Q
OM‐03179‐OP02
June 6, 1995
Rev. E 03‐07‐13
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
0 SERIES PUMPS
MODEL
06C3-GHH06C1-GHH
06D1-GHH 06D3-GHH
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
1995 The Gorman‐Rupp Company
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the
spaces provided below. Your Gorman‐Rupp distributor
needs this information when you require parts or service.
Pump Model:
Serial Number:
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY - SECTION A PAGE A - 1...........................................
INSTALLATION - SECTION B PAGE B - 1....................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
PUMP INSTALLATION PAGE B - 1......................................................
Pump Specifications PAGE B - 1....................................................
Pump Mounting Dimensions PAGE B - 2............................................
DIMENSIONAL DRAWING PAGE B - 3..................................................
VEHICLE REQUIREMENTS PAGE B - 4.................................................
Tank Preparation PAGE B - 4.......................................................
Brake Installation PAGE B - 4......................................................
Air Cylinder Pressure PAGE B - 4...................................................
POSITIONING PUMP PAGE B - 4.......................................................
Lifting PAGE B - 4.................................................................
Mounting Location PAGE B - 4.....................................................
Mounting Brackets PAGE B - 5.....................................................
Drive Flanges PAGE B - 6..........................................................
DRIVE SHAFT AND LINKAGE CONNECTIONS PAGE B - 6................................
Drive Shaft Alignment PAGE B - 6...................................................
Gear Shift Connections PAGE B - 7.................................................
SUCTION AND DISCHARGE PIPING PAGE B - 9.........................................
Typical System Installation PAGE B - 9..............................................
Piping PAGE B - 10................................................................
Valves PAGE B - 10................................................................
Eductors PAGE B - 11..............................................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
GROUNDING PAGE C - 1.............................................................
STARTING PAGE C - 2................................................................
OPERATION PAGE C - 2..............................................................
Operating Controls PAGE C - 2.....................................................
Shifting Sequence PAGE C - 3.....................................................
OPERATING CHECKS PAGE C - 3......................................................
Leakage PAGE C - 3..............................................................
Strainer Check PAGE C - 3.........................................................
Liquid Temperature And Overheating PAGE C - 3.....................................
Pump Vacuum Check PAGE C - 3..................................................
STOPPING PAGE C - 4................................................................
Cold Weather Preservation PAGE C - 4..............................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E - 1................
STANDARD PERFORMANCE CURVE PAGE E - 1........................................
PARTS LISTS:
Pump Model PAGE E - 3..........................................................
i
TABLE OF CONTENTS
(continued)
Gearbox Assembly PAGE E - 5.....................................................
Gearbox Assembly (Cont'd) PAGE E - 7.............................................
Cross Member Kit PAGE E - 9......................................................
PUMP AND SEAL DISASSEMBLY PAGE E - 10............................................
Removing Pump and Gearbox PAGE E - 10...........................................
Suction Head and Wear Ring Removal PAGE E - 11....................................
Impeller Removal PAGE E - 11......................................................
Seal Removal PAGE E - 11..........................................................
Pump Casing Removal PAGE E - 11.................................................
PUMP AND SEAL REASSEMBLY PAGE E - 11............................................
Pump Casing Installation PAGE E - 12................................................
Seal Reassembly and Installation PAGE E - 12........................................
Impeller Installation PAGE E - 14.....................................................
Suction Head and Wear Ring Installation PAGE E - 15..................................
Installing Pump and Gearbox PAGE E - 15............................................
Final Pump Assembly PAGE E - 15..................................................
GEARBOX DISASSEMBLY PAGE E - 15..................................................
Air Shift Cover Disassembly PAGE E - 16.............................................
Drive Flange Removal PAGE E - 16..................................................
Output Shaft Disassembly PAGE E - 16...............................................
Input Shaft Disassembly PAGE E - 16................................................
Idler Shaft Disassembly PAGE E - 17.................................................
Impeller Shaft Disassembly PAGE E - 17..............................................
Cleaning and Inspecting Bearings PAGE E - 17.......................................
GEARBOX REASSEMBLY PAGE E - 18...................................................
Impeller Shaft Reassembly PAGE E - 18..............................................
Idler Shaft Reassembly PAGE E - 18.................................................
Input Shaft Reassembly PAGE E - 19.................................................
Output Shaft Reassembly PAGE E - 20...............................................
Air Shift Cover Reassembly PAGE E - 20..............................................
Pressure Testing PAGE E - 20.......................................................
Drive Flange Installation PAGE E - 21................................................
LUBRICATION PAGE E - 21.............................................................
Seal Assembly PAGE E - 21.........................................................
Trunnion Bracket PAGE E - 21.......................................................
Gearbox Assembly PAGE E - 21.....................................................
Intermittent (Normal Refueler) Duty Cycle PAGE E - 21.................................
Continuous Pumping Duty Cycle PAGE E - 22.........................................
ii
0 SERIES
OM-03179
INTRODUCTION
Thank You for purchasing a Gorman‐Rupp pump.
Read this manual carefully to learn how to safely
install and operate your pump. Failure to do so
could result in personal injury or damage to the
pump.
This manual will alert personnel to known proce
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel. However,
this manual cannot possibly anticipate and provide
detailed precautions for every situation that might
occur during maintenance of the unit. Therefore, it
is the responsibility of the owner/maintenance per
sonnel to ensure that only safe, established main
tenance procedures are used, and that any proce
dures not addressed in this manual are performed
only after establishing that neither personal safety
nor pump integrity are compromised by such prac
tices.
These pumps are 0 Series, enclosed impeller, self‐
priming centrifugal models, with straight‐in suction
without a suction check valve. They are designed
for vehicular mounting in petroleum service.
The pumps are close‐coupled to an integral, 1750
RPM (06C) or 19000 RPM (06D) split‐shaft gearbox
speed increaser with a 2.56:1 ratio. Power is trans
mitted to the gearbox through a customer‐installed
universal shaft assembly.
For information or technical assistance on the truck
chassis, contact the truck manufacturer's local
dealer or representative.
The following are used to alert maintenance per
sonnel to procedures which require special atten
tion, to those which could damage equipment, and
to those which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re
quired and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
If there are any questions regarding the pump or
its application which are not covered in this man
ual or in other literature accompanying this unit,
please contact your Gorman‐Rupp distributor, or:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
Hazards or unsafe practices which COULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi
ble damage which could result from failure
to follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
0 SERIES OM-03179
SAFETY - SECTION A
This information applies to 0 Series
split‐shaft refueler pumps. Gorman‐
Rupp has no control over or particular
knowledge of the truck chassis which
will be used. Refer to the manual ac
companying the truck before attempt
ing to begin operation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre
cautions for each specific application.
Therefore, it is the owner/installer's re
sponsibility to ensure that applications
not addressed in this manual are per
formed only after establishing that nei
ther operator safety nor pump integrity
are compromised by the installation.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Switch off the vehicle ignition and
remove the key, or take other ac
tion to ensure that the pump will re
main inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
any liquids which may damage the
pump or endanger personnel as a result
of pump failure.
If this pump is used with volatile and/or
flammable liquids, be certain proper
safety practices are followed before op
erating or servicing the pump. Provide
adequate ventilation, prohibit smoking,
wear static resistant clothing and
shoes. Clean up all fuel spills immedi
ately after occurrence.
Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed dis
charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.
If this pump is used with volatile and/or
flammable liquids, overheating may
produce dangerous fumes. Take pre
cautions to ensure the area surrounding
the pump is adequately ventilated. Al
low the pump to cool and use extreme
caution when venting the pump, or
when removing covers, plates, plugs, or
fittings.
This pump is designed for vehicular
mounting in petroleum service. Do not
attempt to pump corrosive materials, or
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
PAGE A - 1SAFETY
OM-03179
0 SERIES
gaged to be ejected with great force. Al
low the pump to cool before servicing.
After the vehicle is positioned for pump
maintenance, block the wheels and set
the emergency brake before attempting
to disconnect the drive shaft or remove
the pump. Be sure the pump is properly
reinstalled and secure before opera
tion.
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. Limit the maximum input
speed and operating range as indicated
on the Performance Curve on Page E‐1.
The gearbox provided on this pump is
designed for operation at a maximum in
put speed of 1750 RPM (06C) or 1900
RPM (06D). If operated at a higher RPM,
pump or gearbox components may be
destroyed.
Decals and tags vital to pump operation
were shipped loose with the pump. Affix
these decals in a prominent place vis
ible to the pump operator.
Never Run the pump dry of pumping me
dium. There must be a supply of liquid to
the pump at all times to prevent destruction
of the shaft seal faces.
This pump has been shipped dry of gear
box lubrication, except for a residual coat
ing from the testing process of 90 weight
gear oil and Dow Corning “Molykote M
Gear Guard” (an anti‐wear additive, con
sisting of molybdenum disulphide solid lu
bricants suspended in petroleum oil). The
gearbox must be lubricated before the
pump is operated (see LUBRICATION in
Section E).
PAGE A - 2 SAFETY
INSTALLATION - SECTION B
OM-031790 SERIES
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and ar
range the pump and piping.
Do not test or operate this pump and in
tegral gearbox before reading the in
stallation and operation instructions in
this manual.
This pump is an 0 Series, semi‐enclosed impeller,
self‐priming centrifugal model with straight‐in suc
tion, and an integral split‐shaft gearbox assembly.
The pump is designed for vehicular mounting in
petroleum service, where the liquid is supplied to
the pump under pressure. The gearbox replaces a
part of the main drive shaft connecting the trans
mission to the rear axle.
This design permits full utilization of engine power
to selectively operate either the pump or the rear
driving wheels on the vehicle. Both cannot be op
erated at the same time.
ing, check for loose hardware at mating sur
faces.
c. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties
indicated. Note the direction of rotation indi
cated on the pump. Check that the pump
shaft rotates in the required direction.
Only operate this pump in the direction in
dicated on the gearbox and/or the accom
panying decal. Reverse rotation of the
shaft will adversely effect pump perform
ance, and the pump and/or gearbox could
be seriously damaged.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per
form duties as instructed.
e. If the pump and gearbox have been stored for
more than 12 months, some of the compo
nents or lubricants may have exceeded their
maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv
ice.
For further assistance, contact your Gorman‐Rupp
distributor or the Gorman‐Rupp Company.
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation,
inspect the pump for damage which may have oc
curred during shipment. Check as follows:
a. Inspect the pump and gearbox for cracks,
dents, damaged threads, and other obvious
damage.
b. Check for and tighten loose attaching hard
ware. Since gaskets tend to shrink after dry
If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman‐Rupp distributor or the factory to deter
mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
PUMP INSTALLATION
Pump Specifications
See Table 1 and 2 for the typical pump specifica
tions and gearbox data.
PAGE B - 1INSTALLATION
OM-03179 0 SERIES
Table 1. Pump Specifications
Pump Type Self‐priming, centrifugal with enclosed impeller................................
Suction 6-inch “Victaulic” fitting....................................................
Discharge 4-inch petroleum flange................................................
Nominal Capacity See the Performance Curve, Page E-1.............................
Impeller Shaft Seal Mechanical self‐lubricated........................................
Gearbox (Air Shift)
Air Pressure Required at Shift Cylinder 70-140 psi (5,1-10,2 kg/cm@) through 1/4” line
Gear Ratio 2.56:1 Speed Increase..................................................
Input shaft Rotation Clockwise (when viewed from the trunnion end)....................
Maximum Input Speed (See the Performance Curve, Page E-1)......................
Input & Output Shaft Heavy‐duty 2-3/4 inch - 10 spline..............................
Input & Output Flanges “Dana” Heavy‐Duty 1810 Series...............................
Lubrication 68 U.S. ounces (2011 ml) - See LUBRICATION, Section E for SAE grade....
16 fl. oz. (18 ml) `MolykoteR M Gear Guard' (Dow Corning)
Approx. Net Weight (06C1-GHH) 384 pounds (174 kg)...................................
Approx. Net Weight (06C3-GHH) 434 pounds (197 kg)...................................
Approx. Net Weight (06D1-GHH) 384 pounds (174 kg)...................................
Approx. Net Weight (06D3-GHH) 434 pounds (197 kg)...................................
Table 2. Through Torque Capacity Based On Shaft and Spline Size
Type of Engine Transmission Max Through Torque
Diesel Automatic 11,000
Diesel Manual 10,000
Gasoline Automatic 13,300
Gasoline Manual 12,300
Pump Mounting Dimensions
A 40-inch (1016 mm) cross member is provided
for mounting the output end of the gearbox, and a
trunnion mount is provided for the input end. This
Ft. Lbs.
(M. Kg.)
(1521)
(1383)
(1839)
(1701)
design provides a flexible three‐point suspension.
The trunnion mount prevents the chassis frame
twist from being transmitted through the gearbox.
See Figures 1 on page B-3 for the physical dimen
sions of the pump.
PAGE B - 2 INSTALLATION
DIMENSIONAL DRAWING
INPUT FROM TRANSMISSION ‐ 2.75 (69,9)
DIAMETER ‐ 10 SPLINE SHAFT WITH 1800
SERIES COMPANION FLANGE.
TOP
MOUNTED AIR
SHAFT
12.75
(323,8)
.625‐11 UNC THREAD
4 MOUNTING HOLES
7.09
(180,1)
.46
(11,7)
1.38
(35,1)
2.25
(57,2)
20.78
(527,8)
OUTPUT TO REAR AXLE
2.75 (69,9) DIA. - 10 SPLINE SHAFT
WITH 1800 SERIES COMPANION FLANGE.
7.25
(184,2)
3.625
(92,1)
2.75
(69,9)
.69
(17,5)
2.25
(57,2)
DIA., 2 HOLES
4.00
(101,6)
6.56
(166,6)
DIA.
DIA. DISCHARGE
4.31
(109,5)
5.56
(141,2)
6.44
(163,6)
OM-031790 SERIES
23.02
(584,1)
CROSS
MEMBER
3.50
(88,9)
DIMENSIONS:
(MILLIMETERS)
4.31
(109,5)
16.68
(423,7)
6.00
(152,4)
INCHES
20.00
(508,0)
1.69
(42,9)
VICTAULIC
SUCTION
FURNISHED
LENGTH
4.06
(103,1)
4.81
(122,2)
40.00
FURNISHED LENGTH
(1016,0)
10.64
(270,2)
1.94
(49,3)
2.00
(50,8)
8.70
(221,0)
22.57
(573,3)
17.76
(451,1)
1.00
(25,4)
1.19
(30,2)
.375-16 UNC STUDS
A 5.88 (149,4) DIA. B.C.
2.00
(50,8)
3.67
(93,2)
9.50
(241,3)
16.31
(414,3)
2.00 NPT
DRAIN PLUG
ON
2.50
(63,5)
10.89
(276,6)
.500 -13 UNC
THREAD
2 MOUNTING HOLES
1.00 (25,4) DEEP.
7.50
(190,5)
5.50
(139,7)
4.06
(101,6)
Figure 1. Pump Model 06C/D-GHH Pump Model Dimensions
PAGE B - 3INSTALLATION
OM-03179 0 SERIES
VEHICLE REQUIREMENTS
The following instructions apply equally to new in
stallations, rebuilds or retrofits.
After installation, do not attempt to test run
or operate the pump and integral gearbox
before reading OPERATION, Section B.
The gearbox was shipped dry of lubrica
tion, except for a residual coating from the
testing process of 90 weight gear oil and
Dow Corning `Molykote M Gear Guard'
(an anti‐wear additive, consisting of mo
lybdenum disulphide solid lubricants sus
pended in petroleum oil). Lubricate the
gearbox as instructed in LUBRICATION,
Section E before attempting to operate the
pump.
Tank Preparation
Brake Installation
When shifting from vehicle drive to pump
mode, or vice versa, input shaft rotation
must be limited to no less than 2 RPM or
no more than 15 RPM at the time of the
shift. Stopping the input shaft entirely may
cause a “butt‐shift” condition, which will
prevent the shift from occurring. Shaft rota
tion in excess of 15 RPM causes raking of
the gears. Either of these conditions can
damage gears, resulting in premature
gearbox failure.
Vehicles with automatic transmissions should be
equipped with a brake on the transmission shaft to
slow, but not stop, shaft rotation during shifting.
Air Cylinder Pressure
For proper operation of the gearbox, the air shift
device requires air pressure of 70 to 140 psi (5,1 to
10,2 kg/cm) at the gearbox. See Gear Shift Con
nections for further information.
It is essential that any tank scale, dirt, or other for
eign material be removed from the tank and piping
prior to pump installation. Failure to do so could re
sult in clogging or damage to the pump.
Damage to the pump resulting from debris
in the suction line will not be covered by the
pump warranty.
Before connecting the suction and dis
charge piping, carefully check the storage
tank and piping for construction debris
such as nuts, bolts, wire, weld slag, and
other foreign material. Install a commer
cially available 80 mesh screen in the suc
tion line to prevent debris from entering the
pump.
POSITIONING PUMP
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer‐installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
The pump assembly can be seriously
damaged if the cables or chains used to lift
and move the unit are improperly wrapped
around the pump.
Due to the confined mounting location,
specialized equipment such as a transmis
PAGE B - 4 INSTALLATION
OM-031790 SERIES
sion jack with custom brackets should be
used to lift and position the pump and
gearbox.
Mounting Location
The following factors must be considered when se
lecting a mounting location for the pump.
a. Mounting brackets
b. Universal joint angles
c. Shift linkage
d. Piping
e. Ground clearance
f. Accessibility of pump and gearbox for service..
Any damage to the pump or gearbox resulting from
improper mounting and installation is not covered
by the Gorman‐Rupp Warranty.
Mounting Brackets
The customer must furnish two cross members
which fit between the vehicle chassis side rails (see
Figure 2). They must be heavy enough to support
the weight of the pump assembly and provide easy
access for pump maintenance.
Secure the rear cross member rigidly to the pump
and gearbox using a fabricated mounting bracket
(customer‐furnished). The mounting bracket must
fasten to the threaded holes located in the pump
casing above the pump suction, and in the top of
the gearbox housing. The bracket and cross mem
ber must not obstruct pump operation or impede
removal of the pump casing during maintenance.
The rear cross member or mounting
bracket must not interfere with movement
of the air shift indicator shaft (located on
top of the gearbox). If necessary, drill a
1.25 inch (31,8 mm) diameter hole through
the cross member or bracket to provide
clearance.
RUBBER (MOUNTED
BY CUSTOMER)
1.25 IN. [31,8 mm] DIA.
HOLE FOR AIR SHIFT
POSITION INDICATOR
SHAFT
29 IN.* [736,6 MM] APPROX.
ROAD CLEARANCE
OUTPUT TO REAR AXLE
REAR CROSS MEMBER FURNISHED 40 IN. [1016 MM]
LONG - CUSTOMER TO CUT TO DESIRED LENGTH FOR
INSTALLATION
SHIFT COVER
TRUNNION BRACKET
CLOCKWISE INPUT ROTATION
DRIVE INPUT FROM
TRANSMISSION
FRONT CROSS MEMBER
(SUPPLIED BY CUSTOMER)
16.31 IN.* [414,3 MM] APPROX. ROAD
CLEARANCE
NOTE: DIMENSIONS MARKED WITH AN ASTERISK (*) MAY BE ALTERED TO FACILITATE INSTALLATION OF UNIT
Figure 2. Typical Pump Mounting on Vehicle Chassis
PAGE B - 5INSTALLATION
OM-03179 0 SERIES
The drive input end of the gearbox is fitted with a
trunnion which prevents chassis frame twist from
being transmitted through the gearbox. Mount the
trunnion to the front cross member (not supplied)
to support the drive input end of the pump. When
mounting the trunnion, make certain that it will not
interfere with the input drive flange. The trunnion
mounting foot must be directed toward the input
flange.
Position the cross members and mounted pump
on the side rails of the chassis. The cross members
must be mounted with rubber or other vibration‐
dampening material when secured to the side
rails.
Do not secure the cross members to the side rails
before establishing the exact location and position
of the air shift rod and shift indicator connections.
Be careful not to put the pump in a bind from front
to rear during mounting. Improper alignment could
result in bearing or gear failure, or gearbox break
age (see Drive Shaft Alignment).
minimum. A joint angle of 1 degree is required for
proper needle bearing circulation, but excessive
angles cause accelerated wear and require a lower
maximum operating speed (see Table 3).
Table 3. Joint Angle/Maximum RPM
JOINT ANGLE MAXIMUM
SPEED
5 degrees 5000 RPM
6 degrees, 30 minutes 4000 RPM
8 degrees 3000 RPM
Align the gearbox with the transmission and the
rear axle to obtain the optimum universal joint
angles. See Figure 3 for drive shaft alignment.
Drive Flanges
The input and output shafts on the gearbox (2-3/4
inch, 10‐spline) are equipped with heavy‐duty
Dana 1810 Series flanges. The shaft splines are
designed to produce a tight interference fit with the
drive flange. This fit is intentional to eliminate fret
ting corrosion.
For instructions on removing and installing the
flanges, see the specific areas in MAINTENANCE
AND REPAIR, Section E.
DRIVE SHAFT AND
LINKAGE CONNECTIONS
Drive Shaft Alignment
To promote maximum universal joint and bearing
life, the universal joint angles must be kept to a
Be certain the rear axle position when the
vehicle is empty or fully loaded will not
cause excessive universal joint angles, or
cause the drive shaft slip joints to bottom
out.
When installing and/or aligning univer
sal shaft assemblies, switch off the ve
hicle ignition and remove the key to en
sure that the pump will remain inopera
tive.
PAGE B - 6 INSTALLATION
LUGS MUST BE IN LINE, REGARDLESS
OF OPERATING ANGLE SHOWN BELOW
LUG ALIGNMENT
SHAFTS PARALLEL, ANGLES EQUAL
OM-031790 SERIES
SHAFTS NOT PARALLEL, ANGLES EQUAL
Figure 3. Drive Shaft Alignment
The alignment of the pump and its power source is
critical for trouble‐free mechanical operation. Be
fore checking alignment, make sure that the gear
box mounting bolts are tight.
When connecting the universal joint drive shaft as
sembly to a PTO unit, install, support, and align the
drive shaft in accordance with the manufacturer's
instructions. The pump and the drive power source
are generally positioned so that shaft centerlines
are parallel and horizontal.
Make sure the horizontal and vertical joints are
equal. Limit the angles to 1 to 3 degrees using a
short coupled joint, and less than 8 degrees with a
double joint assembly. The maximum operating
angle should not exceed 15 degrees (see Figure
3).
NOTE
Install a short coupled slip joint on the input side
and a double joint with slip on the output side of the
gearbox to attain the prescribed angles and elimi
nate tensile stress on the shaft.
The input and output shafts should be completely
subassembled and checked for straightness and
balance before installation. Also check the univer
sal joint yokes for proper alignment.
Check the direction of rotation of the PTO unit be
fore starting the pump. The drive shaft must rotate
in the direction shown on the body of the pump,
gearbox, and/or decals, tags, and labels.
Gear Shift Connections
After the pump is mounted to the chassis, hook up
the air shift rod to the proper control stations.
PAGE B - 7INSTALLATION
OM-03179 0 SERIES
top of the air shifter cover is for pump operation.
Seal all hose fittings with “Permatex” or equivalent
compound.
Decals and tags vital to pump operation
were shipped loose with the pump.
These decals must be affixed in a promi
nent place visible to the pump operator.
Proper operation of the gearbox air shift requires
1/4-inch air lines and air pressure of 70 to 140 psi
(5,1 to 10,2 kg/cm) at the gearbox. The air line
connection at the end cap of the air cylinder is for
vehicle operation, and the air line connection at the
When activated, the shifter rod travels through a
hole in the rear cross member. A customer‐
supplied shift indicator (mechanical, electrical, or
air operated device) should be installed in this area
to indicate shifter mode to the pump operator. A
tapped hole is provided in the shaft for conve
nience.
See Figure 4 and 5 for approximate shaft travel and
hole size. See Figure 4, Section E for Air Shift Kit
parts.
Figure 4. Air Shifter Shaft Detail
Figure 5. Optional Manual Shifter
PAGE B - 8 INSTALLATION
OM-031790 SERIES
SUCTION AND DISCHARGE PIPING
Typical System Installation
Most petroleum handling vehicles perform both
fueling and defueling operations. This requires a
system utilizing flow‐directing (FDF) valves, educ
tors, related piping and safety accessories. Some
of the accessories are available from Gorman‐
Rupp as optional equipment.
Refer to Figures 6 and 7 for illustrations of typical
piping systems used on refueling vehicles.
SCHEMATIC SYSTEM USING EDUCTOR FOR DISPENSING AND FILLING
Figure 6. Typical Installation Using Eductor For Filling And Dispensing
SCHEMATIC SYSTEM USING PUMP FOR DISPENSING AND FILLING
Figure 7. Typical Installation Using Pump For Filling And Dispensing
PAGE B - 9INSTALLATION
OM-03179 0 SERIES
Piping
All piping material must be compatible with the liq
uid being pumped. If hose is used in suction lines,
it must be the rigid‐wall, reinforced type to prevent
collapse under suction.
Run the 8‐inch suction piping from the tank sump
to the pump inlet. The suction lines should be as
short and straight as possible to minimize friction
loss.
A suction strainer was not furnished with this pump
since it is not designed to handle liquids containing
solids. However, to protect the pump from acciden
tal damage a commercially available 80 mesh
screen should be installed in the suction line. Make
certain that the total open area of the screen is at
least three or four times the cross section of the
suction line to ensure an adequate supply of liquid
to the pump.
tion line to prevent debris from entering the
pump.
The pump discharge is a 6‐inch petroleum flange.
The discharge should be mounted vertically just
below the top of the chassis frame. It can easily be
piped to the filter inlet, discharge manifold, valves,
etc..
To avoid wracking, flexible connections or bellows
must be installed in the pump suction and dis
charge.
Do not tighten connecting flanges unless they are
properly aligned. Never pull a pipe into place by
tightening the flange bolts.
Valves
Gorman‐Rupp manufactures several sizes of flow‐
diverting (FDF) valves for use in truck‐mounted
pumping applications. The valves are designed to
reverse the flow of liquid with only the turn of a han
dle. This allows the same pump to fill or dispense
from the tank.
Damage to the pump resulting from debris
in the suction line will not be covered by the
pump warranty.
Before connecting the suction and dis
charge piping, carefully check the storage
tank and piping for construction debris
such as nuts, bolts, wire, weld slag, and
other foreign material. Install a commer
cially available 80 mesh screen in the suc
The FDF valve is designed for directing
flow only. It will not serve as a positive shut
off or throttling valve.
See Figures 8 and 9 illustrating the installation di
mensions and theory of operation for a typical FDF
valve. Consult the factory for further assistance or
other sizes.
PAGE B - 10 INSTALLATION
OM-031790 SERIES
11.0
[279,4]
[11,2]
[124,0]
9.0 DIA.
[228,6]
0.44
DIA.-12 HOLES ON
4.88
DIA B.C.
5.5
[139,7]
5.63
[143
]
BOTH
FLANGES
DIA.
11.0
[279,4]
5.0
[127,0]
6.0
[152,4]
5.5
[139,7]
3.06
[77,7]
0.44 DIA. HOLE
[11,2]
DIA.
[11,2]
10.38
[263,7]
0.44
[206,5]
Figure 8. Typical FDF Valve Installation Dimensions
DIA.-12 HOLES ON
8.13
DIA B.C.
6.06
[153,9]
DIMENSIONS:
INCHES
[MILLIMETERS]
BOTH
FLANGES
DIA.
When the center web of the valve is aligned with the
6‐inch ports (fueling position), the flow passes
straight through. When the handle is turned to the
DISPENSING
POSITION
DISPENSE FILLTOP VIEW
Figure 9. FDF Valve Theory of Operation
Eductors
defueling position, the web blocks the straight flow
and opens two paths of flow through the 6‐inch and
3‐inch ports.
FILL
POSITION
collapse the tank service hose after the tank has
been filled or emptied.
An eductor may be used in conjunction with an
FDF valve to increase dispensing rates and im
prove efficiency. An eductor may also be used to
Contact the Gorman‐Rupp Company or an author
ized distributor for specifications and performance
data on eductors or FDF valves.
PAGE B - 11INSTALLATION
0 SERIES
OM-03179
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to the pump.
Whether new installation or rebuild of re
fueler, the following requirements apply:
1. It is essential that tank scale, dirt, and
any other foreign elements be removed
from the tank and piping prior to pump
installation.
2. The gearbox was shipped dry of lubri
cant. Lubrication must be added before
any operation.
3. The pump must not be run dry of prod
uct at any time.
This pump is designed for vehicular
mounting in petroleum service. Do not
attempt to pump corrosive liquids
which may damage the pump or endan
ger personnel as a result of pump fail
ure.
PRIMING
Install the pump and piping as described in IN
STALLATION. Make sure that the piping connec
tions are tight, and that the pump is securely
mounted. Check that the pump and gearbox are
properly lubricated (see LUBRICATION in MAIN
TENANCE AND REPAIR).
This pump is not self‐priming, but should never be
operated unless there is liquid in the pump casing.
Never operate this pump unless there is
liquid in the pump casing. The pump will
not prime when dry. Extended operation of
a dry pump will destroy the seal assembly.
When installed in a flooded suction application,
simply open the system valves and permit the in
coming liquid to evacuate the air. After the pump
and piping system have completely filled, evacu
ate any remaining air pockets in the pump or suc
tion line by loosening a pipe plug or opening
bleeder valves.
Once the pump casing has been filled, the pump
will prime as long as positive suction head is avail
able.
GROUNDING
To eliminate electrostatic build‐up by the liquid be
ing pumped, the pump must be grounded by at
taching a ground wire to a ground rod (grounding
is not required if pumping water). Install the ground
rod in accordance with the National Electrical
Code and all local codes. Be sure the clamp or fas
Never tamper with the governor to gain
more power. The governor establishes
tener has made a tight electrical connection with
the rod.
safe operating limits that should not be
exceeded. The Gearbox provided on
this pump is designed for operation at a
maximum input speed of 1750 RPM
(06C) or 1900 RPM (06D). If operated at
a higher RPM, pump or gearbox compo
nents may be destroyed.
OPERATION PAGE C - 1
Inspect and test the ground wire assembly
for conductivity. Replace broken or frayed
wire before resuming operation.
OM-03179 0 SERIES
STARTING
Consult the operations manual furnished with the
vehicle.
Rotation
The correct direction of pump rotation is clockwise
when facing the gearbox input shaft. The pump
could be damaged and performance adversely af
fected by incorrect rotation. If pump performance
is not within the specified limits (see the curve on
page E‐1), check the direction of rotation before
further troubleshooting.
Only operate the input shaft in a clockwise
direction when facing the input shaft.
Otherwise, pump performance will be ad
versely affected, and the pump and/or
gearbox could be seriously damaged.
OPERATION
Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed dis
charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.
The split drive shaft of the pump gearbox provides
for selective operation of either the pump or the ve
hicle; both cannot be operated at the same time.
Operating Controls
Since Gorman‐Rupp has no control over the actual
installation, it is the obligation of the tank builder or
the installer to devise controls to safely operate the
pump from inside the cab, or from a remote control
panel. All instructions and operational procedures
for the pump and system must be provided to the
pump operator.
Drive
The pump and gearbox assembly are designed to
be mounted midship between the chassis frame
members. The gearbox split shaft replaces a part
of the vehicle drive shaft connecting the transmis
sion to the rear axle.
The gearbox assembly has a ratio of 2.56:1, and is
designed for operation at a maximum input speeds
of 1750 RPM (model 06C) or 1900 RPM (model
06D). Do not operate at a higher input speeds.
The gearbox provided on this pump is
designed for operation at a maximum in
put speed of 1750 RPM (06C) or 1900
RPM (06D). If operated at a higher RPM,
pump or gearbox components may be
destroyed.
Decals and tags vital to pump operation
were shipped loose with the pump.
These decals must be affixed in a promi
nent place visible to the pump operator.
The shift mode indicator must be visible to the op
erator.
Shifting Sequence
In shifting to vehicle operation using the standard
air shift kit, the air shift rod linkage is activated to
engage the output shaft and provide direct drive
(1:1 ratio) through the gearbox to the rear axle of
the vehicle.
In shifting to pump operation, activate the air shifter
to disengage the gearbox drive output shaft, and to
engage the drive input shaft to the gear train which
operates the pump. Never shift from “drive” to
“pump” unless the vehicle is completely stopped.
OPERATIONPAGE C - 2
0 SERIES
OM-03179
The air cylinder must maintain air pressure of 70 to
140 psi (5,1 to 10,2 kg/cm) at the gearbox for air
shift operation.
When shifting from vehicle drive to pump
mode, or vice versa, input shaft rotation
must be limited to no less than 2 RPM or
no more than 15 RPM at the time of the
shift. Stopping the input shaft entirely may
cause a “butt‐shift” condition, which will
prevent the shift from occurring. Shaft rota
tion in excess of 15 RPM causes raking of
the gears. Either of these conditions can
damage gears, resulting in premature
gearbox failure.
could result in personal injury or damage to the
equipment. If backflushing is absolutely neces
sary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve (see Section E,
Page 1).
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160F (71C). Do not apply it at a 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
boil, build pressure, and cause the pump to rup
ture or explode. If overheating occurs, stop the
pump and allow it to cool before servicing it. Refill
the pump casing with cool liquid.
When this pump is operated by a diesel en
gine, low idle speed should be increased
approximately 200 RPM, or to a speed en
suring even, vibration‐free operation of the
drive shaft to prevent excessive wear of
components.
OPERATING CHECKS
Leakage
No leakage should be visible at pump mating sur
faces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maxi
mum pump efficiency.
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
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been in
stalled, monitor and record the readings regularly
to detect strainer blockage.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
Allow an over‐heated pump to cool be
fore servicing. Do not remove plates,
covers, gauges, pipe plugs, or fittings
from an overheated pump. Vapor pres
sure within the pump can cause parts
being disengaged to be ejected with
great force. After the pump cools, drain
the liquid from the pump by removing
the casing drain plug. Use caution when
removing the plug to prevent injury from
hot liquid.
Pump Vacuum Check
Since the pump does not have a suction check
valve, the discharge line must be fitted with a check
valve if a pump vacuum reading is taken.
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads.
Block the suction line and start the pump. At oper
ating speed the pump should pull a vacuum of 15
to 17 inches (381 to 432 mm) or more of mercury
when pumping petroleum. If it does not, check for
air leaks in the seal, gasket, or discharge valve.
OPERATION PAGE C - 3
OM-03179 0 SERIES
Open the suction line, and read the vacuum gauge
with the pump primed and at operation speed.
Shut off the pump. The vacuum gauge reading will
immediately drop proportionate to static suction
lift, and should then stabilize. If the vacuum reading
falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check
the point of installation of the vacuum gauge.
NOTE
Petroleum products are very sensitive to changes
in temperature. Warmer temperatures elevate the
product vapor pressure resulting in low vacuum
readings. Do not mistake temperature problems for
faulty pump installation or performance.
STOPPING
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
GEARBOX TEMPERATURE CHECK
The gearbox runs at higher than ambient tempera
tures because of heat generated by friction and
churning of the lubricating oil. Temperatures of ap
proximately 250
During continuous operation, the oil temperature
can exceed 300
F (121C) are considered normal.
F (149C).
NOTE
For continuous duty operation (when the pumping
period exceeds 30 minutes without a 20 minute
minimum cool‐down period between pumping
cycles), see Continuous Duty Pumping in MAIN
TENANCE AND REPAIR, Section E for lubrication
instructions.
Checking gearbox temperatures by hand is inac
curate. Place a contact‐type thermometer against
the housing and record this temperature for future
reference. The temperature of the lubricating oil
will be approximately 10F (6C) higher than the
housing surface temperature.
On engine driven pumps, reduce the throttle
speed slowly and allow the engine to idle briefly be
fore stopping.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
After stopping the pump, take precautions to en
sure that the pump will remain inoperative.
Cold Weather Preservation
Normal freezing conditions will not damage the
pump. However, during extremely severe condi
tions care should be exercised during start‐up, es
pecially if the pump has been idle for more than a
few hours.
Gearbox components may be damaged
by excessive heat. Limit continuous opera
tion to 30 minutes or less to prevent heat
build‐up. See Continuous Duty Pumping
in MAINTENANCE AND REPAIR, Section
E for specific lubrication instructions if the
pump is operated on a longer duty cycle.
A sudden increase in gearbox temperature is a
warning that the bearings are at the point of failing.
Make certain that the bearing lubricant is of the
proper viscosity and at the correct level (see LU
BRICATION in Section E). Bearing 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 within 20 minutes or less.
OPERATIONPAGE C - 4
0 SERIES
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
Before attempting to open or service
the pump:
1. Familiarize yourself with this manual.
2. Switch off the vehicle ignition and re
move the key, or take other action to
ensure that the pump will remain in
operative.
3. Allow the pump to completely cool if
overheated.
4. Check the temperature before open
ing any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
OM-03179
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO
PRIME
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
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 leak
‐ing or worn seal or gasket.
Strainer clogged. Check strainer and clean if necessary.
Air leak in suction line. Correct leak.
Strainer clogged. Check strainer and clean if necessary.
Pump speed too slow. Check driver output.
Lining of suction hose collapsed. Replace suction hose.
Discharge line clogged or restricted; Check discharge lines; straighten
hose kinked. hose.
TROUBLESHOOTING PAGE D - 1
OM-03179
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
0 SERIES
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
(CONT'D)
PUMP REQUIRES
TOO MUCH
POWER
EXCESSIVE NOISE
Discharge throttling valve partially Open discharge valve fully; check pip‐
closed; check valve is installed improp‐ ing installation.
erly.
Impeller or other wearing parts worn or Replace worn or damaged parts.
damaged. Check that impeller is properly
centered and rotates freely.
Universal joint drive misaligned. Align drive.
Pump speed too high. Check driver output.
Discharge head too low. Adjust discharge valve.
Cavitation in pump. Reduce discharge pressure and/or
pump speed.
Pumping entrained air. Locate and eliminate source of air
bubble.
Pump or drive not securely mounted. Secure mounting hardware.
Universal joint drive misaligned. Align drive.
Low or incorrect lubricant. Check for proper type and level of
lubricant.
BEARINGS RUN
TOO HOT
Bearing temperature is high, but within Check bearing temperature regularly
limits. to monitor any increase.
Low or incorrect lubricant. Check for proper type and level of
lubricant.
Suction and discharge lines not properly Check piping installation for proper
supported. support.
Drive misaligned. Align drive properly.
Bearings in power source or gearbox Check bearings.
worn or binding.
TROUBLESHOOTINGPAGE D - 2
0 SERIES
OM-03179
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and pump wear is directly affected by such things as the
abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended 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 Gorman‐Rupp 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 appearance of
wearing parts should also be documented at each inspection for comparison as well. Also, if records indi
cate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked
and replaced before failure occurs, reducing unscheduled down time.
For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for
your particular application. Subsequent inspections 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
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
0 SERIES
OM-03179
PUMP MAINTENANCE AND REPAIR - SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
*STAND PERFORMANCE FOR PUMP
MODELS 06C1-GHH AND 06C3-GHH
*STAND PERFORMANCE FOR PUMP
MODELS 06D1-GHH AND 06D3-GHH
STANDARD PERFORMANCE FOR PUMP MODELS 06C1-GHH, 06C3-GHH,
06D1-GHH And 06D3-GHH
Based on 70F (21C) clear water at sea level,
corrected to 0.80 specific gravity, with minimum
suction lift. Since pump installations are seldom
identical, your performance may be difference due
to such factors as viscosity, specific gravity, eleva
tion, temperature, and impeller trim.
If your pump serial number is followed by an “N”,
your pump is NOT a standard production model.
Contact the Gorman‐Rupp Company to verify per
formance or part numbers.
Pump speed and operating condition
points must be within the continuous per
formance range shown on the curve.
MAINTENANCE & REPAIR PAGE E - 1
PARTS PAGE
0 SERIESOM-03179
SECTION DRAWING
Figure 1. Pump Model 06C1-GHH, 06C3-GHH, 06D1-GHH And 06D3-GHH
MAINTENANCE & REPAIRPAGE E - 2
0 SERIES
OM-03179
PARTS LIST
Pump Models 06C1, 06C3, 06D1 And 06D3-GHH
(From S/N 1071445 up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact
the Gorman‐Rupp Company to verify part numbers.
ITEM
PART NAME PART
NO.
NUMBER
MAT'L
CODE
QTY ITEM
NO.
PART NAME PART
NUMBER
MAT'L
CODE
QTY
1 PUMP CASING
-06C1 AND 06D1-GHH 8377D 13040 1
-06C3 AND 06D3-GHH 8377D 11000 1
2 IMPELLER
-06C1 AND 06C3-GHH 8375 1304R 1
-06D1 AND 06D3-GHH 9524A 1304R 1
3 SEAL ASSEMBLY 25271-192 --- 1
4 DISCH FLANGE GASKET 5372G 20000 1
5 STUD C0606 1/2 15991 8
6 HEX NUT D06 15991 8
7 TRUNNION 38151-023 11010 1
8 COMPANION FLANGE 24571-912 --- 1
9 LUBE FITTING S186 --- 1
10 CAP PLUG 25141-151 --- 1
11 PUMP CASING O‐RING 25152-155 --- 1
12 BEARING ADJ SHIM SET 8545 15990 1
13 OIL SEAL S2007 --- 1
14 REPAIR GEARBOX ASSY 44161-146 --- 1
15 STUD C0807 15991 6
16 HEX NUT D08 15991 6
17 CASING GASKET 38683-464 18000 1
18 WEAR RING 8464 10018 1
19 IMPELLER ADJ SHIM SET 2X 17090 1
20 DRAIN PLUG P32 10009 1
21 WEAR RING
-06C1 AND 06C3-GHH 64H5 10018 1
-06D1 AND 06D3-GHH 13826 10018 1
22 IMPELLER NUT 22565-307 --- 1
23 SUCTION HEAD
-06C1-GHH 38247-302 13040 1
-06C3-GHH 38247-302 11090 1
-06D1-GHH 38247-401 13040 1
-06D3-GHH 38247-401 11090 1
24 IMPELLER KEY N0405 1/4 15990 1
25 SUCTION HEAD GASKET 8376G 20000 1
26 STUD C0605 1/2 15991 12
27 HEX NUT D06 15991 12
28 COMPANION FLANGE 24571-912 --- 1
29 CROSS‐MEMBER KIT 48123-401 --- 1
NOT SHOWN:
NAME PLATE 38818-020 13990 1
DRIVE SCREW BM#04-03 17000 4
LUBE INSTRUCTION TAG 38817-041 --- 1
SUCTION STICKER 6588AG --- 1
DISCHARGE STICKER 6588BJ --- 1
OPTIONAL:
ALUMINUM IMPELLER W/LOCKING RINGS
06C1-GHH AND 06C3-GHH:
REPAIR KIT 48221-025 --- 1
-IMPELLER 38628-507 1304C 1
-LOCKING RING 24133-025 --- 4
-SPACER 31143-059 15030 1
-IMPELLER NUT 22565-307 --- 1
06D1-GHH AND 06D3-GHH:
REPAIR KIT 48221-026 --- 1
-IMPELLER 38624-507 1304C 1
-LOCKING RING 24133-025 --- 4
-SPACER 31143-059 15030 1
-IMPELLER NUT 22565-307 --- 1
BRONZE FITTED IMPELLER OPTIONS:
06C1-GHH AND 06C3-GHH:
-IMPELLER 8375 14000 1
-CASING WEAR RING 8464 14000 1
-SUCT HD WEAR RING 64H5 14000 1
06D1-GHH AND 06D3-GHH:
-IMPELLER 9524A 14000 1
-CASING WEAR RING 8464 14000 1
-SUCT HD WEAR RING 13826 14000 1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 3
SECTION DRAWING
0 SERIESOM-03179
Figure 2. 44161-146 Repair Gearbox Assembly
MAINTENANCE & REPAIRPAGE E - 4
0 SERIES
ITEM
PART NAME PART
NO.
PARTS LIST
44161-146 Repair Gearbox Assembly
NUMBER
MAT'L
CODE
QTY ITEM
NO.
PART NAME PART
NUMBER
OM-03179
MAT'L
CODE
QTY
1 AIR SHIFT COVER ASSY 44231-501 --- 1
2 -SHIFTER SHAFT ASSY 44231-502 --- 1
-OIL SEAL 25228-506 --- 1
3
4 -O‐RING BOSS PLUG 38649-039 15079 1
5 -SHIFTER COVER 38354-041 10000 1
6 -SOC HD CAPSCREW 21472-478 --- 2
7 -SHIFTER FORK 38584-003 1101X 1
8 -AIR VENT S1703 --- 1
9 -O‐RING 25154-212 --- 1
10 -CYLINDER GASKET 38681-215 19060 1
11 -AIR CYLINDER O‐RING 25154-326 --- 1
12 -CYLINDER 31417-063 14000 1
13 -CYLINDER CAP GSKT 38681-215 19060 1
14 -CYLINDER CAP 38326-002 10000 1
15 -HEX HD CAPSCREW 21472-087 --- 2
16 SHIFTER COVER GSKT 38673-312 19060 1
17 DRIVE GEAR 38541-404 16000 1
18 RETAINING RING S1165 --- 1
19 SPACER 31134-103 15210 1
20 BALL BEARING 23231-515 --- 1
21 BALL BEARING 23251-019 --- 1
22 HEX HD CAPSCREW 21472-139 --- 4
23 OIL SEAL 25228-648 --- 1
24 BEARING CAP 38325-014 10000 1
25 INPUT SHAFT 38521-715 16000 1
26 RETAINING RING 24125-051 --- 1
27 BALL BEARING 23231-515 --- 1
28 SPACER/SLINGER 44148-007 --- 1
29 BEARING CAP GASKET 38687-548 19060 1
30 NAME PLATE 38818-123 13000 1
31 DRIVE SCREW BM#04-03 17000 4
32 HEX HD CAPSCREW 21472-070 --- 7
33 BEARING CAP 38325-015 10000 1
34 ROLLER BEARING 23529-001 --- 1
35 IDLER SHAFT 31711-049 16000 1
36 WOODRUFF KEY AV1009 15990 1
37 IDLER GEAR 38541-405 16000 1
38
BALL BEARING S1088 --- 1
39 IMPELLER SHAFT 38521-201 16000 1
BEARING CAP GASKET 38688-018 19060 1
40
41 GEARBOX HOUSING 38313-026 10000 1
42 BALL BEARING S1088 --- 1
43 ROLLER BEARING 23529-001 --- 1
44 SLIDING CLUTCH 38521-714 16000 1
45 ROLLER BEARING 23528-002 --- 1
46 TAIL SHAFT ASSY 44732-902 --- 1
47 -RETAINING RING S1165 --- 1
48 -ROLLER BEARING 23529-021 --- 1
49 -BEARING RETAINER 38325-012 10000 1
50 -RETAINING RING 24125-051 --- 1
51 -GEAR 38541-004 15000 1
52 -BEARING CAP GASKET 38687-549 19060 1
53 -HEX HD CAPSCREW 21472-139 --- 4
54 -SPACER 31144-034 15210 1
55 -BALL BEARING 23251-019 --- 1
56 -OIL SEAL 25228-648 --- 1
57 -PLUG W/FIB WASHER 22638-001 --- 1
58 -OUTPUT SHAFT 38521-716 16000 1
59 -BEARING CAP 38325-013 10000 1
60 -BUSHING 24571-109 --- 1
61 HEX HD CAPSCREW 21472-139 --- 4
62 BRG CAP GASKET 38687-548 19060 1
72 WASHER 31133-131 18010 2
73 PROTECTIVE CAP 25141-251 --- 2
74 PINION SHAFT COVER 31133-224 18010 1
75 TUBING .500 FT 18523-502 --- 1
76 PROTECTIVE SLEEVE 25141-261 --- 1
NOT SHOWN:
GEAR LUBE DECAL 38816-086 --- 1
LK PLATE WASHER 31215-042 15000 2
HEX HD CAPSCREW 22434-552 --- 4
NOTE: ITEMS ARE PROVIDED FOR SHIPPING PURPOSES ONLY.
THESE PARTS MUST BE REMOVED BEFORE
INSTALLATION.
INDICATES PARTS RECOMMENDED FOR STOCK.
MAINTENANCE & REPAIR PAGE E - 5
SECTION DRAWING
0 SERIESOM-03179
Figure 2A. 44161-146 Repair Gearbox Assembly (Cont'd)
MAINTENANCE & REPAIRPAGE E - 6
0 SERIES
OM-03179
PARTS LIST
44161-146 Gearbox Assembly (Cont'd)
ITEM
NO.
63 HEX HD CAPSCREW 21472-114 --- 2
64 HEX HD CAPSCREW 21472-099 --- 6
65 CERAMIC/MAG PLUG 22618-001 --- 1
66 WASHER 25123-041 --- 1
67 PIPE PLUG W/PATCH 25355-061 --- 1
68 OIL LEVEL PLATE 38816-233 13000 1
69 DRIVE SCREW BM#04-03 17000 2
70 STR DOWEL PIN AA0704 15990 2
71 FLANGED PLUG 24571-174 --- 2
OPTIONAL:
INDICATES PARTS RECOMMENDED FOR STOCK
PART NAME
SPEEDOMETER GEAR DRIVE KIT 48123-010 --- 1
AUXILIARY STUB SHAFT P.T.O. ASSY 44161-149 --- 1
PART
NUMBER
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 7
SECTION DRAWING
0 SERIESOM-03179
Figure 3. 48123-401 Cross Member Kit
MAINTENANCE & REPAIRPAGE E - 8
0 SERIES
OM-03179
PARTS LIST
48123-401 Cross Member Kit
ITEM
NO.
1 CROSS MEMBER 34778-004 15020 1
2 HEX HD CAPSCREW B1004 15991 4
3 LOCKWASHER J10 15991 4
4 HEX HD CAPSCREW B0804 15991 2
5 LOCKWASHER J08 15991 2
6 BRACKET 34125-075 15020 1
7 HEX HD CAPSCREW B0805 15991 2
8 FLAT WASHER K08 15991 2
9 LOCKWASHER J08 15991 2
10 HEX NUT D08 15991 2
PART NAME
PART
NUMBER
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 9
0 SERIESOM-03179
PUMP AND SEAL DISASSEMBLY
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de
cals attached to the pump.
If this pump is used with volatile and/or
flammable liquids, be certain proper
safety practices are followed before op
erating or servicing the pump. Provide
adequate ventilation, prohibit smoking,
wear static‐resistant clothing and
shoes. Clean up all fuel spills immedi
ately after occurrence.
This pump requires little service due to its rugged,
minimum‐maintenance design. However, if it be
comes necessary to inspect or replace the wearing
parts, follow these instructions, which are keyed to
the sectional views (Figures 1, 2 , 2A and 3) and the
accompanying parts lists.
Most service functions, such as wear ring, impeller,
and seal replacement, may be performed by drain
ing the pump and removing the suction head.
However, due to the confined mounting location of
the pump, it is recommended that the pump be re
moved from the vehicle for service. The following
instructions assume complete disassembly is re
quired.
2. Switch off the engine ignition and
remove the key to ensure that the
pump will remain inoperative.
3. Allow the pump to cool if over
heated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
After the vehicle is positioned for pump
maintenance, block the wheels and set
the emergency brake before attempting
to disconnect the drive shaft or remove
the pump. Be sure the pump is properly
reinstalled and secure before opera
tion.
The instructions in this section are keyed to Figure
1 and the accompanying parts lists.
Removing Pump and Gearbox
Due to the confined mounting location of the
pump, it is recommended that the pump be re
moved from the vehicle for service.
If the gearbox requires repair, proceed with PUMP
AND SEAL DISASSEMBLY, followed by GEAR
BOX DISASSEMBLY.
Before attempting to service the pump,switch off
the engine ignition and remove the key ensure that
it will remain inoperative. Close all valves in the suc
tion and discharge lines.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
Due to the confined mounting location,
specialized equipment such as a transmis
sion jack with custom brackets should be
used to lift and position the pump and
gearbox.
Close all valves in the suction and discharge lines.
Remove the casing drain plug (20), and drain the
pump. Clean and reinstall the drain plug.
Remove the suction piping. Remove the nuts se
curing the pump casing to the petroleum flange on
the vehicle tank.
Remove the hardware securing the input and out
put drive flanges (8 and 28) to the drive shafts. Dis
MAINTENANCE & REPAIRPAGE E - 10
0 SERIES
OM-03179
connect the air lines from the air shift cylinder as
sembly on the gearbox.
Remove the hardware securing the gearbox to the
rear cross member. Remove the hardware secur
ing the trunnion to the front cross member.
Move the pump and gearbox to a clean, well‐
equipped shop for maintenance and repair.
Suction Head and Wear Ring Removal
The wear ring (21) and impeller (2) are easily ac
cessible and may be serviced by removing the suc
tion head (23).
Remove the nuts (27) and pull the suction head
and wear ring out of the pump casing. Remove the
suction head gasket (25).
Seal Removal
Remove the seal spring. Lubricate the shaft adja
cent to the seal, and work oil up under the rubber
bellows. Slide the rotating portion of the seal off the
shaft.
Use a pair of stiff wires with hooked ends to remove
the stationary element and O‐ring from the casing
bore.
Pump Casing Removal
The presence of gearbox lubricant in the seal cav
ity behind the stationary element indicates failure
of the gearbox oil seal (13). Before attempting to re
move the seal, remove the gearbox drain plug and
gasket (65 and 66, Figure 2A) and drain the gear
box lubricant. Reinstall the drain plug and gasket.
If the oil seal, O‐ring (11) or gasket (17) require re
placement, or if the gearbox is to be disassembled,
remove the nuts (16) and slide the pump casing off
the shaft.
Use caution not to damage the suction
head when removing the wear ring (21).
Inspect the wear ring for excessive wear or scoring.
If replacement is required, use a chisel or other
suitable tool to cut it from the suction head. Be
careful not to damage the suction head bore.
Impeller Removal
To remove the impeller, block impeller rotation by
inserting a brass rod through the pump discharge
and between the impeller vanes. Use caution not
to damage the impeller. Remove the impeller nut
(22).
Install 1/4-20 UNC by 4‐inch long capscrews (not
supplied) in the tapped holes in the impeller, and
use a suitable puller to remove the impeller from
the shaft. Use caution when removing the impeller;
tension on the seal spring will be released. Retain
the impeller key (24).
Remove the impeller adjusting shims (19). For
ease of reassembly, tie and tag the shims, or mea
sure and record their thickness.
Remove the O-ring and gasket (11 and 17). Use a
set of screwdrivers or other suitable tools to pry the
oil seal (13) from the back of the pump casing.
Use caution not to damage the pump cas
ing when removing the wear ring (18).
Inspect the wear ring (20) for excessive wear or
scoring. If replacement is required, use a small bit
to drill two holes horizontally, 180 apart through
the wear ring. Use a chisel or other suitable tool to
complete the cuts and remove the wear ring from
the pumping casing. Be careful not to damage the
pump casing bore..
If no further disassembly is required, proceed with
PUMP AND SEAL REASSEMBLY. If the gearbox
requires disassembly, do not reassemble the
pump components at this time. Refer to GEAR
BOX DISASSEMBLY and GEARBOX REASSEM
BLY, followed by PUMP AND SEAL REASSEM
BLY.
PUMP AND SEAL REASSEMBLY
The instructions in this section are keyed to Figure
1 and the accompanying parts lists.
MAINTENANCE & REPAIR PAGE E - 11
0 SERIESOM-03179
If the gearbox requires disassembly, refer to
GEARBOX DISASSEMBLY and GEARBOX RE
ASSEMBLY, followed by PUMP AND SEAL REAS
SEMBLY.
Pump Casing Installation
If the wear ring (18) was removed, position the re
placement ring in the pump casing with the cham
fered end toward the bore shoulder. Press the wear
ring into the pump casing until fully seated.
NOTE
The wear ring must seat squarely in teh pump cas
ing; otherwise, binding and/or excessive wear will
occur as the shaft turns.
Apply a thin coat of “Permatex Aviation No. 3 Form‐
A‐Gasket” to the contact surfaces of the oil seal
(13) and the casing bore. Position the oil seal in the
pump casing bore with the lip positioned as shown
in Figure 1. Press the oil seal into the bore until fully
seated against the bore shoulder.
Install the stationary seal element and O‐ring in the
seal bore as described in Seal Reassembly and
Installation before securing the pump casing to
the adaptor.
gearbox housing. Be careful not to damage the lip
of the oil seal or the stationary seal element.
Use “Loctite 242” or equivalent compound on the
nuts (16) and secure the pump casing to the gear
box housing with the nuts.
Seal Reassembly and Installation
(Figures 1 and 4)
Clean the seal cavity and shaft with a cloth soaked
in fresh cleaning solvent.
Most cleaning solvents are toxic and
flammable. Use them only in a wellventilated area free from excessive
heat, sparks, and flame. Read and fol
low all precautions printed on solvent
containers.
The seal is not normally reused because wear pat
terns on the finished faces cannot be realigned
during reassembly. This could result in premature
failure. If necessary to reuse an old seal in an emer
gency, carefully wash all metallic parts in fresh
cleaning solvent and allow to dry thoroughly.
With the stationary seal seat installed in the seal
bore of the pump casing, lubricate the O‐ring (11),
and slide it onto the pump casing shoulder.
Position the pump casing gasket (17) over the cas
ing studs (15).
Before further reassembly, calculate the thickness
of bearing adjusting shims (12) required to obtain a
shaft end play of .005 to .010 inch (0,127 to 0,254
mm). Use a depth micrometer to measure the
height of the pump casing shoulder (with the gas
ket installed), and the depth of the bearing in the
gearbox housing from the gasket mating surface.
Select a combination of shims to make up the dif
ference between the two measurements, and in
stall the bearing shims in the bearing bore.
Lubricate the lip of the oil seal (13) to ease installa
tion. Apply “Never‐Seez” or equivalent compound
to the casing studs (15). Carefully slide the pump
casing over the shaft until fully seated against the
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non‐oil based solvent and a clean, lint‐free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
age. If any components are worn, replace the com
plete 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 bel
lows and stationary element O‐ring with water or a
very small amount of light lubricating oil, and apply
a drop of light lubricating oil on the finished faces.
Assemble the seal as follows, (see Figure 4).
MAINTENANCE & REPAIRPAGE E - 12
0 SERIES
OM-03179
IMPELLER
IMPELLER
KEY
IMPELLER
ADJUSTING
SHIMS
SPRING
BELLOWS
RETAINER
O‐RING
STATIONARY
SEAT
IMPELLER
SHAFT
PUMP
CASING
ROTATING
ELEMENT
Figure 4. 25271-903 Seal Assembly
This seal is not designed for operation at
temperatures above 160F (71C). Do not
use at higher operating temperatures.
Inspect the impeller shaft for distortion, nicks,
scratches, or damage to the shaft keyway. Dress
small nicks and burrs with a fine file or emery cloth.
If the shaft is defective, refer to GEARBOX DISAS
SEMBLY and replace the shaft.
Lubricate the stationary element O‐ring with a light
coat of oil. Place a clean, lint‐free tissue over the
seal face, and use thumb pressure to press the ele
ment and O‐ring into the pump casing until fully
seated. Be careful not to damage the seal face. Af
ter installation wipe the seal face in a concentric
pattern with a clean, lint‐free cloth to remove any
fingerprints.
NOTE
If the pump casing was removed, install the casing
O‐ring and gasket (18 and 19) on the pump casing
studs. Carefully slide the casing over the shaft, and
secure it to the gearbox with the nuts (15).
Install a tapered sleeve (see Figure 5) over the shaft
keyway to ease installation of the rotating portion of
the seal. This tool can be made from steel tubing or
pipe.
MAINTENANCE & REPAIR PAGE E - 13
1.62
41,15 mm
SLEEVE
0 SERIESOM-03179
IMPELLER
SHAFT
1.25 D
31,75 mm
5 TAPER
(APPROX.)
FINISH ALL OVER TO
BE 50 RMS OR LESS
SLEEVE DIMENSIONS SLEEVE INSTALLED
1.50 D
38,1 mm
ENDS TO BE SQUARE
AND PARALLEL
Figure 5. Seal Installation Sleeve
Lubricate the tapered sleeve and position it on the
shaft. Position the rotating portion of the seal (con
sisting of the retainer, bellows and rotating ele
ment) on the sleeve, and apply even pressure
against the shoulder of the seal retainer until the ro
tating subassembly slides onto the shaft and the
seal faces contact. A push tube cut from a piece of
plastic tubing would aid this installation. The I.D. of
the tube should be approximately the same diame
ter as the I.D. of the seal spring.
Remove the tapered sleeve and install the seal
spring.
SEAL
AREA
KEYWAY
Impeller Installation
Inspect the impeller and replace it if cracked or
badly worn.
For maximum pump efficiency, the impeller must
be centered within the volute scroll. Center the im
peller by adding or removing adjusting shims (18).
To verify impeller positioning, measure the pump
casing and impeller as shown in Figure 6. Use
these measurements to calculate the required im
peller location (dimension E). Add or remove im
peller adjusting shims until dimension E is ob
tained.
B
2
AB
CD
D
2
Step 2Step 1 Step 3
B
A
+
-
2
Figure 6. Centering Impeller Within Volute Scroll
C
+
D
2
=
E
MAINTENANCE & REPAIRPAGE E - 14
E
0 SERIES
OM-03179
NOTE
After the impeller has been properly positioned,
check for free rotation. Correct any scraping or
binding before further reassembly.
With the correct thickness of impeller adjusting
shims installed, apply “Locquic Primer T” to the
keyway, key (4) and shaft threads. Apply “Loctite
No. 242” to the key and keyway and install the key.
Align the impeller and press it onto the shaft until
fully seated.
NOTE
It is not recommended that substitute locking mate
rials be used in this application. Use only the rec
ommended “Loctite” products.
After the impeller is installed, install the impeller
nut (22). Secure the impeller by torquing the impel
ler nut to 125 ft. lbs. (1500 in. lbs. or 17,3 m. kg.).
Install the nuts securing the pump discharge to the
vehicle tank.
Install the hardware securing the input and output
drive flanges (8 and 28) to the drive shafts. Install
the air lines from the air shift cylinder assembly on
the gearbox.
Install the hardware securing the gearbox (14) to
the rear cross member. Install the hardware secur
ing the trunnion to the front cross member.
Final Pump Assembly
Install the suction line and open all valves. Make
certain that all piping connections are tight, proper
ly supported and secure.
Be sure the gearbox has been properly lubricated,
see LUBRICATION at the end of this section.
Refer to OPERATION, Section C, and start the
pump.
Suction Head and Wear Ring Installation
If the wear ring (21) was removed, position the re
placement ring in the suction head (23) with the
chamfered end toward the bore shoulder. Press
the wear ring into the suction head until fully
seated.
NOTE
The wear ring must seat squarely in the suction
head; otherwise, binding and/or excessive wear
will occur as the shaft turns.
Apply “Never‐Seez” or equivalent compound to the
studs (26). Slide the suction head gasket (25) and
suction head over the studs, and secure with the
nuts (27).
Installing Pump and Gearbox
GEARBOX DISASSEMBLY
Unless otherwise specified, the instructions in this
section are keyed to Figures 2 and 2A, and the ac
companying parts lists.
When the pump is properly operated and main
tained, the gearbox should not require disassem
bly. Disassemble the gearbox only when there is
evidence of wear or damage.
Gearbox disassembly in the field is not rec
ommended. These operations should be
performed only in a properly‐equipped
shop by qualified personnel.
Due to the confined mounting location of the
pump, it is recommended that the pump be re
moved from the vehicle for service.
Due to the confined mounting location,
specialized equipment such as a transmis
sion jack with custom brackets should be
used to lift and position the pump and
gearbox.
MAINTENANCE & REPAIR PAGE E - 15
Due to the confined mounting location,
specialized equipment such as a transmis
sion jack with custom brackets should be
used to lift and position the pump and
gearbox.
0 SERIESOM-03179
Refer to Removing Pump and Gearbox under
PUMP AND SEAL DISASSEMBLY and remove
the pump and gearbox from the vehicle. Move the
pump and gearbox to a clean, well‐equipped shop
for maintenance and repair.
Disassemble the pump components as indicated
in PUMP AND SEAL DISASSEMBLY.
Air Shift Cover Disassembly
To remove the air shift cover assembly (1), disen
gage the capscrews (63 and 64) securing the as
sembly to the gearbox housing (41).
The cylinder cap (14) and shifter fork (7) must be
removed before the shifter shaft assembly (2) can
be removed. To remove the cylinder cap, disen
gage the capscrews (15).
To remove the shifter fork, disengage the socket
head capscrews (6) securing the fork to the shifter
shaft. Remove the shifter fork.
The output shaft cannot be removed from
the bearing retainer without first removing
the ball bearing (55) and roller bearing (48)
from the shaft. The bearings may be dam
aged during removal.
To remove the output shaft (58), tap against the
splined end of the shaft with a soft‐faced mallet or
brass bar until the shaft is driven approximately 3/4
inch (19 mm) into the bearing retainer. From the op
posite end of the shaft, use the mallet to tap the
shaft back into the bearing retainer. This will unseat
the ball bearing (55) from the retainer.
Use a suitable bearing puller to remove the ball
bearing from the shaft.
Push the shaft through the roller bearing (48) until
the retaining ring (50) seats squarely against the
bearing. Remove the retaining ring (47), and gently
tap the splined end of the shaft until the roller bear
ing is out of the bearing retainer. Carefully slide the
bearing retainer off the shaft. Slide the spacer
sleeve (51) off the shaft. Remove the snap ring (50)
and pull the roller bearing off the shaft.
Remove and inspect the shifter shaft assembly and
piston O‐ring (11) and replace any parts as re
quired. Remove the oil seal (3) and shaft O‐ring (9).
Drive Flange Removal
Disengage the capscrews and remove the lock
plate washers. Use a suitable puller to remove the
input and output drive flanges (8 and 28, Figure 1).
Output Shaft Disassembly
To remove the tail shaft assembly (46), which in
cludes the output drive shaft (65) and related com
ponents, remove the capscrews (61) and pull the
assembly from the gearbox housing. Remove the
bearing retainer gasket (62).
Disengage the hardware (53) and separate the
bearing cap (59) and gasket (52) from the bearing
retainer (49). Inspect the oil seal (56) and, if re
placement is required, press it from the bearing
cap.
Use a suitable puller to remove the bearing (45)
from the output shaft.
Input Shaft Disassembly
To remove the input drive shaft (25), disengage the
capscrews (22) and separate the bearing cap (24)
and gasket (29) from the gearbox housing. Inspect
the oil seal (23) and, if replacement is required,
press it from the bearing cap.
Reach through the tailshaft end of the gearbox
housing and remove the sliding clutch (44). Re
move the retaining ring (26) from the shaft.
Position the gearbox housing on an arbor (or hy
draulic) press with the drive flange (splined) end of
the input shaft facing up. Insert a spacer tool (G‐R
P/N 33144-011) between the drive gear (17) and
the internal wall of the gearbox housing so that the
drive gear is held in place as the shaft is pressed
through. Press the shaft from the housing while
reaching through the top of the gearbox housing to
remove the drive gear, bearings (20), and spacer/
slinger (28).
MAINTENANCE & REPAIRPAGE E - 16
0 SERIES
To prevent damage during removal, it is
recommended that bearings be cleaned
and inspected in place. It is strongly rec
ommended that the bearings be replaced
any time the gearbox is disassembled.
Clean and inspect the bearings (20 and 27) as out
lined in Cleaning and Inspecting Bearings. If the
bearings require replacement, use a suitable puller
to remove them from the drive gear. Remove the re
taining ring (18), and spacer (19) from the drive
gear.
If replacement is required, use a suitable puller to
remove the bearing (21) from the gearbox housing.
Idler Shaft Disassembly
Position the gearbox housing on a solid surface
with the bearing cap (33) facing up. Support the
housing on wooden blocks while in this position.
OM-03179
Pull the outer race of the roller bearing (43) from the
gearbox cavity using a suitable puller.
Impeller Shaft Disassembly
With the pump end disassembled (see PUMP
AND SEAL DISASSEMBLY) and idler shaft re
moved, the impeller shaft (39) and bearings (38
and 42) can be pressed out from either side of the
gearbox.
To prevent damage during removal, it is
recommended that bearings be cleaned
and inspected in place. It is strongly rec
ommended that the bearings be replaced
any time the gearbox is disassembled.
Clean and inspect the bearings as outlined in
Cleaning and Inspecting Bearings. If the bear
ings require replacement, use a suitable puller to
remove them from the shaft.
Disengage the capscrews (32) and remove the
bearing cap and gasket (40). There is a tapped
hole (3/4-10 UNC by 5/8 inch deep) in the end of
the idler shaft (35) to accommodate a specially‐de
signed puller (G‐R P/N 48781-007). Use this tool
to pull the shaft and key (36) through the idler gear
(37), and remove the idler gear through the top of
the gearbox.
To prevent damage during removal, it is
recommended that bearings be cleaned
and inspected in place. It is strongly rec
ommended that the bearings be replaced
any time the gearbox is disassembled.
Separate the outer race of the front roller bearing
(34) from the inner race. Slide the inner race of the
roller bearing (43) out of the outer race.
Cleaning and Inspecting Bearings
It is recommended that bearings be cleaned and
inspect in place as follows.
To prevent damage during removal from
shaft, it is recommended that bearings be
cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the gearbox is disas
sembled.
Clean the gearbox housing, shafts and all compo
nent parts (except the bearings) with a soft cloth
soaked in cleaning solvent. Inspect the parts for
wear or damage and replace as necessary.
Clean and inspect the inner and outer bearing
races as outlined in Cleaning and Inspecting
Bearings. If bearing replacement is required, pull
the inner race of the front bearing (34) off the shaft.
MAINTENANCE & REPAIR PAGE E - 17
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area free from excessive heat,
0 SERIESOM-03179
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will great
ly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail
ure.
Rotate the bearings by hand to check for rough
ness or binding and inspect the bearing balls. If ro
tation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit
onto the shafts or a snug slip fit into the gearbox
housing. Replace the bearings, shafts, or gearbox
housing if the proper bearing fit is not achieved.
Although bearings should be cleaned and in
spected in place to prevent damage during remov
al, it is strongly recommended that bearings be re
placed any time the gearbox is disassembled.
Inspect the shafts for distortion, damaged key
ways, nicks or scratches, or for damage on the im
peller or drive ends. Dress small nicks and burrs
with a fine file or emery cloth. Replace the shafts if
defective.
Check all oil seal and gasket seating surfaces for
nicks and scratches. Dress small nicks and burrs
with a fine file or emery cloth. Be careful not to dis
tort the shape of the surfaces.
When reassembling the gearbox, replace all gas
kets and O‐rings. Apply a light coating of oil on
mating surfaces shafts, gears and oil seals to ease
reassembly.
Impeller Shaft Reassembly
Use two 3/8-16 UNC by 1-1/2 inch long cap
screws (not supplied) to secure the bearing stop
(G‐R P/N 29511-904) to the housing diagonally
across the opening for the bearing cap (33).
Position the gearbox housing on the bed of an ar
bor (or hydraulic) press with the opening for the
bearing cap (33) facing down. Support the gear
box housing on wooden blocks while in this posi
tion.
Use the bearing driver (G‐R P/N 29511-903) to
press the front bearing (38) into the gearbox hous
ing until seated against the bearing stop.
GEARBOX REASSEMBLY
Unless otherwise specified, the instructions in this
section are keyed to Figures 2 and 2A, and the ac
companying parts lists.
Clean and inspect the bearings as indicated in
Cleaning and Inspecting Bearings.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the gearbox is disas
sembled.
To prevent damage to the bearings during
reassembly, do not tap or drive bearings
into place with a hammer. Install bearings
on shafts and into bores using the desig
nated driving tools and an arbor or hydrau
lic press.
Use the bearing driver (G‐R P/N 29511-905) to
press the rear bearing (42) onto the impeller shaft
(39) until fully seated against the shaft shoulder.
Use the bearing driver (G‐R P/N 29511-905) to
press the assembled impeller shaft and bearing
into the gearbox housing until the shaft shoulder
seats squarely against the front bearing (38).
Idler Shaft Reassembly
Reposition the gearbox housing with the opening
for the bearing cap (33) facing up. Support the
MAINTENANCE & REPAIRPAGE E - 18
0 SERIES
OM-03179
gearbox housing on wooden blocks while in this
position. Remove the bearing stop from the gear
box housing.
Position the outer race of the rear roller bearing (43)
in the gearbox housing. Note that one side of the
outer race is solid; this solid outer ring must be po
sitioned toward the outside of the gearbox hous
ing. When installed, the inner race must have the
shouldered side positioned toward the gear.
Use the bearing driver (G‐R P/N 29511-907) to
press the outer race into the gearbox housing bore
until fully seated. Slide the inner race into the outer
race until fully seated.
Position the inner race of the front roller bearing
(43) on the shaft so that the lettered side and cham
fer on the race is toward the shaft shoulder.
Use the bearing driver (G‐R P/N 29511-908) to
press the race onto the shaft until seated squarely
against the shaft shoulder.
Pre‐heat the idler gear to 220-230
(104-110C). Use heavy gloves to reach through
the top of the gearbox and lay the idler gear (39) in
position next to the rear bearing. Position the
spacer fork (G‐R P/N 29511-915) between the
idler gear and the rear bearing.
Install the key (36) in the idler shaft. Coat the idler
shaft and idler gear bore lightly with “Never‐Seez
Black Moly”.
Use one end of the spacer fork tool to align the gear
and rear bearing concentrically. Be sure that the
fork is positioned so the larger diameter (3-9/16
inch or 90 mm) recess faces the bearing. Insert the
idler shaft, making sure the key is properly aligned
with the slot in the gear. Press the shaft through the
idler gear until the shaft shoulder is snug against
the gear.
Screw the pin in the bearing driver (G‐R P/N
29511-909) into the tapped hole in the idler shaft.
Use the driver to press the outer race of the bearing
into the housing until fully seated against the inner
race.
Replace the bearing cap gasket (40), and secure
the bearing cap (33) to the gearbox housing by
torquing the capscrews (32) to 35 ft. lbs. (420 in.
lbs. or 4,8 m. kg.).
Input Shaft Reassembly
Use the bearing driver (G‐R P/N 29511-910) to
press the bearing (21) into the gearbox housing
until fully seated.
Reposition the gearbox housing with the opening
for the output shaft facing up. Support the gearbox
housing on wooden blocks while in this position.
Install the retaining ring (18) in the gear. Use the
bearing driver (G‐R P/N 29511-911) to press the
inner bearing (27) into the drive gear until squarely
seated against the lock ring.
F
Position the spacer (19) against the inner bearing,
and use the bearing driver (G‐R P/N 29511-912)
to press the outer bearing (20) into the gear until
squarely seated against the lock ring and spacer.
Before installing the input shaft, position the
spacer/slinger (28) in the gearbox with the flat side
away from the input shaft opening (facing up). Po
sition the drive gear assembly in the gearbox hous
ing with the exposed bearing next to the spacer/
slinger.
Install the retaining ring (26) in the groove on the
input shaft. Use the bearing driver (G‐R P/N
29511-913) in combination with the bearing sup
port stop (G‐R P/N 29511-920) to press the shaft
through the tail shaft opening until the lock ring
seats against the inner bearing.
Remove the spacer fork and press the shaft and
gear into the rear bearing (43) until the gear shoul
der contacts the bearing.
Position the outer race of the front bearing (34) in
the gearbox housing bore. Note that one side of
the outer race is solid; this solid outer ring must be
positioned toward the inside of the gearbox hous
ing.
Reposition the gearbox housing with the input
splines on the shaft facing up. Support the gearbox
housing on wooden blocks while in this position.
Use the seal driver and stop (G‐R P/N 29511-902)
to press the oil seal (23) into the bearing cap (24)
until fully seated. Install the gasket (29) and secure
the cap to the gearbox housing by torquing the
capscrews (22) to 90 ft. lbs. (1080 in. lbs. or 12,4 m.
MAINTENANCE & REPAIR PAGE E - 19
0 SERIESOM-03179
kg.). Use caution not to damage the oil seal lip on
the shaft splines.
Reposition the gearbox housing with the opening
for the tail shaft facing up. Support the gearbox
housing on wooden blocks while in this position.
Push the sliding clutch (44) over the long splined
end of the input shaft. The narrow row of teeth must
face toward the retaining ring (26). Check for free
movement by sliding the clutch back and forth over
the full length of the splines.
Output Shaft Reassembly
Press the roller bearing (48) into the bearing retain
er (49) until fully seated and install the retaining ring
(47).
Position the roller bearing (45) in the geared end of
the output shaft (58) and press it into the shaft bore
until fully seated.
Slide the splined end of the output shaft through
the bearing until the bearing seats squarely
against the shaft shoulder.
Install the retaining ring (50), and slide the gear
(51) and spacer (54) onto the shaft.
Position the spacer (G‐R P/N 29511-913) over the
geared end of the output shaft, and rest the retain
er, shaft and spacer on the bed of the press with the
splined end of the shaft facing up. Use the bearing
driver (G‐R P/N 29511-913) to press the bearing
(55) over the shaft until fully seated in the bearing
retainer bore.
Air Shift Cover Reassembly
Reinstall the shifter shaft O‐ring (9) and oil seal (3).
Be sure the lip of the oil seal is directed toward the
shifter fork.
Replace the plunger O‐ring (11). Lubricate the O‐
rings, piston and cylinder I.D. with “Parker‐O‐Lube”
and reinstall the shifter shaft assembly (2). Secure
the cylinder cap (14) by tightening the capscrews
(15) equally to prevent cocking the cylinder body;
torque the capscrews to 35 ft. lbs. (420 in. lbs. or
4,8 m. kg.). Check for free movement of the shaft
and piston.
Inspect the shifter fork (7) and replace as neces
sary. Position the shifter fork on the shifter shaft.
Secure the fork to the shaft by torquing the allen
head screws (6) to 45 ft. lbs. (540 in. lbs. or 6,2 m.
kg.).
Engage the shifter fork with the sliding clutch, and
secure the air shift cover to the gearbox housing by
torquing the capscrews (63 and 64) to 35 ft. lbs.
(420 in. lbs. or 4,8 m. kg.).
Apply “Permatex” or equivalent compound on the
hose fittings before installing the air supply lines to
the air cylinder. Air check all possible leak points
with 120 to 150 psi (8,4 to 10,5 kg/cm) before fur
ther reassembly.
Check the shifter fork and sliding clutch alignment
by working the shifter fork back and forth. The shaft
should travel approximately 1-5/8 inches (41,3
mm) between the two positions.
Pressure Testing
Install the bearing retainer gasket (62). Slide the tail
shaft assembly into the gearbox housing until the
bearing retainer seats squarely against the hous
ing shoulder, and the bearing (45) is positioned
over the end of the input shaft. Secure the bearing
retainer to the gearbox housing by torquing the
capscrews (61) to 90 ft. lbs. (1080 in. lbs. or 12,4 m.
kg.).
Use the seal driver and stop (G‐R P/N 29511-902)
to press the oil seal (56) into the bearing cap (59)
until fully seated. Install the gasket (52) and secure
the cap to the bearing retainer by torquing the cap
screws (53) to 50 ft. lbs. (600 in. lbs. or 7 m. kg.).
The gearbox should be pressure tested any time a
sealed surface is disturbed. This includes flange,
gasket or oil seal removal, as well as a complete
overhaul.
To pressure test the gearbox, install the pressure
test sleeves (G‐R P/N 29511-914) over the input
and output shafts, and secure them with the cap
screws and lockplate washers; torque the cap
screws to 90 ft. lbs. (1080 in. lbs. or 12,4 m. kg.).
Remove the breather vent (8) and install a valve
stem and air pressure gauge in the hole. Apply
“Loctite Pipe Sealant with Teflon” or equivalent
compound to the threads before installation.
MAINTENANCE & REPAIRPAGE E - 20
0 SERIES
OM-03179
Use filtered compressed air to pressurize the gear
box until it stabilizes at 6 psi (0,4 kg/cm), then shut
off the air flow and observe the pressure gauge. If
the pressure drops more than 1 psi (0,07 kg/cm)
in 15 seconds, an unacceptable air leak exists at
one of the sealing surfaces.
To find the leak, repressurize the gearbox, and ap
ply a liberal amount of commercially available win
dow cleaner or liquid detergent to each sealing
surface. Watch for air bubbles to appear indicating
a leak. Correct any leaks that are found, and retest
the gearbox.
Drive Flange Installation
The shaft splines are designed to produce a slight
interference fit with the drive flanges. This fit is re
quired to prevent fretting corrosion.
Coat the input and output shaft splines with light
oil. Apply oil to the leading area of the drive flanges
where the oil seal lips seat. Position the input and
output flanges on their respective shafts.
through the lubrication fitting (12) until grease es
capes from the trunnion area.
Gearbox Assembly
(Figure 2A)
The gearbox was shipped from the factory dry of
lubrication, except for a residual coating from the
testing process of 90 weight gear oil and Dow
Corning “Molykote M Gear Guard” (an anti‐wear
additive consisting of molybdenum disulphide sol
id lubricants suspended in petroleum oil). For initial
lubrication of the gearbox, remove the oil level plug
(67), and add approximately 68 U.S. ounces (2011
ml) of premium quality, multi‐purpose, extreme
pressure gear lubricant with an SAE rating per the
following ambient temperatures.
Table 1. Lubrication Specifications
Temperature Range Lubricant
-40F (-53C) to 0F (-018C) Delvac I
-10F (-23C) to +40F (+4C) 80 W 90
+32F (0C) and above 80 W 140
It is recommended that a sleeve be used to drive
the flanges onto the shaft until fully seated. The
sleeve must be sized to fit over the shaft and into
the flange counterbore.
After the flanges have been installed, secure them
to the shafts with the capscrews and lockplate
washers; torque the capscrews to 90 ft. lbs. (1080
in. lbs. or 12,4 m. kg.).
Lubricate the gearbox as indicated in LUBRICA
TION at the end of this section. Install the pump
and gearbox assembly onto the vehicle as de
scribed in Installing Pump and Gearbox at the
end of PUMP AND SEAL REASSEMBLY.
LUBRICATION
Seal Assembly
The seal assembly is lubricated by the liquid being
pumped. No additional lubrication is required.
Trunnion Bracket
(Figure 1)
To lubricate the trunnion (11) and bearing retainer,
add SAE No. 2 lithium‐based pressure gun grease
Fill the gearbox to the bottom of the fill plug hole as
indicated on the oil level plate. If the gearbox is ov
er‐filled, foaming may occur with oil loss through
the breather vent during continuous duty opera
tion. Under‐filling can result in loss of lubrication to
the tailshaft bearing, resulting in premature bear
ing failure. Check the lubricant level regularly, and
maintain it at the recommended level. Reinstall the
oil level plug.
Intermittent (Normal Refueler) Duty Cycle
Change the lubricant in a new gearbox after an ini
tial break‐in period of 24 hours, and before 100
hours of operation. The lubricant should be
changed while the pump is at operating tempera
ture.
To change the lubricant, remove the magnetic
drain plug and gasket (65 and 66), and drain the
gearbox. If operating conditions require changing
grades of oil to Delvac I, it is recommended that the
gearbox be thoroughly flushed with flushing oil
prior to refilling. Always clean the magnetic plug
thoroughly before reinstalling it. Add 6 ounces (18
ml) of Dow Corning “Molykote M Gear Guard”,
and “top off” with approximately 68 U.S. ounces (2
liters) of oil as previously described.
MAINTENANCE & REPAIR PAGE E - 21
0 SERIESOM-03179
After the initial change, the lubricant should be
changed after every 500 hours of operation or ev
ery 6 months, whichever comes first. The lubricant
should be changes more frequently when the
pump is operated under severe conditions, such
as extremely dusty conditions or in areas where ex
treme temperature changes are regularly experi
enced.
Check the oil in the gearbox monthly, and maintain
it at the proper level. Check the gearbox monthly
for leaks.
Contaminated gearbox lubricant or metal
shavings on the magnetic drain plug may
indicate impending pump or gearbox fail
ure. Monitor operation closely and sched
ule maintenance accordingly.
Continuous Pumping Duty Cycle
For duty cycles which do not provide at least a 20
minute cool‐down (non‐pumping) period after
each 30 minutes of continuous pumping, the fol
lowing lubrication schedule shall apply.
1. Change the lubricant in a new gearbox after
an initial break‐in period of 10 hours and be
fore 20 hours of operation. The lubricant
should be changed while the pump is at op
erating temperature. Remove the magnetic
plug and gasket (65 and 66) and drain the
gearbox. Always clean the magnetic plug
thoroughly before reinstalling.
2. After the initial change, the lubricant should
be changed after every 40 hours of opera
tion or 3 months, whichever comes first.
MAINTENANCE & REPAIRPAGE E - 22
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 MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
Loading...