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.