The gearbox provided on this pump is
designed for operation at 1900 RPM
maximum i nput speed. If operated at a
higher RPM, pump components may be
destroyed.
After the vehicle is positioned for pump
maintenance, block t he wheels and set
the emergency brake before attempting
to disconnect the drive shaft or remove
Never run the pump dry of pumping medium. There must be a supply of liquid to
the pump at all times to prevent destruction
of the shaft seal faces.
PAGE A -- 2 SAFETY
INSTALLATION --- SECTION B
OM-- 056880SERIES
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.
Donottestoroperateyourpumpandintegral gearbox before reading the installation and operation instructions in
this manual.
These pumps are self-priming centrifugal models
with an integral gearbox assembly. Each of the
pumps covered by this manual is designed for vehicular mounting in petroleum service, where the
liquid is supplied to the pump under pressure.
Since the pressure supplied to the pump is critical
OUTLINE DRAWING
to performance and safety, be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve (see Section E , Page 1).
The integral gearbox is designed to be driven
through the vehicle transfer case by a customersupplied universal shaft assembly. The pump casing or gearbox may be rotated in 45_ increments to
assist with alignment with the vehicle tank; however, if the gearbox is to be rotated, some modifications must be made to the gearbox to ensure adequate lubrication. Consult the factory for details.
For further assistance, contact your Gorman-Rupp
distributor or t he Gorman-Rupp Company.
Pump Dimensions
SeeFigure1fortheapproximatephysicaldimensionsofthispump.
Figure 1. Pump Model 06C1-- GAR
PAGE B -- 1INSTALLATION
OM-- 05688 0SERIES
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested before shipment from the factory. Before installation,
inspect the pump for damage which may have occurred during shipment. Check as follows:
a. Inspect the pump and gearbox for cracks,
dents, damaged threads, and other obvious
damage.
b. Check for and tighten loose attaching hard-
ware. Since gaskets tend to shrink after drying, check for loose hardware at mating sur faces.
c. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties
indicated.Note the direction of rotation indicated on the pump. Check that the pump
shaft rotates in the required direction.
Only operate this pump in the direction indicated on the pump body and/or the accompanying decal. Reverse rotation of the
shaft will adversely effect pump performance, and the pump and/or gearbox could
be seriously damaged.
d. Check levels and lubricate as necessary. Re-
fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and perform duties as instructed.
e. If the pump and gearbox have been stored for
more than 12 months, some of the components or lubricants may have exceeded their
maximum shelf life. These must be inspected
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 determine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
VEHICLE REQUIREMENTS
The following instructions apply equally to new installations, rebuilds or retrofits.
Tank Preparation
It is essential that any tank scale, dirt, or other foreign material be removed from the tank and piping
prior to pump installation. Failure to do so could result in clogging or damage to the pump.
Damage to the pump resulting from debris
in the suction line will not be covered by
the pump warranty.
Before connecting the suction and discharge piping, carefully check the storage
tank and piping for construction debris
such as nuts, bolts, wire, weld slag, and
other foreign material. Install a commercially available 80 mesh screen in the suction line to prevent debris from entering the
pump.
POSITIONING PUMP
Lifting
Pump unit weights w ill vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer-installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
Thepumpassemblycanbeseriously
damaged if the cables or chains used to lift
and move the unit are improperly wrapped
around the pump.
Due to the confined mounting location,
specialized equipment such as a transmission jack with custom brackets should be
PAGE B -- 2 INSTALLATION
OM-- 056880SERIES
used to lift and position the pump and
gearbox.
NOTE
If the gearbox is rotated out of the standard position
shown in Figure 1, the oil fill and drain plugs must
be relocated. The magnetic drain plug must be relocated to the lowest port, and the oil vent and elbow must be relocated to the highest port. Consult
the factory for correct positioning of the fill plug to
provide for proper lubrication of the gearbox.
ALIGNMENT
When installing and/or alig ni ng universal shaft assemblies, switch off the vehicle ignition and remove the key to ensure that the pump will remain inoperative.
The alignment of the pump and its power source is
critical for trouble-free mechanical operation. Before checking alignment, make sure that the gearbox mounting bolts are tight.
When connecting the universal joint drive shaft assembly to a PTO unit, install, support, and align t he
drive shaft in accordance with the manufacturer’s
instructions. The pump and the drive power source
are generally positioned so that shaft centerlines
are parallel and horizontal. The maximum operating angle should not exceed 15 degrees (see Figure 2).
Check the direction of rotation of the PTO unit before starting the pump. The drive shaft must rotate
in the direction shown on the body of the pump,
gearbox, and/or decals, tags, and labels.
Do not operate the pump without the
guard in place over the rotating parts.
Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to personnel.
After the power take-off has been aligned, block
the wheels of the external power source, engage
the braking system, or t ak e other precautions to
ensure that the power source will remain stationary. Block the wheels on the unit to prevent creeping.
PAGE B -- 3INSTALLATION
OM-- 05688 0SERIES
LUGS MUST BE IN LINE, REGARDLESS
OF OPERATING ANGLE SHOWN BELOW
LUG ALIGNMENT
SHAFTS PARALLEL, ANGLES EQUAL
SHAFTS NOT PARALLEL, ANGLES EQUAL
Figure 2. Proper Installation And Alignment of Universal Assembly
SUCTION AND DISCHARGE PIPING
Typical System Installation
Tank filling and dispensing operations require a
system utilizing flow-directing (FDF) valves, educ-
tors, related piping and safety accessories. Some
oftheaccessoriesareavailablefromGormanRupp as optional equipment.
Refer to Figures 3 and 4 for illustrations of typical
piping systems for tank filling and dispensing.
PAGE B -- 4 INSTALLATION
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