Gorman-Rupp Pumps 16C2-F4L User Manual

ACDE

OM-00725-OE06

February 1, 1989

Rev. B

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

10 SERIES PUMPS

MODEL

16C2−F4L

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

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

Copyright by the Gorman-Rupp Company

TABLE OF CONTENTS

INTRODUCTION PAGE I − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARNINGS − SECTION A PAGE A − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION − SECTION B PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Dimensions PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREINSTALLATION INSPECTION PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

POSITIONING PUMP PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 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 − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

ALIGNMENT PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION − SECTION C PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING TEMPERATURE CHECK PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING − SECTION D PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PERFORMANCE CURVE PAGE E − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

TABLE OF CONTENTS

(continued)

PARTS LISTS:

PUMP MODEL 16C2−F4L PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP END ASSY 16C2−(F4L) PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE ASSY FOR 16C2−F4L PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . .

Back Cover Removal PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Check Valve Removal PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing Removal PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal and Disassembly PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separating Intermediate And Drive Assembly From engine PAGE E − 10. . . . . . . . . . . . . . . . . .

Shaft and Bearing Removal and Disassembly PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Reassembly and Installation PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing Intermediate And Drive Assembly To Engine PAGE E − 12. . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Installation And Adjustment PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Check Valve Installation PAGE E − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Back Cover Installation PAGE E − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Pump Assembly PAGE E − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly PAGE E − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings PAGE E − 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine PAGE E − 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

10 SERIES

OM−00725−06

INTRODUCTION

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

This pump is a 10 Series, semi−open impeller, self­priming centrifugal model with a suction check
valve. The pump is powered by a Deutz Diesel en­gine, model F4L-912D. The pump is designed for
handling dirty water containing specified entrained

The Gorman-Rupp Company or Gorman-Rupp of Canada Limited
P.O. Box 1217 70 Burwell Road
Mansfield, Ohio 44901−1217 St. Thomas, Ontario N5P 3R7

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

The following are used to alert maintenance personnel to procedures which require special attention, to
those which could damage equipment, and to those which could be dangerous to personnel:

solids. The basic material of construction for wet­ted parts is gray iron, with ductile iron impeller and
steel wearing parts.

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

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

Hazards or 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.

Hazards or unsafe practices which COULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi­ble damage which could result from failure
to follow the procedure.

NOTE

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

PAGE I − 1INTRODUCTION

10 SERIES OM−0725−06

SAFETY − SECTION A

These warnings apply to 10 Series En­gine Driven pumps. Refer to the manual
accompanying the engine before at­tempting to begin operation.

Before attempting to open or service the
pump:

Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam­age to equipment. The bail is intended
for use in lifting the pump assembly
only. Suction and discharge hoses and
piping must be removed from the pump
before lifting.

1. Familiarize yourself with this man­ual.

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 over­heated.

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

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cau­tiously.

7. Drain the pump.

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

Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed dis­charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.

This pump is designed to handle dirty
water containing specified entrained
solids. Do not attempt to pump volatile,

corrosive, or flammable materials, or
any liquids which may damage the
pump or endanger personnel as a result
of pump failure.

Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over­heated pump. Vapor pressure within the
pump can cause parts being disen-

PAGE A − 1SAFETY

OM−00725−06

gaged to be ejected with great force. Al­low the pump to cool before servicing.

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

10 SERIES

Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. The maximum continuous
operating speed for this pump is 1900
RPM.

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

PAGE A − 2 SAFETY

INSTALLATION − SECTION B

OM−00725−0610 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 ar­range 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
specific application. Since the pressure supplied

OUTLINE DRAWING

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 Sec­tion E, Page 1). If the pump is fitted with a Gorman­Rupp double grease lubricated seal, the maximum
incoming pressure must be reduced to 10 p.s.i.

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

Pump Dimensions

See Figure 1 for the approximate physical dimen­sions of this pump.

Figure 1. Pump Model 16C2−F4L

PAGE B − 1INSTALLATION

OM−00725−06 10 SERIES

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be­fore shipment from the factory. Before installation,
inspect the pump for damage which may have oc­curred during shipment. Check as follows:

a. Inspect the pump for cracks, dents, damaged

threads, and other obvious damage.

b. Check for and tighten loose attaching hard-

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

c. Carefully read all tags, decals, and markings

on the pump assembly, and follow the instruc­tions indicated.

d. Check levels and lubricate as necessary. Re-

fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per­form duties as instructed.

Table 1. Battery Specifications

Reserve

Capacity

@ 80 F

(Minutes)

365

Amp/

Hr.

Rating

175

Approx.

Overall

Dims.

(Inches)

20.5L
x

8.75W
x

9.75H

Voltage

12 Volts

Cold
Crank
Amps

@ 0 F

960−975

Refer to the information accompanying the battery
and/or electrolyte solution for activation and charg­ing instructions.

Before installing the battery, clean the positive and
negative cable connectors, and the battery termi­nals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corro­sion. Connect and tighten the positive cable first,
then the negative cable.

POSITIONING PUMP

e. If the pump and engine have been stored for

more than 12 months, some of the compo­nents or lubricants may have exceeded their
maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv­ice.

If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman-Rupp distributor or the factory to deter­mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.

Battery Specifications And Installation

Unless otherwise specified on the pump order, the
engine battery was not included with the unit. Re­fer to the following specifications when selecting a
battery.

Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam­age to equipment. The bail is intended
for use in lifting the pump assembly
only. Suction and discharge hoses and
piping must be removed from the pump
before lifting.

Lifting

Use lifting equipment with a capacity of at least
12,000 pounds (5443 kg). This pump weighs ap­proximately 2,360 pounds(1070 kg), not includ­ing the weight of accessories and base. Customer
installed equipment such as suction and dis­charge piping must be removed before attempting
to lift.

The pump assembly can be seriously

PAGE B − 2 INSTALLATION

OM−00725−0610 SERIES

damaged if the cables or chains used to lift
and move the unit are improperly wrapped
around the pump.

Mounting

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

If the pump has been mounted on a movable base,
make certain the base is stationary by setting the
brake and blocking the wheels before attempting
to operate the pump.

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

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in­creased suction lift, discharge elevation, and fric­tion losses. See the performance curve and oper­ating range shown 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, rein­forced type to prevent collapse under suction. Us­ing piping couplings in suction lines is not recom­mended.

Line Configuration

Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini­mum use of elbows and fittings, which 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 ex­actly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or cou­plings.

Lines near the pump must be independently sup­ported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type
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.
Installation closer to the pump may result in erratic
readings.

SUCTION LINES

To avoid air pockets which could affect pump prim­ing, 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 in­stalled with the flat part of the reducers uppermost
to avoid creating air pockets. Valves are not nor­mally used in suction lines, but if a valve is used,
install it with the stem horizontal to avoid air pock­ets.

PAGE B − 3INSTALLATION

OM−00725−06 10 SERIES

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 3 inch (76,2
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 air­tight seal. Follow the sealant manufacturer’s rec­ommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.

Suction Lines In Sumps

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

tion inlet because the inflow will carry air down into
the sump, and air entering the suction line will re­duce pump efficiency.

If it is necessary to position inflow close to the suc­tion 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 dis­tance equal to at least 3 times the diameter of the
suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is
critical 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).

If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc-

PAGE B − 4 INSTALLATION

OM−00725−0610 SERIES

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

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

Valves

If a 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 in­stalled in the discharge line to protect the pump
from excessive shock pressure and reverse rota­tion when it is stopped.

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

PAGE B − 5INSTALLATION

OM−00725−06 10 SERIES

Bypass Lines

If a system check valve is used due to high dis­charge head, it may be necessary to vent trapped
air from the top of the pump during the priming
process. This may be accomplished by installing a
bypass line from the top of the pump, back to the
source of liquid. The end of the bypass line must be
submerged. The line must be large enough to pre-

vent clogging, but not so large as to affect pump
discharge capacity.

ALIGNMENT

The alignment of the pump and the engine is criti­cal for trouble-free mechanical operation. See Sec­tion E, Securing Intermediate And Drive Assem-

bly To Engine for detailed information.

PAGE B − 6 INSTALLATION

10-SERIES

OPERATION − SECTION C

Review all SAFETY information in Section A.

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

OM−00725−06

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.

This pump is designed to handle dirty
water containing specified entrained
solids. Do not attempt to pump volatile,

corrosive, or flammable materials, or
any liquids which may damage the
pump or endanger personnel as a result
of pump failure.

Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. The maximum continuous
operating speed for this pump is 1900
RPM.

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 consider­able length of time.

3. The liquid in the pump casing has evapo­rated.

When installed in a flooded suction application,
simply open the system valves and permit the in­coming liquid to evacuate the air. After the pump
and piping system have completely filled, evacu­ate any remaining air pockets in the pump or suc­tion line by loosening pipe plug or opening bleeder
valves.

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

When installed in a static lift application such as fire
truck filling, always leave enough liquid in the tank
to prime the pump prior to start-up.

NOTE

PRIMING

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

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

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

OPERATION PAGE C − 1

This pump is self-priming; however, it is not suited
for unattended reprime applications. In the event of
suction check valve failure and loss of prime, the
pump casing must be refilled through the fill cover
or fill plug.

STARTING

Consult the operations manual furnished with the
engine.

OM−00725−06

10-SE-

RIES

OPERATION

Lines With a Bypass

Close the discharge throttling valve (if so
equipped) so that the pump will not have to prime
against the weight of the liquid in the discharge
line. Air from the suction line will be discharged
through the bypass line back to the wet well during
the priming cycle. When the pump is fully primed
and liquid is flowing steadily from the bypass line,
open the discharge throttling valve. 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
engine. Priming is indicated by a positive reading
on the discharge pressure gauge or by a quieter
operation. The pump may not prime immediately
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 pres­sure 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.

against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup­ture or explode. If overheating occurs, stop the
pump and allow it to cool before servicing it. Refill

the pump casing with cool liquid.

Allow an over-heated pump to cool be­fore servicing. Do not remove plates,
covers, gauges, or fittings from an over­heated pump. Liquid within the pump
can reach boiling temperatures, and va­por pressure 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 to personnel from hot liquid.

Strainer Check

If a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been in­stalled, monitor and record the readings regularly
to detect strainer blockage.

Leakage

No leakage should be visible at pump mating sur­faces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maxi­mum pump efficiency.

Liquid Temperature And Overheating

The maximum liquid temperature for this pump is
110 F (43 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

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 neces­sary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve. (See Section E,
Page 1). If the pump is fitted with a Gorman-Rupp
double grease lubricated seal, the maximum in­coming pressure must be reduced to 10 p.s.i.

Pump Vacuum Check

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-

OPERATIONPAGE C − 2

10-SERIES

OM−00725−06

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 dis­charge valve.

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.

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.

On engine driven pumps, reduce the throttle
speed slowly and allow the engine to idle briefly be­fore stopping.

solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotat­ing parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids con­taining a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and pre­venting the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.

BEARING TEMPERATURE CHECK

Bearings normally run at higher than ambient tem­peratures because of heat generated by friction.
Temperatures up to 160F (71C) are considered
normal for bearings, and they can operate safely to
at least 180F (82C).

Checking bearing temperatures by hand is inaccu­rate. Bearing temperatures can be measured ac­curately by placing a contact-type thermometer
against the housing. Record this temperature for
future reference.

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

After stopping the pump, switch off the engine igni­tion and remove the key to ensure that the pump

will remain inoperative.

Cold Weather Preservation

In below freezing conditions, drain the pump to
prevent damage from freezing. Also, clean out any

A sudden increase in bearing temperature 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 cor­rect level (see LUBRICATION in MAINTENANCE
AND REPAIR). 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. Con­tinued operation should bring the temperatures
down to normal levels.

OPERATION PAGE C − 3

10 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 engine ignition and re­move the key to ensure that the pump
will remain inoperative.

3. Allow the pump to cool if overheated.

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

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

OM−00725−06

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO
PRIME

Not enough liquid in casing. Add liquid to casing. See PRIM-

ING.

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-

Suction check valve or foot valve
clogged or binding.

Clean or replace check valve.

Correct leak.

Replace suction hose.

leaking or worn seal or gasket.

stall bypass line if needed. See
INSTALLATION.

sary.
Clean valve

TROUBLESHOOTING PAGE D − 1

OM−00725−06

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

10 SERIES

PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE

PUMP REQUIRES
TOO MUCH
POWER

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.

Impeller or other wearing parts worn
or damaged.

Impeller clogged. Free impeller of debris.

Pump speed too slow. Check engine output; consult en-

Suction lift or discharge head too
high.

Pump speed too high. Check engine output.

Discharge head too low. Adjust discharge valve.

Correct leak.

Replace suction hose.

leaking or worn seal or gasket.

sary.

Check installation and correct sub­mergence as needed.

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

gine operation manual.

Check piping installation and in­stall bypass line if needed. See
INSTALLATION.

PUMP CLOGS
FREQUENTLY

Liquid solution too thick. Dilute if possible.

Bearing(s) frozen. Disassemble pump and check

bearing(s).

Liquid solution too thick. Dilute if possible.

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

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

Suction check valve or foot valve
clogged or binding.

Clean valve.

TROUBLESHOOTINGPAGE D − 2

10 SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

OM−00725−06

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 vac­uum and pressure gauge readings
and consult local representative or
factory.

Locate and eliminate source of air
bubble.

Secure mounting hardware.

Clean out debris; replace dam­aged parts.

Check bearing temperature regu­larly to monitor any increase.

lubricant.

Check piping installation for
proper support.

TROUBLESHOOTING PAGE D − 3

10 SERIES

OM−00725−06

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 16C2−F4L

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 dif­ferent due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.

Contact the Gorman-Rupp Company to verify per­formance 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 per­formance range shown on the curve.

PARTS PAGE

10 SERIESOM−00725−06

SECTION DRAWING

Figure 1. Pump Model 16C2-F4L

MAINTENANCE & REPAIRPAGE E − 2

10 SERIES

OM−00725−06

PARTS LIST

Pump Model 16C2-F4L

(From S/N 913960 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 END ASSY 16C2 Fig. 2 1
2 CAUTION DECAL 38816−169 −−−−− 1
3 EXHAUST ELBOW 31912−023 15990 1
4 WEATHER CAP S1331 −−−−− 1
5 TACHOMETER KIT 48312−606 −−−−− 1
6 HOISTING BAIL 13351BB 24000 1

7 HEX HD CAPSCREW B1006 15991 8
8 LOCKWASHER J10 15991 8

9 HEX NUT D10 15991 8
10 FUEL RETURN LINE 11308F −−−−− 1
11 HOSE CLAMP 26518−642 −−−−− 2
12 HOSE BARB FITTING 26523−441 −−−−− 1
13 MALE CONNECTOR 26523−402 −−−−− 1
14 REDUCER ELBOW Q0402 11999 1
15 FUEL RETURN LINE 14294 24030 1
16 MUFFLER GRD ASSY 42331−031 −−−−− 1
17 DEUTZ F4L ENGINE 29217−043 −−−−− 1
18 BATTERY BOX ASSY GRP40−08C −−−−− 1
19 −HEX HD CAPSCREW B0607 15991 2
20 −FLAT WASHER K06 15991 2
21 −FLANGED HEX NUT 21765−314 −−−−− 2

22 −GRD CABLE ASSY 47311−064 −−−−− 1

23 −BATT BOX LID ASSY 42113−012 24150 1
24 −12V BATTERY SEE OPTIONS REF
25 −BATTERY TAG 38818−506 −−−−− 1
26 −BATTERY BOX ASSY 42431−030 24150 1
27 −STUD MOUNT 24631−006 −−−−− 4
28 −FLANGED HEX NUT 21765−314 −−−−− 8

29 CABLE ASSY 47311−114 −−−−− 1
30 HEX HD CAPSCREW B1018 15991 2

31 LOCKWASHER J10 15991 2
32 HEX NUT D10 15991 2

33 HOSE INLET ASSY 46341−769 −−−−− 1
34 MALE CONNECTOR S1447 −−−−− 1
35 OIL DRAIN ASSY 46342−007 −−−−− 1
36 HEX HD CAPSCREW B1007 15991 4
37 LOCKWASHER J10 15991 4
38 HEX NUT D10 15991 4
39 FUEL TANK AND 46711−041 −−−−− 1

GUARD ASSY
40 −FUEL TANK ASSY 46711−042 24150 1
41 −FLANGED HEX NUT 21765−314 −−−−− 6
42 −CARRIAGE BOLT AB0604 15991 6
43 −FLAT WASHER K06 15991 6
44 −FUEL TANK 34851−178 15080 1

GRD ASSY
45 FLANGED HEX NUT 21765−314 −−−−− 10
46 HEX HD CAPSCREW B0604 15991 10
47 BASE ASSY 41566−659 24150 1
48 HEX HD CAPSCREW B1009 15991 2
49 LOCKWASHER J10 15991 2
50 HEX NUT D10 15991 2
51 FLAT WASHER K10 15991 2

NOT SHOWN:

BELT/FAN GRD KIT 48157−701 −−−−− 1

OPTIONAL:

WHEEL KIT GRP30−248F 1

12V BATTERY 29331−506 −−−−− 1

INDICATES PARTS RECOMMENDED FOR STOCK

Above Serial Numbers Do Not Apply To Pumps Made In Canada.

CANADIAN SERIAL NO. .............................. AND UP

MAINTENANCE & REPAIR PAGE E − 3

SECTION DRAWING

10 SERIESOM−00725−06

Figure 2. Pump End Assy 16C2−(F4L)

MAINTENANCE & REPAIRPAGE E − 4

10 SERIES

ITEM

PART NAME PART

NO.

PARTS LIST

Pump End Assy 16C2−(F4L)

NUMBER

MAT’L
CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−00725−06

MAT’L
CODE

QTY

1 PUMP CASING 12583 10010 1

IMPELLER 12584 11000 1

2
3 SEAL ASSEMBLY GS1500 −−−−− 1

4 PIPE PLUG P04 15079 1
5 HEX HD CAPSCREW B1208 15991 8
6 LOCKWASHER J12 15991 8
7 PIPE NIPPLE T96 15070 1
8 PIPE ELBOW R96 11990 1

9 DISCHARGE STICKER 6588BJ −−−−− 1
10 DISCHARGE FLANGE 1758 10010 1
11 DISCH FLANGE GSKT 1679G 18000 1
12 NAME PLATE 38818−023 13990 1
13 DRIVE SCREW BM#04−03 15990 4
14 WARNING DECAL 38816−096 −−−−− 1
15 STUD C0809 15991 8
16 HEX NUT D08 15991 8
17 SEAL GREASE CUP S1509 −−−−− 1
18 PIPE COUPLING AE04 11990 1
19 HEAVY PIPE NIPPLE THA0412 15079 1
20 AIR VENT S1703 −−−−− 1
21 INTERMEDIATE 38263−614 10010 1
22 PIPE PLUG P04 15079 1
23 FILL COVER ASSY 42111−344 −−−−− 1
24 −DRIVE SCREW BM#04−03 15990 2
25 −WARNING PLATE 38816−097 13990 1
26 −COVER PLATE NOT AVAILABLE 1
27 COVER CLAMP SCREW 31912−009 15000 1
28 FILL COVER GSKT 50G 19210 1
29 MACHINE BOLT A1014 15991 2
30 COVER CLAMP BAR 38111−004 11010 1

31 IMPELLER SHIM SET 5091 17090 REF
32 CLOSE NIPPLE T12 15079 1
33 PIPE COUPLING AE12 15079 1
34 OIL SIGHT GAUGE S1471 −−−−− 1
35 INTERMEDIATE GUARD 42381−031 24150 REF

42381−032 24150 REF

36 BRG CAP GSKT 5413G 18000 1
37 HEX HD CAPSCREW B0604 15991 4
38 BEARING CAP 4185A 10010 1
39 SHAFT KEY N0607 15990 1

40 IMPELLER SHAFT 38514−807 16040 1
41 OIL SEAL 25258−622 −−−−− 1
42 WAVY WASHER 23963−327 −−−−− 1
43 BALL BEARING S1077 −−−−− 1

44 INTERM DRAIN PLUG P06 15079 1
45 BALL BEARING 23421−461 −−−−− 1
46 SEAL PLATE ASSY 11895A 10010 1
47 CASING GSKT SET 34G 18000 1
48 OIL SEAL 25258−622 −−−−− 1

49 WEAR PLATE ASSY 2545 15990 1
50 HEX NUT D08 15991 2
51 LOCKWASHER J08 15991 2
52 CASING DRAIN PLUG P16 10009 1
53 BACK COVER GSKT 7668G 20000 1
54 BACK COVER ASSY 42111−935 −−−−− 1
55 −COVER PLATE NOT AVAILABLE 1
56 −DRAIN PLUG P04 15079 1
57 −DRIVE SCREW BM#04−03 15990 4
58 −WARNING PLATE 2613EV 13990 1
59 COVER CLAMP SCREW 2536 24000 1
60 COVER CLAMP 12586 11000 1
61 MACHINE BOLT A1010 15991 2

62 CHECK VALVE GSKT 11402G 19370 1
63 CHECK VALVE SEAT 11402C 10010 1

64 RD HD MACH SCREW X0506 14990 2
65 SUCT FLANGE GSKT 1679G 18000 1
66 HEX HD CAPSCREW B1214 15991 8
67 LOCKWASHER J12 15991 8
68 SUCTION FLANGE 1758 10010 1
69 SUCTION STICKER 6588AG −−−−− 1
70 PIPE PLUG P04 15079 1

71 CHECK VALVE ASSY 46411−064 −−−−− 1
72 −CHECK VALVE NOT AVAILABLE 1
73 −NYLOCK CAPSCREW NOT AVAILABLE 2
74 −SLEEVE NOT AVAILABLE 2
75 −BACKUP PLATE NOT AVAILABLE 1
76 −ADAPTOR NOT AVAILABLE 1
77 CHECK VALVE PIN 11645 17010 1

78 SEAL LINER 7408 14010 REF

NOT SHOWN:

STRAINER 7823A 24000 1
GREASE CUP DECAL 6588BD −−−−− 1
PRIMING STICKER 6588AH −−−−− 1
INSTRUCTION LABEL 2613DK −−−−− 1
LUBE DECAL 38816−079 −−−−− 1

OPTIONAL:

HARDENED IMPELLER 12584 11080 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 5

SECTION DRAWING

1.56

10 SERIESOM−00725−06

13
12

,

12

1.47

.09 REF

3

4

5

11

.03

10

89

,

Figure 3. Drive Assembly For 16C2−F4L

6

7

MAINTENANCE & REPAIRPAGE E − 6

10 SERIES

OM−00725−06

PARTS LIST

Drive Assembly For 16C2−F4L

ITEM
NO.

1 HEX HD CAPSCREW 22645−164 −−−−− 12
2 LOCKWASHER 21171−511 −−−−− 12
3 DRIVE PLATE ASSY 44131−005 24150 1
4 −DRIVE PIN 13819 15030 2
5 SHAFT KEY N0607 15990 1
6 DRIVE ARM ASSY 13817D −−−−− 1
7 −DYNA FLEX JOINT S2110 −−−−− 2
8 HEX HD CAPSCREW 22645−164 −−−−− 8

9 LOCKWASHER 21171−511 −−−−− 8
10 INTERMEDIATE BRACKET 38263−614 10010 1
11 IMPELLER SHAFT 38514−807 16040 REF
12 INTERMEDIATE GUARD 42381−031 24150 1
13 INTERMEDIATE GUARD 42381−032 24150 1

INDICATES PARTS RECOMMENDED FOR STOCK

PART NAME

PART
NUMBER

MAT’L
CODE

QTY

MAINTENANCE & REPAIR PAGE E − 7

10 SERIESOM−00725−06

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.

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

This pump requires little service due to its rugged,
minimum-maintenance design. However, if it be­comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional views (see Figures 1, 2 and 3) and the
accompanying parts lists.

Most service functions, such as wear plate, impel­ler, and seal replacement, may be performed by
draining the pump and removing the back cover
assembly. However, the following instructions as­sume complete disassembly is required.

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cau­tiously.

7. Drain the pump.

Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam­age to equipment. The bail is intended
for use in lifting the pump assembly
only. Suction and discharge hoses and
piping must be removed from the pump
before lifting.

Back Cover Removal

Before attempting to service the pump, switch off
the engine ignition and remove the key to ensure
that it will remain inoperative. Close all valves in the
suction and discharge lines.

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

Before attempting to open or service the
pump:

1. Familiarize yourself with this man­ual.

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 over­heated.

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

(Figure 2)

Before attempting to service the pump, remove the
pump casing drain plug (52) and drain the pump.
Clean and reinstall the drain plug. The wear plate
(49) and check valve (71) are easily accessible and
may be serviced by removing the back cover as­sembly (54).

Remove the cover clamp screw (59) and clamp bar
(60) securing the back cover . Pull the back cover
and assembled wear plate from the pump casing
(1). Inspect the back cover gasket (53) and replace
it if damaged or worn.

Inspect the wear plate and replace it if badly scored
and worn. To remove the wear plate, disengage the
hardware (50 and 51).

Suction Check Valve Removal

(Figure 2)

If the check valve assembly (71) is to be serviced,
reach through the back cover opening and hold
the assembly in place while removing the check
valve pin (77). Slide the assembly from the check
valve seat (63) and remove it from the pump.

MAINTENANCE & REPAIRPAGE E − 8

10 SERIES

OM−00725−06

NOTE

Further disassembly of the check valve is not re­quired since it must be replaced as a complete unit.
Individual parts are not sold separately.

The check valve assembly may also be serviced by
removing the suction flange (68). To remove the
flange, disengage the hardware (66 and 67) and
separate the flange from the check valve seat(63).
Remove the machine screws (64) and pull the seat
and assembled check valve from the suction port.
Remove the check valve pin (77) and pull the check
valve assembly out of the seat.

Replace the flange gaskets (62 and 65) as re­quired.

Pump Casing Removal

(Figure 1)

To service the impeller or seal assembly, discon­nect the suction and discharge piping. Remove the
hardware (47,48 and 49) securing the casing to the
base (46).

(Figure 2)

Remove the nuts (16) securing the pump casing to
the seal plate (46). Install a standard 5/8−11 UNC
lifting eye in the tapped hole in the top of the pump
casing. Be sure to screw the eye into the casing
until fully engaged. Use a hoist and sling of suitable
capacity to separate the casing from the seal plate
and intermediate.

Do not attempt to lift the complete pump
unit using the lifting eye. It is designed
to facilitate removal or installation of in­dividual components only. Additional
weight may result in damage to the
pump or failure of the eye bolt.

Remove any leveling shims used under the casing
mounting feet. Tie and tag the shims for ease of
reassembly.

Impeller Removal

(Figure 2)

Turn the cross arm on the automatic lubricating
grease cup (17) clockwise until it rests against the
cover (see Figure 5). This will prevent the grease
from escaping when the impeller is removed.

To remove the impeller (2), tap the vanes in coun­terclockwise direction (when facing the impeller)
with a block of wood or soft−faced mallet. Be care-
ful not to damage the impeller. When the impeller
breaks loose, unscrew it from the shaft. Use cau­tion when removing the impeller; tension on the
shaft seal spring will be released as the impeller is
unscrewed. Inspect the impeller and replace if
cracked or badly worn.

Slide the impeller adjusting shims (31) off the im­peller shaft (40). Tie and tag the shims or measure
and record their thickness for ease of reassembly.

Seal Removal and Disassembly

(Figure 2)

To remove the seal assembly (3), remove the
grease cup (17) and piping (18 and 19). Slide the
seal plate (46) and seal parts off the shaft as a sin­gle unit. Be careful not to drop or damage any seal
parts.

Carefully remove the stationary and rotating seal
elements, packing rings, seal spring, and shaft
sleeve from the seal plate.

NOTE

The seal assembly may be removed without com­pletely disassembling the pump by removing the
impeller though the back cover opening and using
a stiff wire with a hooked end to pull the seal parts
out of the seal plate.

Inspect the seal liner (78) for wear or grooves
which could cause leakage or damage to the seal
packing rings. The seal liner is a press fit in the seal
plate, and does not normally require replacement.
If replacement is necessary, see Seal Installation.

If no further disassembly is required, refer to Seal

Reassembly And Installation.

MAINTENANCE & REPAIR PAGE E − 9

10 SERIESOM−00725−06

Separating Intermediate And Drive Assembly
From Engine

(Figure 3)

If it is necessary to separate the intermediate (10)
and drive assemblies from the engine, support the
intermediate using a hoist and sling, and remove
the hardware (1 and 2) securing the intermediate
to the engine bellhousing. Separate the assem­blies by pulling the intermediate straight away from
the engine.

As the assemblies are separated, the drive pins (4)
will disengage from the drive arm assembly (6).
The drive arm assembly and the impeller shaft key
(5) are a tight press fit on the shaft (11), and will re­main on the shaft.

It is not necessary to remove the drive plate assem­bly (3) from the engine flywheel unless the drive
pins are bent or worn and must be replaced. To re­move the drive plate assembly, disengage the
hardware (8 and 9) and remove the drive plate.

is not recommended. These operations
should be performed only in a properly-e­quipped shop by qualified personnel.

Remove the intermediate drain plug (44) and drain
the lubricant. Clean and reinstall the drain plug.

Disengage the capscrews (37) and remove the
bearing cap (38), gasket (36), outboard oil seal
(41), and wavy washer (42). Press the oil seal from
the bearing cap.

Place a block of wood against the impeller end of
the shaft (40), and tap the shaft and assembled
bearings from the intermediate. Press the inboard
oil seal (48) from the intermediate.

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

The drive pins are secured into the drive plate by a
tight press fit and peening. To remove the pins, drill
through from the peened end and drive the pins
out using a drift pin.

Use a bearing puller to remove the drive arm as­sembly from the impeller shaft. Remove the shaft
key.

Inspect the dyna flex joints (7), and replace them if
worn. The dyna flex joints are a press fit in the drive
arm.

Shaft and Bearing Removal and Disassembly

(Figure 2)

When the pump is properly operated and main­tained, the bearing housing should not require dis­assembly. Disassemble the shaft and bearings
only when there is evidence of wear or damage.

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.

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

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

Shaft and bearing disassembly in the field

Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.

MAINTENANCE & REPAIRPAGE E − 10

10 SERIES

Bearings must be kept free of all dirt and
foreign material. Failure to do so will great­ly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail­ure.

Rotate the bearings by hand to check for rough­ness or binding and inspect the bearing balls. If ro­tation 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 bearing
housing. Replace the bearings, shaft, or intermedi­ate if the proper bearing fit is not achieved.

If bearing replacement is required, use a bearing
puller to remove the inboard and outboard bear­ings (43 and 45) from the shaft.

OM−00725−06

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.

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. Bear­ings 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.

Shaft and Bearing Reassembly and Installation

(Figure 2)

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.

Position the inboard oil seal (48) in the intermediate
housing bore with the lip positioned as shown in
Figure 2. Press the oil seal into the housing until the
face is just flush with the machined surface on the
housing.

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 con­tinuous motion, to prevent the bearings from cool­ing and sticking on the shaft.

NOTE

Position the inboard bearing (45) on the shaft as in­dicated by the following illustrations.

MAINTENANCE & REPAIR PAGE E − 11

10 SERIESOM−00725−06

BALL LOADING
GROOVE POSITIONED
AWAY FROM IMPELLER

LOADING
GROOVE

DIRECTION OF

THRUST

INSTALLATION OF NEW DEPARTURE OR

BCA/FEDERAL MOGAL 5300W SERIES BEARINGS

(OPEN OR ENCLOSED IMPELLERS)

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

If heating the bearings is not practical, use a suit­able sized sleeve, and an arbor (or hydraulic) press
to install the bearings on the shaft.

BALL LOADING
GROOVE POSITIONED

TOWARD IMPELLER

LOADING
GROOVE

DIRECTION OF

THRUST

INSTALLATION OF MRC/SKF 5300M OR

FAFNIR 5300W SERIES BEARINGS

(OPEN OR ENCLOSED IMPELLERS)

Install the wavy washer (42) and bearing cap gas­ket (36), and secure the bearing cap to the interme­diate with the capscrews (37). Be careful not to
damage the oil seal lip on the shaft keyway.

Lubricate the bearings as indicated in LUBRICA-

TION at the end of this section.

Securing Intermediate And Drive Assembly To
Engine

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 into the in­termediate bore until the inboard bearing (45) is
fully seated against the bore shoulder. Be careful
not to damage the oil seal lip on the shaft threads.

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

Apply a light coating of oil to the lip of the outboard
oil seal (41), and press it into the bearing cap (38)
with the lip positioned as shown in Figure 2. The
face of the oil seal should be just flush with the
outer face of the bearing cap.

(Figure 3)

If the drive pins (4) were removed from the drive
plate assembly (3), install the new pins by pressing
them into the drive plate and peening the ends. Se­cure the drive plate assembly to the engine fly­wheel with the hardware (8 and 9).

If the dyna flex joints (7) were removed from the
drive arm assembly, lubricate the O.D. of the re­placement dyna flex joints with a fine film of rubber
lubricant (Parker O Lube or equivalent), and press
them into the drive arm until centered.

Install the impeller shaft key (5) and press the drive
arm assembly (6) onto the impeller shaft.

Make certain that the drive plate and drive
arm assemblies are mounted in accor­dance with the dimensions shown in Fig­ure 3. THESE DIMENSIONS ARE CRITI-
CAL. If the drive arm assembly is not prop­erly positioned on the shaft, a preload con­dition can cause premature bearing failure.

MAINTENANCE & REPAIRPAGE E − 12

10 SERIES

OM−00725−06

The end of the shaft must be recessed in
the bore of the drive arm 0.03 inch (0,76
mm). This will allow a clearance of approxi­mately .09 inch (2,29 mm) between the
drive arm assembly and the drive plate af­ter the intermediate is installed on the en­gine bellhousing.

Seal Reassembly and Installation

(Figures 2 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 well-ven­tilated area free from excessive heat,
sparks, and flame. read and follow all
precautions printed on solvent contain­ers.

The seal is not normally reused because wear pat­terns on the finished faces cannot be realigned

during reassembly. This could result in premature
failure. If necessary to reuse an old seal in an emer­gency, 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 leak­age. Clean and polish the shaft sleeve, or replace 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 pack­ing rings and seal liner with water or a very small
amount of oil, and apply a drop of light lubricating
oil on the finished faces. Assemble the seal as fol­lows, (see Figure 4).

MAINTENANCE & REPAIR PAGE E − 13

10 SERIESOM−00725−06

IMPELLER
ADJ SHIMS

IMPELLER

SHAFT

IMPELLER

SHAFT SLEEVE

SEAL PLATE

PIPE NIPPLE

PACKING RINGS

SEAL LINER

ROTATING ELEMENT

STATIONARY

SEAL SEAT

STATIONARY WASHER

Figure 4. GS1500 Seal Assembly

This seal is not designed for operation at
temperatures above 110F (43C). Do not
use at higher operating temperatures.

Inspect the seal plate, seal liner, and the impeller
shaft for burrs or sharp corners, and remove any
that exist. Replace the seal liner (78) if wear or
grooves exist which could cause leakage or dam­age to the seal packing rings. To replace the seal
liner, position the seal plate (46) on the bed of an
arbor (or hydraulic) press and use a new sleeve to
force the old one out. After the new liner is properly
installed, a 1/4 inch (6,35 mm) diameter hole must
drilled through it to permit the flow of lubricant to
the seal assembly. Be careful to center the drill in
the threaded grease pipe hole and not damage the
threads. Deburr the hole from the inside of the seal
liner after drilling.

SPRING

Slide the seal plate onto the shaft until fully seated
against the intermediate. Align the threaded seal
lubricant hole with the intermediate opening and
temporarily secure the seal plate to the intermedi­ate with two capscrews and nuts (1/2 UNC X 1−1/2
inch long, not supplied).

Install the inboard rotating element with the cham­fered side facing the shaft shoulder.

Subassemble the stationary seal seats, packing
rings, stationary washers, and spring onto the
shaft sleeve. Apply a drop of light oil on the preci­sion finished faces of the stationary seats; never
use grease. Slide the entire subassembly into the
lubricated seal liner until it bottoms against the in­board rotating element.

Install the outboard rotating element with the
chamfered side facing the impeller.

Reinstall the automatic grease cup and piping (17,
18, and 19).

Lubricate the seal as indicated in LUBRICATION,
after the impeller has been installed.

STATIONARY WASHER

MAINTENANCE & REPAIRPAGE E − 14

10 SERIES

OM−00725−06

Impeller Installation And Adjustment

(Figure 2)

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

The shaft and impeller threads must be
completely clean before reinstalling the im­peller. Even the slightest amount of dirt on
the threads can cause the impeller to seize
to the shaft, making future removal difficult
or impossible without damage to the im­peller or shaft.

Install the same thickness of impeller adjusting
shims as previously removed, and screw the im­peller onto the shaft until tight.

NOTE

An alternate method of adjusting this clearance is to
reach through the discharge port with a feeler
gauge and measure the gap. Add or subtract pump
casing gaskets accordingly.

If a lifting eye was used to move the pump casing,
be sure to remove the lifting eye from the pump
casing.

Do not attempt to lift the complete pump
unit using the lifting eye. It is designed
to facilitate removal or installation of in­dividual components only. Additional
weight may result in damage to the
pump or failure of the eye bolt.

Suction Check Valve Installation

NOTE

At the slightest sign of binding, immediately back
the impeller off, and check the threads for dirt. Do

not try to force the impeller onto the shaft.

A clearance of .025 to .040 inch (0,64 to 1,02 mm)
between the impeller and the seal plate is neces­sary for maximum pump efficiency. Measure this
clearance, and add or remove impeller adjusting
shims as required.

Remove the two capscrews temporarily holding
the seal plate and install the same thickness of cas­ing gaskets (47) as previously removed. Secure
the seal plate and pump casing to the intermediate
with the nuts (16). Do not fully tighten the nuts (16)
until the impeller face clearance has been set.

A clearance of .010 to .020 inch (0,25 to 0,51 mm)
between the impeller and the wear plate is also rec­ommended for maximum pump efficiency. This
clearance must be set after installing the back
cover, by adding or removing gaskets in the pump
casing gasket set (47) until the impeller scrapes
against the wear plate when the shaft is turned. Af­ter the impeller scrapes, add .015 inch (0,38 mm)
of gaskets.

(Figure 2)

Inspect the check valve assembly, and replace it if
badly worn.

NOTE

The check valve assembly must be replaced as a
complete unit. Individual parts are not sold sepa­rately.

Reach through the back cover opening with the as­sembled check valve, and position the check valve
adaptor in the mounting slot in the check valve
seat. Align the adaptor with the seat hole and se­cure the assembly with the check valve pin (77).

NOTE

If the suction flange or check valve seat was re­moved, replace the respective gaskets, apply ‘Per­matex Aviation No. 3 Form−A−Gasket’ or equiva­lent compound to the mating surfaces.

Back Cover Installation

(Figure 2)

If the wear plate (49) was removed for replace­ment, carefully center it on the back cover and se-

MAINTENANCE & REPAIR PAGE E − 15

10 SERIESOM−00725−06

cure it with the hardware (50 and 51). The wear
plate must be concentric to prevent binding when
the back cover is installed.

Clean any scale or debris from the contacting sur­faces in the pump casing that might interfere or
prevent a good seal with the back cover. Replace
the back cover gasket (53) and slide the back
cover assembly 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 which contacts the pump casing. This ac­tion will reduce rust and scale build-up.

Secure the back cover assembly by tightening the
cover clamp screw (59). Do not over-tighten the
clamp screw; it should be just tight enough to en­sure a good seal at the back cover shoulder.

base (46) with the hardware (47, 48 and 49). Be
sure the pump is secured to the base and engine.

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

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

Remove the fill cover assembly (23). Fill the pump
casing with clean liquid. Reinstall the fill cover plate
and tighten it.

Refer to OPERATION, Section C, and start the
pump.

LUBRICATION

Seal Assembly

(Figure 2)

Final Pump Assembly

(Figure 1)

Install any leveling shims used under the pump
casing mounting feet and secure the casing to the

POSITION

WHEN

EMPTY

GREASE

FITTING

Fill the grease cup (17) through the grease fitting
with No. 2 lithium base grease until grease es­capes from the relief hole. Turn the grease cup arm
counterclockwise until it is at the top of the stem;
this will release the spring to apply grease to the
seal (see Figure 5).

POSITION

FOR

FILLING

CROSS

ARM

RELIEF
HOLE

POSITION

WHEN

IN USE

Figure 5. Automatic Lubricating Grease Cup

MAINTENANCE & REPAIRPAGE E − 16

10 SERIES

OM−00725−06

Bearings

(Figure 2)

The intermediate was fully lubricated when
shipped from the factory. Check the oil level regu­larly through the sight gauge (34)
the middle of the gauge. When lubrication is re­quired, add SAE No. 30 non-detergent oil through
the oil hole cover (20). Do not over-lubricate. Over-
lubrication can cause the bearings to over-heat, re­sulting in premature bearing failure.

and maintain it at

NOTE

The white reflector in the sight gauge must be posi­tioned horizontally to provide proper drainage.

Under normal conditions, drain the intermediate
once each year and refill with approximately 7 1/2
ounces (0,22 liter) of clean oil. Change the oil more
frequently if the pump is operated continuously or

installed in an environment with rapid temperature
change.

Monitor the condition of the bearing lubri­cant regularly for evidence of rust or mois­ture condensation. This is especially im­portant 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.

Engine

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

MAINTENANCE & REPAIR PAGE E − 17

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty

or call:

U.S.: 419−755−1280

International: +1−419−755−1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty

or call:

519−631−2870

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

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