Gorman-Rupp Pumps 16C2-F4L User Manual

ACDEU

OM−00725−OE09

February 25, 2002

Rev. A 04/11/02

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

10 SERIES PUMP

MODEL

16C2−F4L

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

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

ECopyright by the Gorman-Rupp Company

The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.

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 − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Suction Line Positioning PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLOAT SWITCHES PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bypass Lines PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC AIR RELEASE VALVE PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Release Valve Installation PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

STARTING PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Starting PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Starting PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lines With a Bypass PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lines Without a Bypass PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leakage PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature And Overheating PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainer Check PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Stopping PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Stopping PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

TABLE OF CONTENTS

(continued)

Safety Shutdown System PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION IN EXTREME HEAT PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING TEMPERATURE CHECK PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PREVENTIVE MAINTENANCE PAGE D − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

PARTS LISTS:

PUMP MODEL PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP END ASSY PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE ASSEMBLY PAGE E − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . .

Back Cover Removal PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Check Valve Removal PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing Removal PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal and Disassembly PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separating Intermediate And Drive Assembly From Engine PAGE E − 9. . . . . . . . . . . . . . . . . .

Shaft and Bearing Removal and Disassembly PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Reassembly and Installation PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing Intermediate And Drive Assembly To Engine PAGE E − 11. . . . . . . . . . . . . . . . . . . . . .

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

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

Suction Check Valve Installation PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Back Cover Installation PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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
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:

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901−1217

or

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

cording to all national, local and industry stan­dards.

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:

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.

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

Because pump installations are seldom identical,
this manual cannot possibly provide detailed in­structions and precautions for every aspect of
each specific application. Therefore, it is the re­sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety nor pump integrity are com­promised by the installation. Pumps and related
equipment must be installed and operated ac-

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

SAFETY − SECTION A

This information applies to 10 Series en­gine driven pumps. Refer to the manual
accompanying the engine before at­tempting to begin operation.

Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre­cautions for each specific application.
Therefore, it is the owner/installer’s re­sponsibility to ensure that applications
not addressed in this manual are per­formed only after establishing that nei­ther operator safety nor pump integrity
are compromised by the installation.

Before attempting to open or service the
pump:

1. Familiarize yourself with this man­ual.

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

3. Allow the pump to completely cool
if overheated.

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

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cau­tiously.

7. Drain the pump.

vent injury during automatic operation.
Disconnect the positive battery cable
before performing any maintenance.
Failure to do so may result in serious
personal injury.

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.

Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam­age to equipment. Suction and dis­charge hoses and piping must be re­moved from the pump before lifting.

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

If the pump is equipped with the option­al automatic starting system, it is sub­ject to automatic restart. Keep hands
and clothing away from the unit to pre-

Do not operate the pump against a
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.

PAGE A − 1SAFETY

OM−00725

10 SERIES

Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over­heated pump. Vapor pressure within the
pump can cause parts being disen­gaged to be ejected with great force. Al­low the pump to cool before servicing.

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.

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.

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.

PAGE A − 2 SAFETY

INSTALLATION − SECTION B

OM−0072510 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

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 dry-

PAGE B − 1INSTALLATION

OM−00725 10 SERIES

ing, 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.

e. If the pump and

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

engine have been stored for

sion. Connect and tighten the positive cable first,
then the negative cable.

POSITIONING PUMP

Use lifting and moving equipment in
good repair and with adequate capacity
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.

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.

Table 1. Battery Specifications

Cold Reserve Approx.

Crank Capacity Amp/ Overall

Voltage

12 Volts 960-975 365 175 8.75W

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 corro-

Amps @80°F Hr. Dims.
@ 0°F (Minutes) Rating (Inches)

20.5L
x

x

9.75H

The pump assembly can be seriously
damaged if the cables or chains used to lift
and move the unit are improperly wrapped
around the pump.

Mounting

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

The pump may have to be supported or shimmed
to provide for level operation or to eliminate vibra­tion.

If the pump has been mounted on a 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

PAGE B − 2 INSTALLATION

OM−0072510 SERIES

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

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.

Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini­mum use of elbows and fittings, which substan­tially 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.

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

PAGE B − 3INSTALLATION

OM−00725 10 SERIES

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.

If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc­tion 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. veloc­ity.

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

OM−0072510 SERIES

FLOAT SWITCHES

Installation

The standard pump is not furnished with a means
to automatically regulate liquid level. However, if
the unit is equipped with the optional auto-start
control system, the pump can be conformed to
start and stop as the liquid level in the wet well or
sump rises and falls. The autostart option employs
either a single or double float switch system, where
a bulb raises or lowers (floats) with the liquid level,
thus activating an enclosed miniature switch. The
floats are equipped with a socket type connector
that plugs into a matching receptacle on the auto­start control box.

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

When installing the floats, note the following:

a. Be sure to provide sufficient room in the wet

well or sump so that floats do not get ob­structed or drawn into the suction line. If a flex­ible suction hose is used, it may be extended
to lay along the bottom of the wet well or sump

and the float can be attached to the hose
above the point where it bends along the bot­tom. Direct the suction line toward the flow,
and the float(s) away from the flow. If a stand­pipe is available, attach the float switch cable
to the standpipe in the sump at the approxi­mate desired liquid level.

b. In a single float system, the cable can be teth-

ered to the suction line or standpipe approxi­mately 6 inches (152 mm) above the float.
This setting allows approximately 9 inches
(229 mm) of liquid rise between pump start/
stop. The start/stop interval may be increased
by extending the float end of the cable. The
liquid level in the sump will increase approxi­mately 8 inches (203 mm) between start/stop
intervals for every 6 inches (152 mm) of cable
increase.

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

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

d. Refer to Figure 3 for additional float switch

data.

ENGINE

CONTROL

BOX

ON

(Emptying)

OFF

(Filling)

OPERATING

CABLE

TETHER

RANGE

(See Table Below)

POINT

OFF

(Emptying)

1.25" Pipe
(Not Furnished)

ON

(Filling)

Figure 3. Float Switch Data

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 si-

3.0

(0.9)

2.5

(.76)

2.0

(0.6)

1.5

(.46)

1.0

(0.3)

0.5

(.15)

1.0

(0.3)

APPROXIMATE FREE CORD LENGTH IN FT. (M)

2.0

(0.6)

3.0

(0.9)

4.0

(1.2)

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

PAGE B − 5INSTALLATION

OM−00725 10 SERIES

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.

Bypass Lines

Self-priming pumps are not air compressors. Dur­ing 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 dis­charge side of the pump must be opened to atmos­pheric pressure through a bypass line installed be­tween 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 dis­charge check valve closed.

NOTE

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

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

It is also recommended that pipe unions be in­stalled 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 re­duce 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 Auto­matic Air Release Valve. Consult your Gorman­Rupp distributor, or contact the Gorman-Rupp
Company for selection of an Automatic Air Release
Valve to fit your application.

Except in certain specific applications (to
prevent flooding during service of an auto­matic air release valve in a below-ground
lift station), if a manual shut-off valve is in­stalled anywhere in a bypass line, it must
be a full-opening, ball-type valve to pre-
vent plugging by solids.

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.

PAGE B − 6 INSTALLATION

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 dan­gerous overheating and possible explo­sive rupture of the pump casing. Per­sonnel could be severely injured.

Allow an over-heated pump to cool
before servicing. Do not remove

plates, covers, gauges, or fittings from
an over-heated 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.

AUTOMATIC AIR RELEASE VALVE

When properly installed and correctly adjusted to
the specific hydraulic operating conditions of the
application, the Gorman-Rupp Automatic Air Re­lease Valve will permit air to escape through the by­pass line, and then close automatically when the
pump is fully primed and pumping at full capacity.

Theory of Operation

OM−0072510 SERIES

Figure 5. Valve in Closed Position

When the pump is fully primed, pressure resulting
from flow against the valve diaphragm com­presses the spring and closes the valve (Figure 5).
The valve will remain closed, reducing the bypass
of liquid to 1 to 5 gallons per minute, until the pump
loses its prime or stops.

Some leakage (1 to 5 gallons (3,8 to 18,9
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.

When the pump shuts down, the spring returns the
diaphragm to its original position. Any solids that
may have accumulated in the diaphragm chamber
settle to the bottom and are flushed out during the
next priming cycle.

Figure 4. Valve in Open Position

Figures 4 and 5 show a cross-sectional view of the
Automatic Air Release Valve, and a corresponding
description of operation.

During the priming cycle, air from the pump casing
flows through the bypass line, and passes through
the Air Release Valve to the wet well (Figure 4).

NOTE

The valve will remain open if the pump does not
reach its designed capacity or head. Valve closing
pressure is dependent upon the discharge head of
the pump at full capacity. The range of the valve
closing pressure is established by the tension rate
of the spring as ordered from the factory. Valve clos­ing pressure can be further adjusted to the exact
system requirements by moving the spring retain­ing pin up or down the plunger rod to increase or
decrease tension on the spring. Contact your Gor­man-Rupp distributor or the Gorman-Rupp Compa­ny for information about an Automatic Air Release
Valve for your specific application.

Air Release Valve Installation

The Automatic Air Release Valve must be inde­pendently mounted in a horizontal position and

PAGE B − 7INSTALLATION

OM−00725 10 SERIES

connected to the discharge line of the self-priming
centrifugal pump (see Figure 6).

NOTE

CLEAN-OUT
COVER

INSTALL AIR RELEASE VALVE
IN HORIZONTAL POSITION

90_ LONG

RADIUS
ELBOW

SUPPORT
BRACKET

BLEED LINE 1"

(25,4 MM) DIA. MIN.

(CUSTOMER
FURNISHED)
EXTEND 6"

(152,4 MM)

BELOW LIQUID

LEVEL SURFACE

SUCTION
LINE

If the Air Release Valve is to be installed on a staged
pump application, contact the factory for specific
installation instructions.

DISCHARGE PIPE

DISCHARGE
CHECK VALVE

PUMP DISCHARGE

SELF-PRIMING
CENTRIFUGAL

PUMP

WET WELL
OR SUMP

Figure 6. Typical Automatic Air Release Valve Installation

The valve inlet line must be installed between the
pump discharge port and the non-pressurized side
of the discharge check valve. The valve inlet is at
the large end of the valve body, and is provided
with standard 1 inch NPT pipe threads.

The valve outlet is located at the opposite end of
the valve, and is also equipped with standard 1
inch NPT pipe threads. The outlet should be con­nected to a bleed line which slopes back to the wet
well or sump. The bleed line must be the same size
as the inlet piping, or larger. If piping is used for the
bleed line, avoid the use of elbows whenever pos­sible.

NOTE

It is recommended that each Air Release Valve be

fitted with an independent bleeder line directed
back to the wet well. However, if multiple Air Re­lease Valves are installed in a system, the bleeder
lines may be directed to a common manifold 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 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 − 8 INSTALLATION

10 SERIES

OM−00725

OPERATION − SECTION C

Review all SAFETY information in Section A.

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

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.

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.

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.

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.

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.

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

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

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

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 lubri-

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.

NOTE

10 SERIESOM−00725

STARTING

If the pump is equipped with the option­al automatic starting system, it is sub­ject to automatic restart. Keep hands
and clothing away from the unit to pre­vent injury during automatic operation.
Disconnect the positive battery cable
before performing any maintenance.
Failure to do so may result in serious
personal injury.

Consult the operations manual furnished with the
engine.

Manual Starting

On initial start-up, set the engine speed at the half­throttle position. Turn the keyswitch on the control
box to the START" position until the engine starts.
Release the key and the switch will return to the
RUN" position.

the switch in the AUTO START" position.

Press and hold the white AUTO" button on the
control panel until the red AUTO" light illuminates.
The auto-start system is now armed.

NOTE

The unit can continue to be started manually with
the keyswitch in the AUTO START" position by
pressing the white MAN" button on the control. The
Single Lightning Bolt" light on the control will illu­minate in conjunction with an audible alarm before
the unit starts. The unit can then be stopped manu­ally by pressing the OFF/SET" button.

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

When the liquid level in the sump or wet well is suffi­ciently pumped down, the unit will automatically
shut down.

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

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

Automatic Starting

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

Follow the procedures outlined for manual starting
and throttle adjustment, then turn the key to the
AUTO START" position.

NOTE

If the keyswitch is moved to the OFF" position
while in the auto-start mode, the engine will stop.
However, the auto-start process will continue as
soon as the keyswitch is moved back to the AUTO
START" position. To cancel the auto-start process,
press the OFF/SET" button.

The control panel is equipped with high oil temper­ature, low oil pressure, V-belt and start failure (3 at­tempts) safety shutdowns. If any of these problems
occur, the red Double Lightning Bolt" light will illu­minate to indicate a system fault. When the prob­lem is corrected, press the OFF/SET" button to re­set the control.

NOTE

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

NOTE

For security purposes, the key can be removed with

The unit can be started manually with the key­switch in the AUTO START" position by pressing

OPERATIONPAGE C − 2

10 SERIES

OM−00725

the white MAN" button. The Single Lightning
Bolt" light will illuminate in conjunction with an au­dible alarm before the unit starts.

Stop the unit manually by pressing the OFF/SET"
button.

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.

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
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.

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.

OPERATION PAGE C − 3

10 SERIESOM−00725

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 oper­ating speed the pump should pull a vacuum of 20
inches (508 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.

Manual Stopping

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

Safety Shutdown System

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

1. If the engine exceeds its safe operating tem­perature.

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

3. If the engine fails to start within a pre-set peri­od of time.

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

5. If the engine fan belt breaks.

Lights on the control panel will indicate which of the
safety features has caused the engine to shut
down.

Should any of the safety features cause the engine
to shut down, the cause must be determined and
corrected before putting the unit back into service.
The engine will not restart until the HAND-OFF­AUTO switch has been returned to the ‘OFF’ posi­tion for at least 10 seconds.

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

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

After stopping the pump, close and lock the control
panel cover, or disconnect the positive battery
cable to ensure that the pump will remain inopera­tive.

Automatic Stopping

In the automatic mode, the pump will stop when
the liquid in the wet well or sump lowers and acti­vates the Off" float switch(s). The pump will restart
automatically when the liquid rises and activates
the On" float switch(s).

Never disconnect any of the safety shut­down features; this will void the warran­ty and could result in serious damage to
the unit and/or injury to personnel. Safe­ty shutdown features are pre-set at the
factory; do not attempt to adjust any of
the settings. Determine the cause of
shutdown before putting the unit back
into service. Consult the factory for ad­ditional information.

OPERATION IN EXTREME HEAT

The safety shutdown system will automatically
stop the unit if engine operating temperature ex-

OPERATIONPAGE C − 4

10 SERIES

OM−00725

ceeds design limits. If engine over-temperature
shutdown occurs, allow the unit to cool before re­starting.

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

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

If the pump is equipped with the option­al automatic starting system, it is sub­ject to automatic restart. Keep hands
and clothing away from the unit to pre­vent injury during automatic operation.
Disconnect the battery before perform­ing any maintenance. Failure to do so
may result in serious personal injury.

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.

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.

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 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.

OPERATION PAGE C − 5

TROUBLESHOOTING − SECTION D

OM−0072510 SERIES

Review all SAFETY information in Section A.

Before attempting to open or service the
pump:

1. Familiarize yourself with this man­ual.

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

3. Allow the pump to completely cool
if overheated.

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

Table 1. Trouble Shooting Chart

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cau­tiously.

7. Drain the pump.

If the pump is equipped with the option­al automatic starting system, it is sub­ject to automatic restart. Keep hands
and clothing away from the unit to pre­vent injury during automatic operation.
Disconnect the positive battery cable
before performing any maintenance.
Failure to do so may result in serious
personal injury.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME Not enough liquid in casing.

Suction check valve contaminated or
damaged.

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gas­ket.

Suction lift or discharge head too
high.

Strainer clogged.

PUMP STOPS OR FAILS
TO DELIVER RATED
FLOW OR PRESSURE

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gas­ket.

Add liquid to casing. See PRIMING.

Clean or replace check valve.

Correct leak.

Replace suction hose.

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

Check piping installation and install
bypass line if needed. See INSTAL-
LATION.

Check strainer and clean if neces­sary.

Correct leak.

Replace suction hose.

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

TROUBLESHOOTING PAGE D − 1

OM−00725 10 SERIES

Table 1. Trouble Shooting Chart (cont.)

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

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

PUMP REQUIRES TOO
MUCH POWER

Strainer clogged.

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

Impeller or other wearing parts
worn or damaged.

Impeller clogged.

Discharge head too high.

Suction lift too high.

Pump speed too slow.

Pump speed too high.

Discharge head too low.

Liquid solution too thick.

Check strainer and clean if neces­sary.

Check installation and correct sub­mergence as needed.

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

Free impeller of debris.

Install bypass line.

Measure lift w/vacuum gauge. Re­duce lift and/or friction losses in
suction line.

Check engine output; consult en­gine operation manual.

Check engine output.

Adjust discharge valve.

Dilute if possible.

Bearing(s) frozen.

PUMP CLOGS
FREQUENTLY

EXCESSIVE NOISE Cavitation in pump.

Discharge flow too slow.

Liquid solution too thick.

Discharge line clogged or re­stricted; hose kinked.

Suction check valve or foot valve
clogged or binding.

Pumping entrained air.

Pump or drive not securely
mounted.

Disassemble pump and check
bearing(s).

Open discharge valve fully to in­crease flow rate, and run engine at
maximum governed speed.

Dilute if possible.

Check discharge lines; straighten
hose.

Clean valve.

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.

Impeller clogged or damaged.

Clean out debris; replace damaged
parts.

TROUBLESHOOTINGPAGE D − 2

Table 1. Trouble Shooting Chart (cont.)

OM−0072510 SERIES

TROUBLE

BEARINGS RUN TOO
HOT

POSSIBLE CAUSE PROBABLE REMEDY

Bearing temperature is high, but
within limits.

Low or incorrect lubricant.

Suction and discharge lines not
properly supported.

Drive misaligned.

PREVENTIVE MAINTENANCE

Since pump applications are seldom identical, and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
of the liquid being pumped, this section is intended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine pre­ventive maintenance schedule will help assure
trouble-free performance and long life from your
Gorman-Rupp pump. For specific questions con­cerning your application, contact your Gorman­Rupp distributor or the Gorman-Rupp Company.

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

Check bearing temperature regular­ly to monitor any increase.

Check for proper type and level of
lubricant.

Check piping installation for proper
support.

Align drive properly.

equipped) between regularly scheduled inspec­tions can indicate problems that can be corrected
before system damage or catastrophic failure oc­curs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records 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 inspec­tions should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.

TROUBLESHOOTING PAGE D − 3

OM−00725 10 SERIES

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

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

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

Daily Weekly Monthly Semi-

Annually

Annually

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

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

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

TROUBLESHOOTINGPAGE D − 4

10 SERIES

OM−00725

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

SECTION DRAWING

Figure 1. Pump Model 16C2-F4L

MAINTENANCE & REPAIRPAGE E − 2

10 SERIES

OM−00725

PARTS LIST

Pump Model 16C2-F4L

(From S/N 1237525 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 (SAE 4/10) 1
2 CONTROL PANEL 48122−501 −−− 1
3 EXHAUST ELBOW 31912−023 15990 1
4 WEATHER CAP S1331 −−− 1
5 HOISTING BAIL 13351BB 24000 1

6 HEX HD CAPSCREW B1006 15991 8
7 LOCKWASHER J10 15991 8
8 HEX NUT D10 15991 8

9 FUEL RETURN LINE 11308F −−− 1
10 HOSE CLAMP 26518−641 −−− 2
11 HOSE BARB FITTING 26523−443 −−− 1
12 MALE CONNECTOR 26523−382 −−− 1
13 REDUCER ELBOW Q0402 11999 1
14 FUEL RETURN LINE 14294 24030 1
15 MUFFLER GRD ASSY 42331−031 −−− 1
16 DEUTZ F4L ENGINE 29217−043 −−− 1
17 CAUTION DECAL 38816−169 −−− 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 −T TYPE LOCKWASHER BL06 15991 1

30 POS CABLE ASSY 47311−114 −−− 1

31 HEX HD CAPSCREW B1017 15991 2
32 LOCKWASHER J10 15991 2
33 HEX NUT D10 15991 2

34 HOSE INLET ASSY 46341−800 −−− 1
35 MALE CONNECTOR S1447 −−− 1
36 OIL DRAIN ASSY 46342−007 −−− 1
37 HEX HD CAPSCREW B1007 15991 4
38 LOCKWASHER J10 15991 4
39 HEX NUT D10 15991 4
40 FUEL TANK AND 46711−041 −−− 1

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

GUARD ASSY
46 FLANGED HEX NUT 21765−314 −−− 10
47 FLAT WASHER K06 15991 10
48 HEX HD CAPSCREW B0604 15991 10
49 BASE ASSY 41566−659 24150 1
50 HEX HD CAPSCREW B1009 15991 2
51 LOCKWASHER J10 15991 2
52 HEX NUT D10 15991 2
53 FLAT WASHER K10 15991 2

OPTIONS:

WHEEL KIT GRP30−248F−−− 1

12V BATTERY 29331−506 −−− 1

REP MUFFLER GRD ASSY 42331−048 −−− 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 3

SECTION DRAWING

10 SERIESOM−00725

Figure 2. 16C2−(SAE 4/10) Pump End Assy

MAINTENANCE & REPAIRPAGE E − 4

10 SERIES

ITEM

PART NAME PART

NO.

PARTS LIST

16C2−(SAE 4/10) Pump End Assy

NUMBER

MAT’L
CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−00725

MAT’L
CODE

QTY

1 PUMP CASING 12583 10010 1

IMPELLER 12584 11010 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 17000 4
14 WARNING DECAL 2613FE −−− 1
15 STUD C0809 15991 8
16 HEX NUT D08 15991 8
17 SEAL GREASE CUP S1509 −−− 1
18 PIPE COUPLING AE04 15079 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 17000 2
25 −WARNING PLATE 38816−097 13990 1
26 −COVER PLATE NOT AVAILABLE 1

27 −FILL COVER GSKT 50G 19210 1
28 COVER CLAMP SCREW 31912−009 15000 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 24152 1
36 INTERMEDIATE GUARD 42381−032 24152 1

37 BRG CAP GSKT 5413G 18000 1
38 HEX HD CAPSCREW B0604 15991 4
39 LOCKWASHER J06 15991 4
40 BEARING CAP 4185A 10010 1
41 SHAFT KEY N0607 15990 1
42 IMPELLER SHAFT 38514−807 1706H 1

43 OIL SEAL 25258−622 −−− 1

44 WAVY WASHER 23963−327 −−− 1
45 BALL BEARING S1077 −−− 1

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

51 WEAR PLATE ASSY 2545 15990 1
52 HEX NUT D08 15991 2
53 LOCKWASHER J08 15991 2
54 CASING DRAIN PLUG P16 10009 1

55 BACK COVER GSKT 7668G 20000 1
56 BACK COVER ASSY 42111−935 −−− 1
57 −COVER PLATE NOT AVAILABLE 1
58 −DRAIN PLUG P04 15079 1
59 −DRIVE SCREW BM#04−03 17000 4
60 −WARNING PLATE 2613EV 13990 1
61 COVER CLAMP SCREW 2536 24000 1
62 COVER CLAMP 12586 11010 1
63 MACHINE BOLT A1010 15991 2

64 CHECK VALVE GSKT 11402G 19370 1
65 CHECK VALVE SEAT 11402C 10010 1

66 RD HD MACH SCREW X0506 14990 2
67 SUCT FLANGE GSKT 1679G 18000 1

68 HEX HD CAPSCREW B1214 15991 8
69 LOCKWASHER J12 15991 8
70 SUCTION FLANGE 1758 10010 1
71 SUCTION STICKER 6588AG −−− 1
72 PIPE PLUG P04 15079 1
73 CHECK VALVE ASSY 46411−064 −−− 1
74 CHECK VALVE PIN 11645 17010 1
75 PRIMING STICKER 6588AH −−− 1

76 SEAL LINER 7408 14010 REF

NOT SHOWN:

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

OPTIONAL:

AQ MEEHANITE 12584 1108H 1
D.I. IMPELLER

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 5

SECTION DRAWING

10 SERIESOM−00725

Figure 3. 16C2−(SAE 4/10) Drive Assembly

PARTS LIST

ITEM
NO.

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

PART NAME

PART
NUMBER

MAT’L
CODE

MAINTENANCE & REPAIRPAGE E − 6

QTY

10 SERIES

OM−00725

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.

As described on the following pages, this manual
will alert personnel to known procedures 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 personnel to en­sure that only safe, established maintenance pro-
cedures are used, and that any procedures not ad­dressed in this manual are performed only after es-
tablishing that neither personal safety nor pump in­tegrity are compromised by such practices.

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

3. Allow the pump to completely cool
if overheated.

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

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cau­tiously.

7. Drain the pump.

Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam­age to equipment. Suction and dis­charge hoses and piping must be re­moved from the pump before lifting.

Back Cover Removal

(Figure 2)

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.

Before attempting to service the pump, switch off
the engine ignition and disconnect the positive bat­tery cable to ensure that the pump 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.

Before attempting to service the pump, remove the
pump casing drain plug (54) and drain the pump.
Clean and reinstall the drain plug. The wear plate
(51) and check valve (73) are easily accessible and
may be serviced by removing the back cover as­sembly (56).

Remove the cover clamp screw (61) and clamp bar
(62) securing the back cover. Pull the back cover
and assembled wear plate from the pump casing
(1). Inspect the back cover gasket (55) and replace
it if damaged or worn.

Inspect the wear plate and replace it if badly scored
or worn. To remove the wear plate, disengage the
hardware (52 and 53).

Suction Check Valve Removal

(Figure 2)

If the check valve assembly (73) is to be serviced,
reach through the back cover opening and hold
the assembly in place while removing the check

MAINTENANCE & REPAIR PAGE E − 7

10 SERIESOM−00725

valve pin (74). Slide the assembly out of the check
valve seat (65) and remove it from the pump.

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 (70). To remove the
flange, disengage the hardware (68 and 69) and
separate the flange from the check valve seat. Re­move the machine screws (66) and pull the seat
and assembled check valve from the suction port.
Remove the check valve pin and pull the check
valve assembly out of the seat.

Replace the flange gaskets (64 and 67) as re­quired.

Pump Casing Removal

(Figure 1)

and tag the gaskets and 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 6). 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 (42). Tie and tag the shims or measure
and record their thickness for ease of reassembly.

To service the impeller or seal assembly, discon­nect the suction and discharge piping. Remove the
hardware (50, 51, 52 and 53) securing the casing
to the base (49).

(Figure 2)

Remove the nuts (16) securing the pump casing to
the seal plate (48). 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.

Seal Removal and Disassembly

(Figure 2)

To remove the seal assembly (3), remove the
grease cup and piping (17, 18 and 19). Slide the
seal plate 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 through the back cover opening and using
a pair of stiff wires with hooked ends to pull the seal
parts out of the seal plate.

Inspect the seal liner (76) 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.

Remove the casing gaskets (49) and any leveling
shims used under the casing mounting feet. Tie

If no further disassembly is required, refer to Seal

Reassembly And Installation.

MAINTENANCE & REPAIRPAGE E − 8

10 SERIES

OM−00725

Separating Intermediate And Drive Assembly
From Engine

(Figure 3)

If it is necessary to separate the intermediate and
drive assemblies from the engine, support the in­termediate using a hoist and sling, and remove the
hardware (6 and 7) securing the intermediate to
the engine bellhousing. Remove the intermediate
guards (35 and 36, Figure 2), and separate the as­semblies by pulling the intermediate straight away
from the engine.

As the assemblies separate, the flexible portion of
the coupling assembly (3) will remain on the shaft.
To remove the coupling from the shaft, unscrew the
two allen head setscrews from the bushing (2).
Screw one of the setscrews into the puller hole on
the circumference of the bushing. As the coupling
and bushing separate, remove the bushing, and
slide the coupling off the shaft. Remove the shaft
key (41, Figure 2).

It is not necessary to remove the outer ring of the
coupling from the engine flywheel unless the cou­pling must be replaced. To remove the ring, disen­gage the hardware (4 and 5) securing it to the fly­wheel.

(43), and wavy washer (44). Press the oil seal from
the bearing cap.

Place a block of wood against the impeller end of
the shaft (42), and tap the shaft and assembled
bearings from the intermediate. Press the inboard
oil seal (50) from the intermediate.

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
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.

Shaft and Bearing Removal and Disassembly

(Figure 2)

When the pump is properly operated and main­tained, the intermediate should not require disas­sembly. 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 intermediate drain plug (46) and drain
the lubricant. Clean and reinstall the drain plug.

Disengage the hardware (38 and 39) and remove
the bearing cap (40), gasket (37), outboard oil seal

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.

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

Bearings must be kept free of all dirt and
foreign material. Failure to do so will 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 ro-

MAINTENANCE & REPAIR PAGE E − 9

10 SERIESOM−00725

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 intermedi­ate. 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 (45 and 47) from the shaft.

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 (50) 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.

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

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.

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.

To prevent damage during removal from

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)

Figure 4. Inboard Bearing Positioning

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

NOTE

Position the inboard bearing (47) on the shaft as in­dicated in Figure 4.

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)

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

MAINTENANCE & REPAIRPAGE E − 10

10 SERIES

OM−00725

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.

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 is fully
seated against the bore shoulder. Be careful not to
damage the lip of the oil seal (50) 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 (43), and press it into the bearing cap (40)
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.

Install the wavy washer (44) and bearing cap gas­ket (37), and secure the bearing cap to the interme­diate with the hardware (38 and 39). Be careful not
to damage the lip of the oil seal (43) 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

(Figure 3)

Install the shaft key (41, Figure 2) in the shaft key­way. Position the flexible portion of the coupling as­sembly (3) on the shaft as shown in Figure 3.

NOTE

The flexible portion of the coupling must be proper­ly positioned on the shaft. The heads of the caps-

crews in the center of the coupling must be posi-
tioned toward the pump end of the shaft.

Align the keyway in the bushing (2) with the shaft
key, and slide it onto the shaft until it is just flush
with the end of the shaft. Rotate the flexible portion
of the coupling until the tapped holes for the two
setscrews align with those in the bushing, and in­stall the setscrews.

Make certain that the flexible portion of the
coupling is mounted as shown in Figure 3.
This is critical. If the coupling is not prop­erly positioned on the shaft, the coupling
parts may not fully engage, or a pre-load
condition can cause premature bearing
failure.

The end of the shaft must be just flush with
the face of the bushing. This will allow the
two portions of the coupling to fully engage
when the intermediate is secured to the en­gine bellhousing, without pre-loading the
bearings.

With the flexible portion of the coupling and the
bushing properly positioned on the shaft, tighten
the two setscrews in an alternating sequence until
the bushing and coupling are fully secured. Torque
the setscrews to 14.6 ft. lbs. (175 in. lbs. or 2 m.
kg.).

If the complete coupling assembly is being re­placed, apply ‘Loctite Retaining Compound No.
242’ or equivalent to the threads of the hardware (4
and 5), and secure the outer ring of the coupling to
the engine flywheel by torquing the hardware to 45
ft. lbs. (540 in. lbs. or 6,2 m. kg.).

Using a suitable lifting device, position the as­sembled coupling, intermediate, shaft and bear­ings so the flexible portion of the coupling seats in­side the outer ring attached to the engine flywheel.

NOTE

To ease installation, lightly lubricate the rubber por­tion of the coupling with a non-petroleum based
lubricant such as vegetable oil or glycerin, or a sili­con-based lubricant such as WD40" or equivalent.

MAINTENANCE & REPAIR PAGE E − 11

10 SERIESOM−00725

Do not use petroleum-based lubricants, or any oth­er substance which may soften or otherwise dam­age the rubber.

Install the intermediate guards (35 and 36, Figure

2), and secure the intermediate to the engine bell­housing with the previously removed hardware (6
and 7).

NOTE

Mount the intermediate guard (36) on the intermedi­ate so it is over the sight gauge (34, Figure 2).

Seal Reassembly and Installation

(Figures 2 and 5)

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 5).

MAINTENANCE & REPAIRPAGE E − 12

10 SERIES

OM−00725

IMPELLER
ADJ SHIMS

IMPELLER
SHAFT

IMPELLER

SHAFT SLEEVE

SEAL PLATE

PIPE NIPPLE

PACKING RINGS

SEAL LINER

ROTATING ELEMENT

STATIONARY
SEAL SEAT

STATIONARY WASHER

Figure 5. 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 (76) 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 (48) 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 (6,4 mm) diameter hole must
be 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

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).

STATIONARY WASHER

Slide the seal plate onto the shaft until fully seated
against the intermediate. Align the threaded seal

MAINTENANCE & REPAIR PAGE E − 13

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

10 SERIESOM−00725

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 (49) as previously removed. Se­cure the seal plate and pump casing to the inter­mediate with the nuts (16). Do not fully tighten the
nuts 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 (49) until the impeller scrapes
against the wear plate when the shaft is turned. Af­ter the impeller scrapes, add approximately .010
inch (0,25 mm) of gaskets.

(Figure 2)

Inspect the check valve assembly (73), 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
(65). Align the adaptor with the seat hole, and se­cure the assembly with the check valve pin (74).

NOTE

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

Back Cover Installation

(Figure 2)

If the wear plate (51) was removed for replace­ment, carefully center it on the back cover and se-

MAINTENANCE & REPAIRPAGE E − 14

10 SERIES

OM−00725

cure it with the hardware (52 and 53). 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 (55) 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 (61) against the clamp bar (62).
Do not over-tighten the clamp screw; it should be
just tight enough to ensure a good seal at the back
cover shoulder.

base (49) with the hardware (50, 51, 52 and 53). 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 gasket (27), and tighten the cover.

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 6).

POSITION

FOR

FILLING

CROSS

ARM

RELIEF
HOLE

POSITION

WHEN

IN USE

When installing a new grease cup, lubricate
the cup as indicated on the installation tag
furnished with the grease cup.

NOTE:

Figure 6. Automatic Lubricating Grease Cup

MAINTENANCE & REPAIR PAGE E − 15

10 SERIESOM−00725

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 hole for 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 (22 ml) of clean oil. Change the oil more fre­quently if the pump is operated continuously or in-

stalled 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 & REPAIRPAGE E − 16

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