Gorman-Rupp Pumps 16A20-B User Manual

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Page 1

OM‐00710‐04

February 11, 1985

Rev. B 06‐24‐2014

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

10 SERIES PUMP

MODEL

16A20‐B

GORMAN‐RUPP PUMPS

www.grpumps.com

e1985 Gorman‐Rupp Pumps Printed in U.S.A.

Page 2

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:

Page 3

TABLE OF CONTENTS

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

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

INSTALLATION - SECTION B PAGE B - 1....................................

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

PREINSTALLATION INSPECTION PAGE B - 2............................................

POSITIONING PUMP PAGE B - 2.......................................................

Lifting PAGE B - 2.................................................................

Mounting PAGE B - 2.............................................................

Clearance PAGE B - 2.............................................................

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

Materials PAGE B - 3..............................................................

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

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

Gauges PAGE B - 3...............................................................

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

Fittings PAGE B - 3...............................................................

Strainers PAGE B - 3..............................................................

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

Suction Lines In Sumps PAGE B - 4.................................................

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

DISCHARGE LINES PAGE B - 5........................................................

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

Valves PAGE B - 5................................................................

Bypass Lines PAGE B - 5..........................................................

AUTOMATIC AIR RELEASE VALVE PAGE B - 6...........................................

Air Release Valve Installation PAGE B - 6................................................

ALIGNMENT PAGE B - 7..............................................................

Coupled Drives PAGE B - 8........................................................

V‐Belt Drives PAGE B - 8...........................................................

V‐BELT TENSIONING PAGE B - 9......................................................

General Rules of Tensioning PAGE B - 9.............................................

Tension Measurement PAGE B - 9..................................................

OPERATION - SECTION C PAGE C - 1......................................

PRIMING PAGE C - 1.................................................................

STARTING PAGE C - 1................................................................

Rotation PAGE C - 1..............................................................

OPERATION PAGE C - 2..............................................................

Lines With a Bypass PAGE C - 2....................................................

Lines Without a Bypass PAGE C - 2.................................................

Leakage PAGE C - 2..............................................................

Liquid Temperature and Overheating PAGE C - 2.....................................

Strainer Check PAGE C - 2.........................................................

Pump Vacuum Check PAGE C - 2..................................................

STOPPING PAGE C - 3................................................................

BEARING TEMPERATURE CHECK PAGE C - 3..........................................

Cold Weather Preservation PAGE C - 3..............................................

Page 4

TABLE OF CONTENTS

(continued)

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

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

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

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

PARTS LIST:

Pump Model PAGE E - 3..........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 4.........................

Suction Check Valve Removal and Disassembly PAGE E - 4...........................

Back Cover Removal PAGE E - 5...................................................

Pump Casing Removal PAGE E - 5.................................................

Impeller Removal PAGE E - 5......................................................

Seal Removal and Disassembly PAGE E - 5..........................................

Shaft and Bearing Removal and Disassembly PAGE E - 6.............................

Shaft and Bearing Reassembly and Installation PAGE E - 7............................

Seal Reassembly and Installation PAGE E - 8........................................

Impeller Installation and Adjustment PAGE E - 10......................................

Pump Casing Installation PAGE E - 10................................................

Back Cover Installation PAGE E - 10.................................................

Suction Check Valve Installation PAGE E - 10.........................................

Final Pump Assembly PAGE E - 10..................................................

LUBRICATION PAGE E - 11.............................................................

Bearings PAGE E - 11..............................................................

Seal Assembly PAGE E - 11.........................................................

Power Source PAGE E - 11.........................................................

Page 5

10 SERIES

OM‐00710

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump. Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so could result in personal injury or damage to the pump.

This pump is a 10 Series, semi‐open impeller, self‐ priming centrifugal model with a suction check valve. The pump is designed for handling most non‐volatile, non‐flammable liquids containing specified entrained solids. The basic material of construction for wetted parts is cast iron, with duc tile iron impeller, steel wear plate and alloy steel im peller shaft.

This manual will alert personnel to known proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices.

For information or technical assistance on the pow er source, contact the power source manufactur er's local dealer or representative.

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:

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

Page 6

10 SERIES

OM‐00710

SAFETY ‐ SECTION A

This information applies to 10 Series ba sic pumps. Gorman‐Rupp has no con trol over or particular knowledge of the power source which will be used. Refer to the manual accompanying the power source before attempting to begin oper ation.

This manual will alert personnel to known procedures which require spe cial attention, to those which could damage equipment, and to those which could be dangerous to personnel. How ever, this manual cannot possibly antici pate and provide detailed instructions and precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance personnel to ensure that only safe, established main tenance procedures are used, and that any procedures not addressed in this manual are performed only after estab lishing that neither personal safety nor pump integrity are compromised by such practices.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Disconnect or lock out the power source to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Check the temperature before opening any covers, plates, or plugs.

5. Close the suction and discharge valves.

6. Vent the pump slowly and cau tiously.

7. Drain the pump.

This pump is designed to handle most non‐volatile, non‐flammable liquids containing specified entrained solids. Do not attempt to pump volatile, flam mable or corrosive liquids which may damage the pump or endanger person nel as a result of pump failure.

Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.

After the pump has been installed, make certain that the pump and all piping or hose connections are tight, properly supported and secure before operation.

PAGE A - 1SAFETY

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10 SERIESOM‐00710

Do not remove plates, covers, gauges, pipe plugs, or fittings from an over heated pump. Vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Al low the pump to completely cool before servicing.

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.

Do not operate the pump without the shields and/or guards in place over the drive shaft, belts, and/or couplings, or other rotating parts. Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to person nel.

Never run this pump backwards. Be cer tain that rotation is correct before fully engaging the pump.

Pumps and related equipment must be in stalled and operated according to all na tional, local and industry standards.

Overheated pumps can cause severe burns and injuries. If overheating of the pump occurs:

1. Stop the pump immediately.

2. Ventilate the area.

3. Allow the pump to completely cool.

4. Check the temperature before opening any covers, plates, gauges, or plugs.

5. Vent the pump slowly and cau tiously.

6. Refer to instructions in this manual before restarting the pump.

PAGE A - 2 SAFETY

Page 8

10 SERIES OM‐00710

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping.

Most of the information pertains to a standard static lift application where the pump is positioned above the free level of liquid to be pumped.

If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line configuration, and priming must be tailored to the

OUTLINE DRAWING

specific application. Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve (see Sec tion E, Page 1).

For further assistance, contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company.

Pump Dimensions

See Figure 1 for the approximate physical dimen sions of this pump.

Figure 1. Pump Model 16A20-B

PAGE B - 1INSTALLATION

Page 9

OM‐00710 10 SERIES

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 for cracks, dents, damaged

threads, and other obvious damage.

b. Check for and tighten loose attaching hard

ware. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces.

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties indicated.

POSITIONING PUMP

Only operate this pump in the direction in dicated by the arrow on the pump body and on the accompanying decal. Other wise, the impeller could become loosened from the shaft and seriously damage the pump. Refer to Rotation in OPERATION, Section C.

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 has been stored for more than 12

months, some of the components or lubri cants may have exceeded their maximum shelf life. These must be inspected or re

placed to ensure maximum pump service.

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.

Mounting

Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mount ing is essential for proper operation.

The pump may have to be supported or shimmed to provide for level operation or to eliminate vibra tion.

Clearance

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.

PAGE B - 2 INSTALLATION

It is recommended that 18 inches (457,2 mm) of clearance be provided in front of the back cover to permit removal of the cover and easy access to the pump interior. A minimum clearance of 9 inches (228,6 mm) must be maintained to permit removal of the cover.

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10 SERIES OM‐00710

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve on Page E-1 to be sure your overall application allows pump to operate within the safe operation range.

Materials

Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended.

Line Configuration

Installation closer to the pump may result in erratic readings.

SUCTION LINES

To avoid air pockets which could affect pump prim ing, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ets.

Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or cou plings.

Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose‐type lines are used, they should have adequate support to secure them when filled with liquid and under pressure.

Gauges

Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457,2 mm) from the suction and discharge ports and install the lines.

Strainers

If a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a strainer furnished with the pump will also pass through the pump itself.

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

This pump is designed to handle up to 2-1/2 inch (63,5 mm) diameter spherical solids.

Sealing

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

PAGE B - 3INSTALLATION

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OM‐00710 10 SERIES

Suction Lines In Sumps

If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1‐1/2 times the diame ter of the suction line.

If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump, and air entering the suction line will re duce pump efficiency.

If it is necessary to position inflow close to the suc tion inlet, install a baffle between the inflow and the suction inlet at a distance 1‐1/2 times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet.

If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency

of one or both pumps. To avoid this, position the suction inlets so that they are separated by a dis tance equal to at least 3 times the diameter of the suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is

critical to efficient pump operation. recommended minimum submergence vs. veloc ity.

Figure 2 shows

NOTE

The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

PAGE B - 4 INSTALLATION

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10 SERIES OM‐00710

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line. Otherwise, a si phoning action causing damage to the pump could result.

Valves

If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line.

With high discharge heads, it is recommended that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped.

NOTE

The bypass line should be sized so that it does not affect pump discharge capacity; however, the by pass line should be at least 1 inch (25,4 mm) in di ameter to minimize the chance of plugging.

In low discharge head applications (less than 30 feet (9,1 m)), it is recommended that the bypass line be run back to the wet well, and located 6 inches below the water level or cut‐off point of the low level pump. In some installations, this bypass outline may be terminated with a six‐to‐eight foot (1,8 to 2,4 m) length of 1‐1/4 inch (31,8 mm) I.D. smooth‐bore hose; air and liquid vented during the priming process will then agitate the hose and break up any solids, grease, or other substances likely to cause clogging.

A bypass line that is returned to a wet well must be secured against being drawn into the pump suction inlet.

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

Bypass Lines

Self‐priming pumps are not air compressors. Dur ing the priming cycle, air from the suction line must be vented to atmosphere on the discharge side. If the discharge line is open, this air will be vented through the discharge. However, if a check valve has been installed in the discharge line, the dis charge side of the pump must be opened to atmos pheric pressure through a bypass line installed be tween the pump discharge and the check valve. A self‐priming centrifugal pump will not prime if there is sufficient static liquid head to hold the dis charge check valve closed.

It is also recommended that pipe unions be in stalled at each 90_ elbow in a bypass line to ease disassembly and maintenance.

In high discharge head applications (more than 30 feet (9,1 m), an excessive amount of liquid may be bypassed and forced back to the wet well under the full working pressure of the pump; this will re duce overall pumping efficiency. Therefore, it is

recommended that a Gorman‐Rupp Automatic Air Release Valve be installed in the bypass line.

Gorman‐Rupp Automatic Air Release Valves are reliable, and require minimum maintenance. See Automatic Air Release Valves in this section for installation and theory of operation of the Auto matic Air Release Valve. Consult your Gorman‐ Rupp distributor, or contact the Gorman‐Rupp Company for selection of an Automatic Air Release Valve to fit your application.

PAGE B - 5INSTALLATION

Page 13

OM‐00710 10 SERIES

ter the pump completely cools, drain the liquid from the pump by removing the casing drain plug. Use caution when re

Except in certain specific applications (to prevent flooding during service of an auto

moving the plug to prevent injury to per sonnel from hot liquid.

matic air release valve in a below‐ground lift station), if a manual shut‐off valve is in

AUTOMATIC AIR RELEASE VALVE

stalled anywhere in a bypass line, it must be a full‐opening, ball‐type valve to pre vent plugging by solids.

When properly installed, a Gorman‐Rupp Auto matic Air Release Valve will permit air to escape through the bypass line and then close automati cally when the pump is fully primed and pumping at full capacity.

A manual shut‐off valve should not be installed in any bypass line. A manual shut‐off valve may inadvertently be left closed during operation. A pump which has lost prime may continue to operate without reaching prime, causing dan

Some leakage (1 to 5 gallons [3.8 to 19 liters] per minute) will occur when the valve is fully closed. Be sure the bypass line is directed back to the wet well or tank to prevent hazardous spills.

gerous overheating and possible explo sive rupture of the pump casing. Per sonnel could be severely injured.

Consult the manual accompanying the Air Release Valve for additional information on valve installation and performance.

Allow an over‐heated pump to com pletely cool before servicing. Do not re

Air Release Valve Installation

move plates, covers, gauges, or fittings from an over‐heated pump. Liquid with in the pump can reach boiling tempera tures, and vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Af

The Automatic Air Release Valve must be inde pendently mounted in a horizontal position be tween the pump discharge port and the inlet side of the discharge check valve (see Figure 3). The inlet opening in the Air Release Valve is equipped with standard 1‐inch NPT pipe threads.

PAGE B - 6 INSTALLATION

Page 14

10 SERIES OM‐00710

INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION

90_ LONG

RADIUS ELBOW

BLEED LINE 1” (25,4 MM) DIA. MIN. (CUSTOMER FUR NISHED) DO NOT EX TEND BELOW PUMP OFF LIQUID LEVEL

SUPPORT BRACKET

CLEAN‐OUT COVER

SUCTION LINE

WET WELL OR SUMP

DISCHARGE PIPE

DISCHARGE CHECK VALVE

PUMP DISCHARGE

SELF‐PRIMING CENTRIFUGAL

PUMP

Figure 3. Typical Automatic Air Release Valve Installation

Connect the valve outlet to a bleed line which slopes back to the wet well or sump. The bleed line must be the same size as the outlet opening or larger, depending on which Air Release Valve is be ing used. If piping is used for the bleed line, avoid the use of elbows whenever possible.

NOTE

For multiple pump installations, it is recommended that each Air Release Valve be fitted with an inde pendent bleeder line directed back to the wet well. If multiple Air Release Valves are installed in a sys tem, do not direct bleeder lines to a common mani fold pipe. Contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company for information about installation of an Automatic Air Release Valve for your specific application.

ALIGNMENT

The alignment of the pump and its power source is critical for trouble‐free mechanical operation. In either a flexible coupling or V‐belt driven system, the driver and pump must be mounted so that their shafts are aligned with and parallel to each other. It is imperative that alignment be checked after the pump and piping are installed, and before opera tion.

NOTE

Check Rotation, Section C, before final alignment of the pump.

When mounted at the Gorman‐Rupp factory, driver and pump are aligned before shipment. Misalign ment will occur in transit and handling. Pumps must be checked and realigned before operation. Before checking alignment, tighten the foundation bolts. The pump casing feet and/or pedestal feet, and the driver mounting bolts should also be tightly secured.

PAGE B - 7INSTALLATION

Page 15

OM‐00710 10 SERIES

When checking alignment, disconnect the power source to ensure that the pump will remain inoperative.

Adjusting the alignment in one direction may alter the alignment in another direc tion. Check each procedure after altering alignment.

Coupled Drives

When using couplings, the axis of the power source must be aligned to the axis of the pump shaft in both the horizontal and vertical planes. Most couplings require a specific gap or clearance between the driving and the driven shafts. Refer to the coupling manufacturer's service literature.

Align spider insert type couplings by using calipers to measure the dimensions on the circumference of the outer ends of the coupling hub every 90_. The coupling is in alignment when the hub ends are the same distance apart at all points (see Fig ure 4A).

Figure 4B. Alignment of V‐Belt Driven Pumps

Check parallel adjustment by laying a straightedge across both coupling rims at the top, bottom, and side. When the straightedge rests evenly on both halves of the coupling, the coupling is in horizontal parallel alignment. If the coupling is misaligned, use a feeler gauge between the coupling and the straightedge to measure the amount of misalign ment.

V‐Belt Drives

When using V‐belt drives, the power source and the pump must be parallel. Use a straightedge along the sides of the pulleys to ensure that the pul leys are properly aligned (see Figure 4C). In drive systems using two or more belts, make certain that the belts are a matched set; unmatched sets will cause accelerated belt wear.

Figure 4A. Alignment of V‐Belt Driven Pumps

Align non‐spider type couplings by using a feeler

MISALIGNED:

SHAFTS

NOT PARALLEL

Figure 4C. Alignment of V‐Belt Driven Pumps

MISALIGNED:

SHAFTS

NOT IN LINE

ALIGNED: SHAFTS

PARALLEL AND

SHEAVES IN LINE

gauge or taper gauge between the coupling halves every 90_. The coupling is in alignment when the hubs are the same distance apart at all points (see Figure 4B).

Tighten the belts in accordance with the belt manu facturer's instructions. If the belts are too loose, they will slip; if the belts are too tight, there will be

PAGE B - 8 INSTALLATION

Page 16

10 SERIES OM‐00710

excessive power loss and possible bearing failure. Select pulleys that will match the proper speed ra tio; overspeeding the pump may damage both pump and power source.

Do not operate the pump without the guard in place over the rotating parts. Exposed rotating parts can catch cloth ing, fingers, or tools, causing severe in jury to personnel.

V‐BELT TENSIONING

General Rules of Tensioning

For new V‐belts, check the tension after 5, 20 and 50 hours of operation and re‐tension as required (see the following procedure for measuring belt tension). Thereafter, check and re‐tension if re quired monthly or at 500 hour intervals, whichever comes first.

Ideal V‐belt tension is the lowest tension at which the belt will not slip under peak load conditions. Do not over‐tension V‐belts. Over‐tensioning will short en both V‐belt and bearing life. Under‐tensioning will cause belt slippage. Always keep belts free from dirt, grease, oil and other foreign material which may cause slippage.

Tension Measurement

Belt Span

Deflection

Figure 5. Belt Tension Measurement

The ratio of deflection to belt span is 1:64 for both ASA and metric units. Therefore, a belt with a span of 64 inches would require a deflection of 1 inch at the force shown on the Tables for your particular application.

For example, if the span as measured in Figure 5 is 32 inches (813 mm), the V‐belt cross‐section is C, the smallest sheave diameter is 8 inches, the pump speed is 1250 RPM, and the belts are uncogged Yy‐T type, then 11.5 lbs. of force on the tensioner should show 1/2‐inch (12,7 mm) of deflection.

A tension tester is available as an option from Gor man‐Rupp (P/N 29513-001). Other tension test ers are available from your local belt/sheave dis tributor, and work on a similar principal.

To use the Gorman‐Rupp tensioner, measure the belt span as shown in Figure 5. Position the bottom of the large O‐ring on the span scale of the tension er at the measured belt span. Set the small O‐ring on the deflection force scale to zero.

Place the tension tester squarely on the belt at the center of the belt span. Apply force on the plunger, perpendicular to the belt span, until the bottom of the large O‐ring is even with the top of the next belt, or with the bottom of a straight edge laid across the sheaves.

Correct v‐belt tension can be achieved using a V‐ belt tension tester and Table 1 or 2. Use the tables to find the V‐belt size (cross‐section), the smallest sheave diameter, the belt type for your application. The corresponding deflection force required for new or used belts is shown opposite the RPM range of the pump.

Read the force applied from the bottom of the small O‐ring on the deflection force scale. Compare this force with the value shown in Table 1 or 2 and ad just the tension accordingly. Note that the tension for new belts is higher than that for used belts to allow for expected belt stretching. Do not over‐ten sion used belts to the higher deflection forces shown for new belts.

PAGE B - 9INSTALLATION

Page 17

OM‐00710 10 SERIES

Table 1. Sheave Diameter (Inches)

Deflection Force (Lbs.)

Belt Deflection Force

Uncogged Hy‐T Belts & Uncogged Hy‐T Torque

200‐850

Team

Used Belt

3.7

2.8

4.5

3.8

5.4

4.7

11.5

14.1

12.5

11.5

30.4

25.6

12.7

11.2

15.5

14.6

33.0

26.8

39.6

35.3

5.3

4.5

6.3

6.0

9.4

3.6

3.0

4.9

4.4

Cross Section

A,AX

B,BX

C,CX

3V, 3VX

5V, 5VX

Smallest Sheave Diameter Range

3.0 ‐ 3.6

3.8 ‐ 4.8

5.0 ‐ 7.0

3.4 ‐ 4.2

4.4 ‐ 5.6

5.8 ‐ 8.6

7.0 ‐ 9.0

9.5 ‐ 16.0

12.0 ‐ 16.0

18.0 ‐ 20.0

2.2 ‐ 2.4

2.65 ‐ 3.65

4.12 ‐ 6.90

4.4 ‐ 6.7

7.1 ‐ 10.9

11.8 ‐ 16.0 500‐1740

12.5 ‐ 17.0

18.0 ‐ 22.4

R.P.M. Range

1000‐2500 2501‐4000

860‐2500

2501‐4000

860‐2500

2501‐4000

860‐2500

2501‐4000

500‐1740

1741‐3000

500‐1740

1741‐3000

851‐1500

1000‐2500 2501‐4000

500‐1749 1750‐3000 3001‐4000

500‐1740

1741‐3000

851‐1500

New Belt

5.5

4.2

6.8

5.7

8.0

7.0

17.0

13.8

21.0

18.5

17.0

13.8

45.2

38.0

18.9

16.7

23.4

21.8

49.3

39.9

59.2

52.7

7.9

6.7

9.4

8.9

5.1

4.4

7.3

6.6

Cogged Torque‐Flex & Machined Edge torque Team Belts

Used Belt

4.1

3.4

5.0

4.3

5.7

5.1

4.9

4.2

7.1

8.5

7.3

14.7

11.9

15.9

14.6

14.7

11.9

3.3

2.9

4.2

3.8

5.3

4.9

10.2

8.8

5.6

14.8

13.7

17.1

16.8

New Belt

6.1

5.0

7.4

6.4

9.4

7.4

10.5

12.6

10.9

21.8

17.5

23.5

21.6

21.8

17.5

15.2

13.2

22.1

20.1

25.5

25.0

7.2

6.2

9.1

4.9

4.3

6.2

5.6

7.9

7.3

8.5

Table 2. Sheave Diameter (Millimeters)

Deflection Force (KG.)

Belt Deflection Force

Uncogged Hy‐T Belts & Uncogged Hy‐T Torque

200‐850

Team

Used Belt

1.7

1.3

2.0

1.7

2.4

2.1

11.3

13.8

11.6

15.0

12.2

18.0

16.0

2.4

2.0

2.9

2.7

5.2

4.3

6.4

5.7

9.6

1.6

1.4

2.2

2.0

5.8

5.1

7.0

6.6

New Belt

2.5

1.9

3.1

2.6

3.6

3.2

3.6

3.0

4.3

4.0

7.7

6.3

9.5

8.4

16.8

14.2

20.5

17.2

2.3

2.0

3.3

3.0

8.6

7.6

10.6

9.9

22.4

18.1

26.8

23.9

Cross Section

A,AX

B,BX

C,CX

3V, 3VX

5V, 5VX

Smallest Sheave Diameter Range

75 ‐ 90

91 ‐ 120

125 ‐ 175

85 ‐ 105

106 ‐ 140

141 ‐ 220

175 ‐ 230

231 ‐ 400

305 ‐ 400

401 ‐ 510

91 ‐ 175

110 ‐ 170

171 ‐ 1275

276 ‐ 400 500‐1740

315 ‐ 430

431 ‐ 570

55 ‐ 60

61 ‐ 90

R.P.M. Range

1000‐2500 2501‐4000

860‐2500

2501‐4000

860‐2500

2501‐4000

860‐2500

2501‐4000

500‐1740

1741‐3000

500‐1740

1741‐3000

851‐1500

1000‐2500 2501‐4000

500‐1749 1750‐3000 3001‐4000

500‐1740

1741‐3000

851‐1500

Cogged Torque‐Flex & Machined Edge torque Team Belts

Used Belt

1.9

1.5

2.3

2.0

2.6

2.3

2.2

1.9

3.2

3.9

3.3

6.7

5.4

7.2

6.6

1.5

1.3

1.9

1.7

2.4

2.2

4.6

4.0

2.5

6.7

6.2

7.8

7.6

New Belt

10.7

10.0

11.6

11.3

2.8

2.3

3.4

2.9

4.3

3.4

3.3

2.8

4.8

4.1

5.7

4.9

9.9

7.9

9.8

2.2

2.0

2.8

2.5

3.6

3.3

6.9

6.0

3.9

9.1

PAGE B - 10 INSTALLATION

Page 18

10 SERIES

OM‐00710

OPERATION - SECTION C

Review all SAFETY information in Section A.

Follow the instructions on all tags, labels and decals attached to the pump.

Pump speed and operating condition points must be within the continuous per formance range shown on the curve (see Section E, Page 1).

Add liquid to the pump casing when:

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

2. The pump has not been used for a consider able length of time.

3. The liquid in the pump casing has evapo rated.

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

After filling the pump casing, reinstall and tighten the fill plug. Do not attempt to operate the pump unless all connect ing piping is securely installed. Other wise, liquid in the pump forced out un der pressure could cause injury to per sonnel.

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

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 is properly lubri cated (see LUBRICATION in MAINTENANCE AND REPAIR).

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

STARTING

Consult the operations manual furnished with the power source.

Rotation

The correct direction of pump rotation is indicated by an arrow on the pump body or accompanying decals. If the pump is operated in the wrong direc tion, the impeller could become loosened from the shaft and seriously damage the pump.

The pump must operate in the direction in 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.

OPERATION PAGE C - 1

dicated by the arrow on the pump, or ac

companying decals. Reverse rotation

could loosen the impeller and seriously

damage the pump.

Page 19

OM‐00710 10 SERIES

Consult the operating manual furnished with the pump power source before attempting to start the power source.

If an electric motor is used to drive the pump, re move V‐belts, couplings, or otherwise disconnect the pump from the motor before checking motor rotation. Operate the motor independently while observing the direction of the motor shaft, or cool ing fan.

If rotation is incorrect on a three‐phase motor, have a qualified electrician interchange any two of the three phase wires to change direction. If rotation is incorrect on a single‐phase motor, consult the lit erature supplied with the motor for specific instruc tions.

OPERATION

Lines With a Bypass

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.

Liquid Temperature and Overheating

The maximum liquid temperature for this pump is

160_ F (71_C). 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.

If a Gorman‐Rupp Automatic Air Release Valve has been installed, the valve will automatically open to allow the pump to prime, and automatically close after priming is complete (see INSTALLATION for Air Release Valve operation).

If the bypass line is open, air from the suction line will be discharged through the bypass line back to the wet well during the priming cycle. Liquid will then continue to circulate through the bypass line while the pump is in operation.

Lines Without a Bypass

Open all valves in the discharge line and start the power source. Priming is indicated by a positive reading on the discharge pressure gauge or by a quieter operation. The pump may not prime imme diately because the suction line must first fill with liquid. If the pump fails to prime within five minutes, stop it and check the suction line for leaks.

After the pump has been primed, partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pres sure which could damage pipe ends, gaskets, sprinkler heads, and any other fixtures connected to the line. When the discharge line is completely filled, adjust the throttling valve to the required flow rate.

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over

heated pump. Vapor pressure within the

pump can cause parts being disen

gaged to be ejected with great force. Al

low the pump to cool before servicing.

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

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).

Pump Vacuum Check

With the pump inoperative, install a vacuum gauge

in the system, using pipe dope on the threads.

OPERATIONPAGE C - 2

Page 20

10 SERIES

OM‐00710

Block the suction line and start the pump. At oper ating speed the pump should pull a vacuum of 20 inches (508,0 mm) or more of mercury. If it does not, check for air leaks in the seal, gasket, or dis charge valve.

Open the suction line, and read the vacuum gauge with the pump primed and at operating 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.

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.

normal for bearings, and they can operate safely to

at least 180_F (82_C).

Checking bearing temperatures by hand is inaccu

rate. Bearing temperatures can be measured ac

curately by placing a contact‐type thermometer

against the housing. Record this temperature for

future reference.

A sudden increase in bearing temperatures is a

warning that the bearings are at the point of failing

to operate properly. Make certain that the bearing

lubricant is of the proper viscosity and at the cor

rect level (see LUBRICATION in Section E). Bear

ing overheating can also be caused by shaft

misalignment and/or excessive vibration.

When pumps are first started, the bearings may

seem to run at temperatures above normal. Con

tinued operation should bring the temperatures

down to normal levels.

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

After stopping the pump, disconnect the power source or lock it out to ensure that the pump will re main inoperative.

BEARING TEMPERATURE CHECK

Bearings normally run at higher than ambient tem peratures because of heat generated by friction. Temperatures up to 160_F (71_C) are considered

Cold Weather Preservation

In below freezing conditions, drain the pump to

prevent damage from freezing. Also, clean out any

solids by flushing with a hose. Operate the pump

for approximately one minute; this will remove any

remaining liquid that could freeze the pump rotat

ing parts. If the pump will be idle for more than a

few hours, or if it has been pumping liquids con

taining a large amount of solids, drain the pump,

and flush it thoroughly with clean water. To prevent

large solids from clogging the drain port and pre

venting the pump from completely draining, insert

a rod or stiff wire in the drain port, and agitate the

liquid during the draining process. Clean out any

remaining solids by flushing with a hose.

OPERATION PAGE C - 3

Page 21

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. Disconnect or lock out the power source to ensure that the pump will remain inoperative.

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‐0071010 SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

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

damaged.

Air leak in suction line.

Lining of suction hose collapsed.

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

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

Strainer clogged. Check strainer and clean if neces

Air leak in suction line.

Lining of suction hose collapsed.

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

Strainer clogged. Check strainer and clean if neces

Suction intake not submerged at proper level or sump too small.

Clean or replace check valve.

Correct leak.

Replace suction hose.

leaking or worn seal or gasket.

stall bypass line if needed. See INSTALLATION.

sary.

Correct leak.

Replace suction hose.

leaking or worn seal or gasket.

sary.

Check installation and correct sub mergence as needed.

TROUBLESHOOTING PAGE D - 1

Page 22

OM‐00710 10 SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

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

PUMP REQUIRES TOO MUCH POWER

PUMP CLOGS FREQUENTLY

Impeller or other wearing parts worn or damaged.

Impeller clogged. Free impeller of debris.

Pump speed too slow. Check driver output; check belts

Discharge head too high. Install bypass line.

Suction lift too high. Measure lift w/vacuum gauge. Re

Pump speed too high. Check driver output; check that

Discharge head too low. Adjust discharge valve.

Liquid solution too thick. Dilute if possible.

Bearing(s) frozen. Disassemble pump and check

Liquid solution too thick. Dilute if possible.

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

Suction check valve or foot valve clogged or binding.

Replace worn or damaged parts. Check that impeller is properly centered and rotates freely.

or couplings for slippage.

duce lift and/or friction losses in suction line.

sheaves or couplings are cor rectly sized.

bearing(s).

crease flow rate, and run power source at maximum governed speed.

Clean valve.

EXCESSIVE NOISE Cavitation in pump.

Pumping entrained air.

Pump or drive not securely mounted.

Impeller clogged or damaged.

BEARINGS RUN TOO HOT

Bearing temperature is high, but within limits.

Low or incorrect lubricant. Check for proper type and level of

Suction and discharge lines not properly supported.

Drive misaligned. Align drive properly.

Reduce suction lift and/or friction losses in suction line. Record vac uum and pressure gauge readings and consult local representative or factory. Locate and eliminate source of air bubble. Secure mounting hardware.

Clean out debris; replace dam aged parts.

Check bearing temperature regu larly to monitor any increase.

lubricant.

Check piping installation for proper support.

TROUBLESHOOTINGPAGE D - 2

Page 23

OM‐0071010 SERIES

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 pre ventive maintenance schedule will help assure trouble‐free performance and long life from your Gorman‐Rupp pump. For specific questions con cerning 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 inspec tions can indicate problems that can be corrected before system damage or catastrophic failure oc curs. The appearance of wearing parts should also be documented at each inspection for comparison as well. Also, if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced 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 inspec tions should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

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

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

Daily Weekly Monthly Semi‐

Annually

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

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

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

TROUBLESHOOTING PAGE D - 3

Page 24

10 SERIES OM‐00710

PUMP MAINTENANCE AND REPAIR ‐ SECTION E

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

STANDARD PERFORMANCE FOR PUMP MODEL 16A20-B

Based on 70_F (21_C) clear water at sea level

with minimum suction lift. Since pump installations are seldom identical, your performance may be dif ferent due to such factors as viscosity, specific

gravity, elevation, temperature, and impeller trim.

Contact the Gorman‐Rupp Company to verify per formance or part numbers.

Pump speed and operating condition

If your pump serial number is followed by an “N”, your pump is NOT a standard production model.

MAINTENANCE & REPAIR PAGE E - 1

points must be within the continuous per formance range shown on the curve.

Page 25

PARTS PAGE

10 SERIESOM‐00710

SECTION DRAWING

Figure 1. Pump Model 16A20-B

MAINTENANCE & REPAIRPAGE E - 2

Page 26

10 SERIES OM‐00710

PARTS LIST

Pump Model 16A20‐B

(From S/N 818301 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.

. 1 PUMP CASING SEE NOTE BELOW

2 IMPELLER 7759B 11000 1 3 SEAL ASSEMBLY 12461 ----- 1 4 DISCH FLANGE GSKT 1679G 18000 1 5 DISCHARGE STICKER 6588BJ ----- 1

6 HEX HD CAPSCREW B1208 15991 8 7 LOCKWASHER J12 15991 8 8 DISCHARGE FLANGE 1758 10010 1 9 NAME PLATE 38818-023 13990 1

10 DRIVE SCREW BM#04-03 17000 4

.11 ACCESSORY PLUG P04 15079 1 .12 ACCESSORY PLUG P04 15079 1 .13 MACHINE BOLT A1014 15991 2

14 CLAMP BAR 38111-004 11010 1 15 FILL COVER ASSEMBLY 42111-344 ----- 1 16 -COVER PLATE NOT AVAILABLE 1

17 -FILL COVER GSKT 50G 19210 1 18 -WARNING PLATE 38816-097 13990 1 19 -DRIVESCREW BM#04‐03 17000 2 20 CLAMP BAR SCREW 31912-009 15000 1

21 SHAFT SLEEVE 11907 16000 1 22 IMPELLER SHIM SET 5091 17090 REF 23 AIR VENT S2162 ----- 1

24 PIPE COUPLING AE02 15079 1 25 PIPE NIPPLE T02 15079 1 26 STUD C0607 15991 6 27 LOCKWASHER J06 15991 6 28 HEX NUT D06 15991 6 29 BEARING CAP 38322-418 10010 1 30 BOTTLE OILER S1933 ----- 1 31 PIPE ELBOW R02 11999 1 32 PIPE NIPPLE T0212 15079 1 33 ST ELBOW AGS02 11999 1 34 BALL BEARING S1030 ----- 1

35 OIL SEAL 25227-534 ----- 1 36 AIR VENT S1703 ----- 1 37 PEDESTAL 3020B 10010 1 38 ROTATION DECAL 2613M ----- 1 39 BALL BEARING S1077 ----- 1 40 O‐RING 25152-245 ----- 1 41 BRG RETAINING RING S1165 ----- 1 42 SHAFT KEY N0615 15990 1 43 IMPELLER SHAFT 38515-516 16040 1 44 OIL SEAL 25227-534 ----- 1 45 RD HD MACH SCREW X#10-01 1/2S 15991 2

46 LOCKWASHER J#10 15991 2 47 BEARING RETAINER 38322-522 26000 1 48 BEARING SHIM SET 8546 15990 1

49 OIL LEVEL SIGHT GAUGE S1471 ----- 1 50 PIPE PLUG P12 15079 1 51 PEDESTAL DRAIN PLUG P06 15079 1 52 O-RING 25152-248 ----- 1

53 OIL SEAL S1935 ----- 1 54 SLINGER RING 3209 19120 1

NUMBER

INDICATES PARTS RECOMMENDED FOR STOCK

MAT'L CODE

QTY ITEM

NO.

55 SEAL DRAIN PLUG P02 15079 1

.56 STUD C0810 15991 8

57 HEX NUT D08 15991 8 58 SEAL PLATE 38272-517 10010 1 59 CASING GSKT SET 34G 18000 1 60 IMPELLER WASHER 10278 15030 1 61 SOC HD CAPSCREW DM1004S 15991 1

.62 CASING DRAIN PLUG P16 10009 1

63 HEX NUT D08 15991 2 64 LOCKWASHER J08 15991 2 65 BACK COVER PLT GSKT 7668G 20000 1 66 BACK COVER PLT ASSY 42111-932 ----- 1 67 -BACK COVER PLATE NOT AVAILABLE 1 68 -DRAIN PLUG P08 15079 1 69 -WARNING PLATE 2613EV 13990 1 70 DRIVE SCREW BM#04-03 17000 4 71 CLAMP BAR SCREW 2536 24000 1 72 CLAMP BAR 2547 11010 1 73 WEAR PLATE ASSY 2545 15990 1

74 CHECK VALVE GSKT 7261G 18000 1 75 CHECK VALVE SEAT 7261 10010 1

76 SUCTION FLANGE GSKT 1679G 18000 1 77 HEX HD CAPSCREW B1212 15991 8 78 LOCKWASHER J12 15991 8 79 SUCTION FLANGE 1758 10010 1 80 RD HD MACH SCREW X0404 17090 2 81 CHECK VALVE ASSY 7265 ----- 1 82 -HEX HD CAPSCREW B0403 17000 2 83 -LOCKWASHER J04 17090 2 84 -VALVE WEIGHT 7263 15990 1 88 -CHECK VALVE GASKET 7264 19070 1 86 -VALVE WEIGHT 7262 24000 1 87 SUCTION STICKER 6588AG ----- 1

NOT SHOWN:

OPTIONAL:

PART NAME PART

NUMBER

STRAINER 7823 24000 1 WARNING DECAL 2613FE --- 1 G‐R DECAL GR-03 --- 1 INSTR LABEL 2613DK --- 1 LUBRICATION DECAL 38816-079 --- 1 INSTRUCTION TAG 38817-011 --- 1 INSTRUCTION TAG 38817-012 --- 1 PRIMING STICKER 6588AH ---

SUCTION FLANGE 11402B 10010 1 DISCHARGE FLANGE 11402B 10010 1

HI TEMP SHUT-DOWN KITS:

-145_ F 48313-186 ----- 1

-130_ F 48313-256 ----- 1

-120_ F 48313-257 ----- 1

CASING HEATER & THERMOSTAT ASSY:

-120 VOLT 47811-016 ----- 1

-240 VOLT 47811-017 ----- 1

MAT'L CODE

QTY

. INCLUDED WITH 46471-510 --- 1

REPAIR PUMP CASING ASSY

MAINTENANCE & REPAIR PAGE E - 3

Page 27

10 SERIESOM‐00710

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.

Follow the instructions on all tags, label and de cals attached to the pump.

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 view (see Figure 1) and the accompa nying parts list.

Before attempting to service the pump, disconnect or lock out the power source to ensure that the pump will remain inoperative. Close all valves in the suction and discharge lines.

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.

Suction Check Valve Removal and Disassembly

Before attempting to service the pump, remove the pump casing drain plug (68) and drain the pump. Clean and reinstall the drain plug.

For power source disassembly and repair, consult the literature supplied with the power source, or contact your local power source representative.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Disconnect or lock out the power source to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

The check valve assembly (81) may be serviced by removing the suction flange (79). To remove the flange, disconnect the suction piping. Disengage the hardware (77 and 78) and separate the suction flange from the check valve seat (75). Remove the machine screws (80), and pull the seat and as sembled check valve from the suction port. Pull the check valve out of the seat.

Inspect the check valve components for wear or damage. If replacement is required, disengage the hardware (82 and 83) and separate the valve weights (84 and 86) and gasket (85).

Replace the flange gaskets (74 and 76) as re quired.

If no further disassembly is required, see Suction

Check Valve Installation.

MAINTENANCE & REPAIRPAGE E - 4

Page 28

OM‐0071010 SERIES

Back Cover Removal

The wear plate (73) is easily accessible and may be serviced by removing the back cover assembly (66). Loosen the clamp bar screw (71) and remove the clamp bar (72). Pull the back cover and wear plate from the pump casing. Remove the back cov er gasket (65). Clean the mating surfaces of the back cover plate and pump casing.

Inspect the wear plate and replace it if badly scored or worn. To remove the wear plate, disengage the hardware (63 and 64) securing it to the back cover.

If no further disassembly is required, see Back

Cover Installation.

Pump Casing Removal

To service the impeller or seal assembly, discon nect the discharge piping. Remove the hardware securing the pump to the base and disconnect the power source. Tie and tag any leveling shims used under the mounting feet to ease reassembly.

Remove the nuts (57) and separate the pump cas ing and gasket set (59) from the seal plate (58) and pedestal (37). Clean the mating surfaces of the seal plate and pump casing. Tie and tag the gas kets or measure and record their thickness for ease of reassembly.

Impeller Removal

(when facing the drive end of the shaft) as shown in Figure 2. Use caution not to damage the shaft or keyway. When the impeller breaks loose, remove the lathe dog and wood block.

Turn

Counterclockwise

Lathe Dog Arm

“V” Notch

Heavy

Bar Stock

Figure 2. Loosening Impeller

Unscrew the impeller from the shaft. Use caution when removing the impeller; tension on the seal spring will be released as the impeller is un screwed.

Inspect the impeller and replace it if cracked or badly worn. Slide the impeller adjusting shims (22) off the impeller shaft. Tie and tag the shims or mea sure and record their thickness for ease of reas sembly.

Shaft Key

Impeller Shaft

Lathe Dog

Setscrew

Before removing the impeller, remove the bottle oiler and piping (30, 31, 32 and 33). Remove the seal drain plug (55) and drain the oil from the seal cavity to prevent the oil from escaping when the im peller is removed. Clean and reinstall the drain plug.

Immobilize the impeller by wedging a block wood between the vanes. If removed, install the shaft key (42). Install a lathe dog on the drive end of the shaft (43) with the “V” notch positioned over the shaft keyway. Remove the impeller capscrew and wash er (60 and 61).

With the impeller rotation still blocked, use a long piece of heavy bar stock to pry against the arm of the lathe dog in a counterclockwise direction

MAINTENANCE & REPAIR PAGE E - 5

Seal Removal and Disassembly

Remove the spring centering washer and seal spring. Slide the shaft sleeve (21) and rotating por tion of the seal off the shaft as a single unit. Apply oil to the sleeve and work it up under the bellows. Slide the rotating portion of the seal off the sleeve.

Slide the seal plate and stationary portion of the seal assembly off the shaft as a single unit. Place the seal plate on a flat surface with the impeller side down. Use a suitably sized dowel to press the sta tionary seal components from the seal plate. Press the oil seal (53) from the seal plate.

If no further disassembly is required, see Seal

Reassembly and Installation.

Page 29

10 SERIESOM‐00710

Shaft and Bearing Removal and Disassembly

When the pump is properly operated and main tained, the pedestal should not require disassem bly. Disassemble the shaft and bearings only when there is evidence of wear or damage.

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

Remove the pedestal drain plug (51) and drain the pedestal. Clean and reinstall the plug.

Remove the slinger ring (54) from the shaft. Re move the pedestal mounting hardware from the base. Tie and tag any shims used under the mounting feet for leveling.

Use snap ring pliers to remove the bearing retain ing ring (41) from the pedestal bore. Remove the bearing shim set (48); tie and tag the shims, or measure and record their thickness for ease of reassembly.

be replaced any time the shaft and bear ings are removed.

Clean the pedestal, shaft and all component parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or dam age and replace as necessary.

Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, 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.

Loosen the machine screws (45) and pry the bear ing retainer (47) from the pedestal bore using a pair of screwdrivers against the heads of the machine screws. Do not use the machine screws to jack against the ball bearing.

Press the oil seal (44) from the bearing retainer and remove the O‐ring (40) from the pedestal bore.

Disengage the hardware (27 and 28) and remove the the assembled bearing cap (29) and oil seal (35). Press the oil seal out of the bearing cap.

Place a block of wood against the drive end of the shaft and tap the shaft and assembled bearings (34 and 39) out of the pedestal.

After removing the shaft and bearings, clean and inspect the bearings in place as follows.

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

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 shaft and a snug slip fit into the pedestal. Replace the bearings, shaft, or pedestal if the proper bearing fit is not achieved.

If bearing replacement is required, use a bearing puller or arbor (or hydraulic) press to remove the bearings from the shaft.

MAINTENANCE & REPAIRPAGE E - 6

Page 30

OM‐0071010 SERIES

Shaft and Bearing Reassembly and Installation

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

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 shaft and bear ings are removed.

Inspect the shaft for distortion, nicks or scratches, or for thread damage on the impeller end. Dress small nicks and burrs with a fine file or emery cloth. Replace the shaft if defective.

The bearings may be heated to ease installation. An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bear ings should never be heated with a direct flame or directly on a hot plate.

NOTE

If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thor oughly filtered.

Position the inboard bearing on the shaft with the retaining ring facing toward the impeller end of the shaft.

Heat the bearings to a uniform temperature no higher than 250_F (120_C), and slide the bearings onto the shaft, one at a time, until they are fully seated. This should be done quickly, in one con tinuous motion, to prevent the bearings from cool ing and sticking on the shaft.

movement has occurred, use a suitably sized sleeve and a press to reposition the bearings against the shaft shoulders.

If heating the bearings is not practical, use a suit ably sized sleeve and arbor (or hydraulic) press to position the bearings on the shaft until fully seated against the shaft shoulders.

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

Slide the shaft and assembled bearings (34 and

39) into the pedestal until the inboard bearing re taining ring seats against the pedestal bore.

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

Install the oil seal (35) in the bearing cap (29) with the lip positioned as shown in Figure E-1. Apply a thin film of `Loctite Gasket Eliminator' or equivalent to the face of the bearing cover, and slide the bear ing cover and oil seal over the shaft. Be careful not to damage the oil seal lip. Secure the bearing cover with the hardware (27 and 28).

Install the O‐ring (40) in the groove in the pedestal (37). Apply a light coating of soft grease to the O‐ ring.

Press the outboard oil seal (44) into the bearing re tainer (47) with the lip positioned as shown in Fig ure E-1.

Be sure the lockwashers and machine screws (45 and 46) are fully screwed into the bearing retainer, and that the machine screws are positioned hori zontally in line. Press the bearing retainer into the

Use caution when handling hot bear ings to prevent burns.

After the bearings have been installed and allowed to cool, check to ensure that they have not moved away from the shaft shoulders in shrinking. If

MAINTENANCE & REPAIR PAGE E - 7

pedestal until it seats against the bearing. Be care ful not to damage the oil seal lip on the shaft key

way.

Install the same thickness of bearing adjusting shims (48) as previously removed. Secure the

Page 31

10 SERIESOM‐00710

bearing retainer with the retaining ring (41). Check the shaft endplay.

NOTE

Shaft endplay should be between .002 and .010 inch (.05 to .25 mm). Add or remove bearing adjust ing shims to achieve the correct endplay.

Lubricate the pedestal as indicated in LUBRICA TION at the end of this section.

Seal Reassembly and Installation

Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.

Inspect the impeller shaft for damage. Small scratches or nicks may be removed with a fine file

or emery cloth. If excessive wear exists, the shaft will have to be replaced.

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.

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. Clean and polish the shaft sleeve (21), or re place it if there are nicks or cuts on either end. If any components are worn, replace the complete seal; never mix old and new seal parts.

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

To ease installation of the seal, lubricate the O‐ rings, bellows and shaft sleeve with water or a very small amount of oil, and apply a drop of light lubri cating oil on the finished faces. Assemble the seal as follows, (see Figure 3).

MAINTENANCE & REPAIRPAGE E - 8

Page 32

OM‐0071010 SERIES

SEAL

SPRING

IMPELLER

SHIMS

IMPELLER

SPRING CENTERING

WASHER

ROTATING

ELEMENT

BELLOWS

O‐RING

DRIVE BAND

SEAL PLATE

STATIONARY

SEAL SEAT

SHAFT

SLEEVE

IMPELLER

SHAFT

OIL SEAL

STATIONARY

ELEMENT

Figure 3. Seal Assembly

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

Inspect the seal plate and replace it if cracked or badly worn.

Place the seal plate on a flat surface with the impel ler side down. Apply a light coat of oil to the oil seal (53) and press it into the seal plate (58) with the lip positioned as shown in Figure E-1.

Slide the seal plate over the shaft until fully seated against the pedestal (37). Be careful not to dam age the oil seal lip on the shaft threads. Align the threaded seal lubricant hole with the pedestal opening and temporarily secure the seal plate us ing two capscrews and nuts (1/2 UNC X 1‐1/2 inch long, not supplied).

Press the stationary subassembly (consisting of the stationary seat, O‐rings and stationary ele ment) into the seal plate until the stationary seat bottoms against the seal plate bore. A push tube cut from a length of plastic pipe would aid this in stallation. The I.D. of the pipe should be approxi mately the same diameter as the I.D. of the seal spring.

Slide the rotating subassembly (consisting of the rotating element, retainer and bellows) onto the lu bricated shaft sleeve until the rotating element is just flush with the chamfered end of the sleeve. Slide the sleeve and rotating subassembly onto the shaft until the seal elements contact. Continue to push the sleeve through the seal until it bottoms against the shaft shoulder. Be careful not to dam age or roll the lip of the oil seal (53). Install the seal spring and the spring centering washer.

Reinstall the bottle oiler and piping (30, 31, 32 and

33), and lubricate the seal assembly as indicated in LUBRICATION, after the impeller has been in stalled.

MAINTENANCE & REPAIR PAGE E - 9

Page 33

10 SERIESOM‐00710

Impeller Installation and Adjustment

Inspect the impeller and replace it if cracked or badly worn. Install the same thickness of impeller shims (22) as previously removed. Apply `Never‐ Seez' or equivalent to the shaft threads and screw the impeller onto the shaft until tight.

A clearance of .010 to .040 inch (0,25 to 1,02 mm) between the impeller and the seal plate is neces sary for maximum pump efficiency. Measure this clearance and add or remove impeller shims until this clearance is reached.

NOTE

Be sure the seal plate is tight against the pedestal while measuring this clearance.

Install the impeller washer and capscrew (60 and

61). Immobilize the impeller shaft as indicated in Impeller Removal and secure the impeller to the shaft by torquing the impeller screw to 90 ft. lbs. (12,4 m. kg.).

Pump Casing Installation

Back Cover Installation

If the wear plate (73) was removed for replace ment, secure it to the cover plate (66) using the at taching hardware (63 and 64) at this time. The wear plate must be concentric to prevent binding when the back cover is installed.

Clean any scales or debris from the contacting sur faces on the pump casing that might prevent a good seal with the back cover. Replace the back cover gasket (65) and slide the back cover assem bly (66) into the pump casing. Be sure the wear plate does not bind against the impeller.

NOTE

To ease future disassembly, apply a film of grease or `Never‐Seez' on the back cover shoulder, or any surface that contacts the pump casing. This action will reduce rust and scale build‐up.

Secure the back cover assembly by installing the clamp bar (72) and tightening the clamp bar screw (71). Do not over‐tighten the clamp bar screw; it should be just tight enough to seal the back cover shoulder.

Suction Check Valve Installation

Remove the hardware temporarily securing the seal plate to the pedestal. Install the same thick ness of pump casing gaskets (59) as previously re moved and secure the pump casing to the seal plate and pedestal with the nuts (57). Do not fully tighten the nuts at this time.

NOTE

The back cover assembly must be in place to adjust the impeller face clearance.

A clearance of .008 to .015 inch (0,20 to 0,38 mm) between the impeller and the wear plate (73) is also recommended for maximum pump efficiency. Set this clearance by adding or removing gaskets in the pump casing gasket set (59) until the impeller scrapes against the wear plate when the shaft is turned by hand. After the impeller scrapes, add ap proximately .008 inch (0,20 mm) of gaskets.

After the face clearance has been set, tighten the nuts (57) securing the pump casing to the pedes tal.

(Figure E-1)

NOTE

When replacing the gaskets (74 and 76) apply `Per matex Aviation No. 3 Form‐A‐Gasket' or equivalent compound to the mating surfaces.

Inspect the check valve components and replace as required. Subassemble the check valve weights (84 and 86) and check valve gasket (85) using the attaching hardware (82 and 83).

Install the check valve assembly (81) in the check valve seat (75) with the large weight towards the in side of the casing. Install the gasket (74) and se cure the check valve seat to the pump casing with the screws (80). Install the gasket (76) and suction flange (87) and secure with the hardware (77 and

78). Check the operation of the check valve to en sure proper seating and free movement.

(Figure 3)

Inspect the check valve components, and replace the parts as required. Subassemble the check

MAINTENANCE & REPAIRPAGE E - 10

Page 34

OM‐0071010 SERIES

valve gasket (85) and weights (84 and 86) using hardware (82 and 83). Position the assembled check valve in the mounting slot in the seat.

NOTE

Apply `Permatex Aviation No. 3 Form‐A‐Gasket' or equivalent compound to the suction flange and check valve seat mating surfaces before reassemb ly.

Replace the seat gasket (74) and secure the check valve and seat to the pump casing with the round head machine screws (80).

Replace the suction flange gasket (76) and secure the suction flange to the check valve seat and pump casing with the hardware (77 and 78).

Final Pump Assembly

LUBRICATION

Bearings

The pedestal was fully lubricated when shipped from the factory. Check the oil level regularly through the sight gauge (51) and maintain it at the middle of the gauge. When lubrication is required, add SAE No. 30 non‐detergent oil through the hole for the air vent (34). Do not over‐lubricate. Over‐lu brication can cause the bearings to over‐heat, re sulting in premature bearing failure.

Under normal conditions, drain the pedestal once each year and refill with clean oil to the middle of the sight gauge. Change the oil more frequently if the pump is operated continuously or installed in an environment with rapid temperature change.

Secure the pump to the base with the previously re moved hardware. Be sure to reinstall any leveling shims used under the pump mounting feet.

Be sure the pump and power source are securely mounted to the base.

Install the suction and discharge lines and open all valves. Make certain that all piping connections are tight, properly supported and secure. Open all the valves in the suction and discharge lines.

Be sure the pump and power source have been properly lubricated, see LUBRICATION.

Remove the fill cover assembly (15) and fill the pump casing with clean liquid. Reinstall the fill cov er and tighten it.

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

Monitor the condition of the bearing lubri cant regularly for evidence of rust or mois ture condensation. This is especially im portant in areas where variable hot and cold temperatures are common.

For cold weather operation, consult the factory or a lubricant supplier for the recommended grade of oil.

Seal Assembly

Fill the bottle oiler (30) with SAE 30 non‐detergent oil. Check the oil level regularly and keep the bottle oiler full.

Power Source

Consult the literature supplied with the power source, or contact your local power source repre sentative.

MAINTENANCE & REPAIR PAGE E - 11

Page 35

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

GORMAN‐RUPP PUMPS