Gorman-Rupp Pumps 810A2-F6L User Manual

ACE

OM−02754−06

August 22, 2005

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

80 SERIES PUMP

MODEL

810A2−F6L

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

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

www.grpumps.com

2005 The Gorman-Rupp Company

Register your new

Gorman-Rupp pump online at

www.grpumps.com

Valid serial number and e-mail address required.

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

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the
spaces provided below. Your Gorman-Rupp distributor
needs this information when you require parts or service.

Pump Model:

Serial Number:

TABLE OF CONTENTS

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

SAFETY − SECTION A PAGE A − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Sealing PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

FLOAT SWITCHES PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Bypass Lines PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

i

TABLE OF CONTENTS

(continued)

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

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

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

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

PARTS LISTS:

Pump Model PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump End Assembly PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Check Valve Removal PAGE E − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Disassembly PAGE E − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separating Intermediate And Drive Assembly From Engine PAGE E − 7. . . . . . . . . . . . . . . . . .

Shaft And Bearing Removal And Disassembly PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Reassembly And Installation PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing Intermediate And Drive Assembly To Engine PAGE E − 10. . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Installation PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Reassembly PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Check Valve Installation PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Pump Reassembly PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

80 SERIES

OM−02754

INTRODUCTION

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

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

This pump is an 80 Series, semi-open impeller, self­priming centrifugal model with a suction check
valve. The pump is designed for handling dirty wa­ter containing specified entrained solids. It is pow­ered by an air-cooled Deutz diesel engine. The ba­sic material of construction for all wetted parts is
gray iron.

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 ac­cording to all national, local and industry stan­dards.

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 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.

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901−1217

Phone: (419) 755−1011

or:

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631−2870

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

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

80 SERIES

OM−02754

SAFETY - SECTION A

This information applies to 80 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:

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

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.

This pump is designed to handle dirty
water containing specified entrained
solids. Do not attempt to pump volatile,
corrosive, or flammable liquids which

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.

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 completely before
servicing.

Do not operate an internal combustion

PAGE A − 1SAFETY

80 SERIESOM−02754

engine in an explosive atmosphere.
When operating an internal combustion
engine in an enclosed area, make sure
exhaust fumes are piped to the outside.
These fumes contain carbon monoxide,
a deadly gas that is colorless, tasteless
and odorless.

Pumps and related equipment must be in­stalled and operated according to all na­tional, local and industry standards.

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 run-

ning 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 1980
RPM.

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

PAGE A − 2 SAFETY

80 SERIES OM−02754

INSTALLATION − SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and 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 810A2−F6L

PAGE B − 1INSTALLATION

OM−02754 80 SERIES

PREINSTALLATION INSPECTION

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

a. Inspect the pump and engine for cracks,

dents, damaged threads, and other obvious
damage.

b. Check for and tighten loose attaching hard-

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

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties
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 engine have been stored for

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

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

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

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

POSITIONING PUMP

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.

Lifting

Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer-installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.

Battery Specifications And Installation

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

Table 1. Battery Specifications

Cold Reserve Approx.

Crank Capacity Amp/ Overall

Voltage

12 Volts 960-975 365 175 8.75W

PAGE B − 2 INSTALLATION

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.

80 SERIES OM−02754

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

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

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in­creased suction lift, discharge elevation, and fric­tion losses. See the performance curve on Page
E−1 to be sure your overall application allows
pump to operate within the safe operation range.

Materials

Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is
used in suction lines, it must be the rigid-wall, rein­forced type to prevent collapse under suction. Us­ing piping couplings in suction lines is not recom­mended.

Line Configuration

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

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 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.

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

Sealing

Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an 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.

PAGE B − 3INSTALLATION

OM−02754 80 SERIES

Suction Line Positioning

The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2 shows
recommended minimum submergence vs. veloc-

ity.

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

DISCHARGE LINES

Siphoning

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

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.

Valves

Bypass Lines

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

PAGE B − 4 INSTALLATION

If a system check valve is used due to high dis­charge head, it may be necessary to vent trapped
air from the top of the pump during the priming

80 SERIES OM−02754

process. This may be accomplished by installing a
bypass line from the top of the pump, back to the
source of liquid. The end of the bypass line must be
submerged. The line must be large enough to pre­vent clogging, but not so large as to affect pump
discharge capacity.

ALIGNMENT

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

bly To Engine for detailed information.

PAGE B − 5INSTALLATION

80 SERIES

OPERATION − SECTION C

Review all SAFETY information in Section A.

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

OM−02754

Never operate this pump unless there is
liquid in the pump casing. The pump will
not prime when dry. Extended operation of
a dry pump will destroy the seal assembly.

This pump is designed to handle dirty
water containing specified entrained
solids. Do not attempt to pump volatile,
corrosive, or flammable 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 1980
RPM.

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

PRIMING

Add liquid to the pump casing when:

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

2. The pump has not been used for a consider­able length of time.

3. The liquid in the pump casing has evapo­rated.

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

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

Install the pump and piping as described in IN-
STALLATION. Make sure that the piping connec­tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri­cated (see LUBRICATION in MAINTENANCE
AND REPAIR).

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

OPERATION PAGE C − 1

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

STARTING

If the pump is equipped with the option-

OM−02754

80 SERIES

al 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.

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

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

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

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.

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.

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.

Strainer Check

Lines Without a Bypass

Open all valves in the discharge line and start the
power source. Priming is indicated by a positive

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

OPERATIONPAGE C − 2

80 SERIES

OM−02754

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.

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.

After stopping the pump, switch off the engine igni­tion and disconnect the positive battery cable to
ensure that the pump will remain inoperative.

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.

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

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’.

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

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.

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 PAGE C − 3

OM−02754

80 SERIES

OPERATION IN EXTREME HEAT

The safety shutdown system will automatically
stop the unit if engine operating temperature ex­ceeds 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 temperatures is a
warning that the bearings are at the point of failing
to operate properly. Make certain that the bearing
lubricant is of the proper viscosity and at the cor­rect level (see LUBRICATION in Section E). Bear­ing overheating can also be caused by shaft
misalignment and/or excessive vibration.

When pumps are first started, the bearings may
seem to run at temperatures above normal. 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.

OPERATIONPAGE C − 4

TROUBLESHOOTING − SECTION D

Review all SAFETY information in Section A.

Before attempting to open or service the
pump:

1. Familiarize yourself with this manual.

2. Switch off 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.

OM−0275480 SERIES

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.

Suction check valve or foot valve
clogged or binding.

PUMP STOPS OR FAILS
TO DELIVER RATED
FLOW OR PRESSURE

Air leak in suction line.

Lining of suction hose collapsed.

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.

Repair priming device or check
installation.

Correct leak.

Replace suction hose.

Leaking or worn seal or pump gas­ket.

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

TROUBLESHOOTING PAGE D − 1

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

Check installation and correct sub­mergence as needed.

OM−02754 80 SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

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

PUMP REQUIRES TOO
MUCH POWER

PUMP CLOGS
FREQUENTLY

Strainer clogged.

Impeller or other wearing parts worn
or damaged.

Impeller clogged.

Suction lift too high.

Pump speed too slow.

Pump speed too high.

Discharge head too low.

Liquid solution too thick.

Bearing(s) frozen.

Discharge flow too slow.

Check strainer and clean if neces­sary.

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

Free impeller of debris.

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.

Disassemble pump and check bear­ing(s).

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

Suction check valve or foot valve
clogged or binding.

Discharge line clogged or restricted;
hose kinked.

EXCESSIVE NOISE Cavitation in pump.

Pumping entrained air.

Pump or drive not securely mounted.

Impeller clogged or damaged.

BEARINGS RUN TOO
HOT

Bearing temperature is high, but
within limits.

Low or incorrect lubricant.

Suction and discharge lines not
properly supported.

Clean valve.

Check discharge lines; straighten
hose.

Reduce suction lift and/or friction
losses in suction line. Record vacu­um and pressure gauge readings
and consult local representative or
factory.

Locate and eliminate source of air
bubble.

Secure mounting hardware.

Clean out debris; replace damaged
parts.

Check bearing temperature regularly
to monitor any increase.

Check for proper type and level of lu­bricant.

Check piping installation for proper
support.

Drive misaligned.

Align drive properly.

TROUBLESHOOTINGPAGE D − 2

OM−0275480 SERIES

PREVENTIVE MAINTENANCE

Since pump applications are seldom identical, and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
of the liquid being pumped, this section is intended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine 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

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.

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

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

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

Daily Weekly Monthly Semi-

Annually

Annually

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

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

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

TROUBLESHOOTING PAGE D − 3

80 SERIES

OM−02754

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 810A2−F6L

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

80 SERIESOM−02754

SECTION DRAWING

Figure 1. Pump Model 810A2−F6L

MAINTENANCE & REPAIRPAGE E − 2

80 SERIES

OM−02754

PARTS LIST

Pump Model 810A2−F6L

(From S/N 1479254 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
NO.

10 FUEL RETURN LINE 14294 24030 1
11 MUFFLER GUARD ASSY 42331−035 −−− 1
12 DEUTZ F6L ENGINE 29217−361 −−− 1
13 CAUTION DECAL 2613FJ −−− 1
14 POS BATTERY CABLE 47311−114 −−− 1
15 BATTERY BOX ASSY GRP40−08C −−− 1
16 −HEX HD CAPSCREW B0607 15991 2
17 −FLAT WASHER KE06 15991 2
18 −FLANGED HEX NUT 21765−314 −−− 2
19 −BATTERY BOX LID 42113−012 24150 1
20 −GROUND CABLE ASSY 47311−064 −−− 1
21 −12V BATTERY SEE OPTIONS LIST REF
22 −BATTERY TAG 38818−506 −−− 1
23 −BATTERY BOX 42431−030 24150 1
24 −FLANGED HEX NUT 21765−314 −−− 8
25 −T TYPE LOCKWASHER BL06 15991 1
26 −STUD MOUNT 24631−006 −−− 4
27 HEX HD CAPSCREW B0604 15991 10
28 FLAT WASHER K06 15991 10
29 FLANGED HEX NUT 21765−314 −−− 10
30 FUEL TANK/GRD ASSY 46711−041 −−− 1
31 −FLAT WASHER K06 15991 6
32 −CARRIAGE BOLT AB0604 15991 6

PART NAME PART

NUMBER

1 PUMP END ASSY 810A2−(F6L) −−− 1
2 EXHAUST ELBOW 31912−036 15210 1
3 WEATHER CAP S1387 −−− 1
4 CONTROL PANEL KIT 48122−526 −−− 1
5 HOISTING BAIL 13351BB 24000 1
6 4’ FUEL RETURN LINE 18513−302 −−− 1
7 HOSE CLAMP 26518−642 −−− 2
8 MALE CONNECTOR 26523−333 −−− 2
9 REDUCER ELBOW R04 11999 1

MAT’L
CODE

QTY ITEM

NOT SHOWN:

OPTIONAL:

PART NAME PART

NO.

33 −FLANGED HEX NUT 21765−314 −−− 6
34 −FUEL TANK 46711−042 24150 1
35 −TANK GUARD ASSY 34851−178 15080 1
36 HEX HD CAPSCREW B0816 15991 2
37 FLAT WASHER K08 15991 2
38 LOCKWASHER J08 15991 2
39 HEX NUT D08 15991 2
40 HOSE INLET ASSY 46341−803 −−− 1
41 MALE CONNECTOR S1447 −−− 1
42 HEX HD CAPSCREW B1006 15991 8
43 LOCKWASHER J10 15991 8
44 HEX NUT D10 15991 8
45 HEX HD CAPSCREW B0816 15991 2
46 FLAT WASHER K08 15991 2
47 LOCKWASHER J08 15991 2
48 HEX NUT D08 15991 2
49 COMBINATION BASE 41566−687 24150 1
50 HEX HD CAPSCREW B1209 15991 2
51 LOCKWASHER J12 15991 2
52 HEX NUT D12 15991 2

WARNING DECAL 2613FE −−− 1
ENGINE START-UP TAG 38816−269 −−− 1
STRAINER 3756 −−− 1

12V BATTERY 29331−506 −−− 1

WHEEL KIT GRP30−248F −−− 1
TRAILER JACK 29313−146 −−− 1
REPAIR MUFFLER
GUARD ASSY 42331−050 −−− 1

NUMBER

MAT’L
CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 3

SECTION DRAWING

80 SERIESOM−02754

Figure 2. Pump End Assembly 810A2−(F6L)

MAINTENANCE & REPAIRPAGE E − 4

80 SERIES

OM−02754

PARTS LIST

Pump End Assembly 810A2−(F6L)

ITEM
NO.

10 HEX NUT D14 15991 24
11 DISCH FLANGE GSKT 2751G 18000 2
12 CASING GASKET SET 48211−051 −−− 1

13 STUD C0809 15991 8
14 HEX NUT D08 15991 8
15 SEAL GREASE CUP S1509 −−− 1
16 PIPE COUPLING AE04 15079 1
17 HEAVY PIPE NIPPLE THA0412 15079 1
18 AIR VENT S1703 −−− 1
19 INTERMEDIATE 38263−718 10010 1
20 LOCKWASHER 21171−511 −−− 12
21 CAPSCREW 22645−164 −−− 12

22 BEARING GSKT SET 5413G 18000 1
23 HEX HD CAPSCREW B0604 15991 4
24 BEARING CAP 4185A 10010 1

25 IMPELLER SHAFT 38525−001 16040 1
26 DRIVE PLATE ASSY 24521−165 −−− 1
27 LOCKWASHER 21171−511 −−− 8
28 SOC HD CAPSCREW 22644−215 −−− 8

29 WAVY WASHER 23963−327 −−− 1
30 OIL SEAL 25258−622 −−− 1
31 OUTBOARD BEARING S1077 −−− 1

32 PEDESTAL DRAIN PLUG P06 15079 1
33 INBOARD BEARING 23421−461 −−− 1
34 OIL SEAL 25258−622 −−− 1
35 CASING DRAIN PLUG P24 10009 1
36 SEAL PLATE ASSY 42111−068 −−− 1

PART NAME PART

NUMBER

1 PUMP CASING 38224−704 10010 1
2 IMPELLER 38615−073 11010 1
3 SEAL ASSY GS1500 −−− 1
4 IMPELLER SHIM SET 5091 17090 REF

5 DISCHARGE STICKER 6588BJ −−− 1
6 FILL PLUG ASSY 48271−069 −−− 1
7 DISCHARGE FLANGE 2751 10010 1
8 FLANGED ELBOW S5016 −−− 1
9 HEX HD CAPSCREW B1414 15991 24

MAT’L
CODE

QTY ITEM

‘57 SIGHT GAUGE S1471 −−− 1

NOT SHOWN:

PART NAME PART

NO.

−SEAL LINER 7408 14010 REF

37 PIPE PLUG P24 10009 1
38 O-RING S1865 −−− 1
39 WEAR PLATE 38691−860 10010 1

40 STUD C0808 15991 3
41 LOCKWASHER J08 15991 3
42 HEX NUT D08 15991 3
43 CASING DRAIN PLUG P20 10009 1
44 CHECK VALVE SEAT 3286 10010 1

45 SUCT FLANGE GASKET 2751G 18000 1
46 STUD C1215 15991 12
47 HEX NUT D12 15991 12
48 SUCTION FLANGE 2751 10010 1
49 CHECK VALVE ASSY 3289 −−− 1
50 −VALVE WEIGHT 3287 10010 1
51 −HEX HD CAPSCREW B0605 17000 2
52 −LOCKWASHER J06 17000 2
53 −VALVE WEIGHT 3288 11000 1

54 −CHECK VALVE GSKT 3290 19080 1
55 PIPE PLUG P04 15079 1
56 PIPE NIPPLE T12 15079 1

58 PIPE COUPLING AE12 15079 1
59 INTERM GUARD 42381−506 24152 1
60 INTERM GUARD 42381−507 24152 1

STRAINER 3756 −−− 1
NAME PLATE 38818−024 13990 1
DRIVE SCREW BM#04−03 17000 4
G-R DECAL GR−06 −−− 1
LUBE DECAL 38816−079 −−− 1
INSTRUCTION TAG 38817−085 −−− 1
SUCTION STICKER 6588AG −−− 1
PRIMING STICKER 6588AH −−− 1
GREASE CUP INSTR 6588BD −−− 1

NUMBER

MAT’L
CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 5

80 SERIESOM−02754

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 and 2) and the
accompanying parts lists.

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 main-
tenance procedures are used, and that any proce­dures not addressed in this manual are performed
only after establishing that neither personal safety
nor pump integrity are compromised by such prac­tices.

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.

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.

Suction Check Valve Removal

(Figure 2)

Before attempting to service the pump, remove the
pump casing drain plug (43) and drain the pump.
Clean and reinstall the drain plug.

For access to the check valve (49), remove the suc­tion piping. Remove the nuts (47) and separate the
suction flange (48) and gasket (45) from the pump
casing (1). Replace the suction flange gasket as re­quired.

Pull the check valve seat (44) and check valve as­sembly from the suction port.

Inspect the check valve parts for wear or damage.
If replacement is required, remove the hardware
(51 and 52) and separate the check valve gasket
(54) and weights (50 and 53).

Pump Disassembly

(Figure 2)

To service the wear plate (39), impeller (2), or seal
assembly (3), the pump casing (1) must be sepa­rated from the base and intermediate (19). See Fig­ure 1 and remove the hardware (50, 51 and 52) se­curing the pump casing to the base (49).

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.

Tie and tag any leveling shims used under the
pump casing mounting feet to ease reassembly.

Support the pump casing using a suitable hoist
and sling. Remove the nuts (14) and separate the
pump casing and casing gasket set (12) from the
seal plate (36) and intermediate (19). Replace the
gasket set as required.

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

MAINTENANCE & REPAIRPAGE E − 6

OM−0275480 SERIES

to prevent injuries to personnel or dam­age to equipment. Suction and dis­charge hoses and piping must be re­moved from the pump before lifting.

For ease of reassembly, tie and tag the casing gas­ket set or measure and record their thickness.

Inspect the wear plate (39) and replace if scored or
worn. To remove the wear plate, disengage the
hardware (41 and 42) from the wear plate studs
(40) and pull the wear plate and O-ring (38) from
the pump casing. Remove the O-ring.

NOTE

Do not remove the impeller until the rotating assem­bly has been removed from the pump casing.

Impeller Removal

(Figure 2)

For ease of disassembly, the seal and seal plate
(36) may be removed as a single unit. Before at­tempting to remove the seal plate, remove the seal
cavity grease cup and piping (15, 16 and 17).

Remove the outer rotating element. Slide the seal
plate and seal parts off the shaft as a unit. Use cau­tion not to drop or damage the seal parts while slid­ing them off the shaft.

Carefully remove the outer stationary seat, packing
ring, seal washer and seal spring from the seal
plate. Remove the spacer sleeve, inner seal wash­er, packing ring, stationary seat and rotating ele­ment.

NOTE

An alternate method of removing the seal without
removing the seal plate is to remove the outer rotat­ing element, and use a stiff wire with a hooked end
to pull the remaining seal parts out of the seal plate.

Before removing the impeller, turn the cross arm on
the automatic lubricating grease cup (15) clock­wise until it rests against the cover (see Figure 5 in
LUBRICATION). This will prevent the grease in the
cup from escaping when the impeller is removed.

Use an impeller wrench to remove the impeller. If
an impeller wrench is not available, place a block of
wood against one of the vanes and strike it sharply
with a hammer. Be careful not to damage the
vane. Unscrew the impeller in a counterclockwise
direction (when facing the impeller). Use caution
when removing the impeller; tension on the seal
spring will be released as the impeller is un­screwed.

Inspect the impeller and replace it if cracked or
badly worn. Slide the impeller adjusting shims (4)
off the shaft (25). For ease of reassembly, tie and
tag the shims or measure and record their thick­ness.

Seal Removal

Inspect the seal liner for wear or grooves that could
cause leakage or damage to the seal packing
rings. The seal liner is secured by a press fit into the
seal plate and does not normally require replace­ment. If replacement is required, see Seal Installa-
tion.

If no further disassembly is required, refer to Seal

Installation.

Separating Intermediate And Drive Assembly
From Engine

(Figure 2)

If it is necessary to separate the intermediate and
drive assembly from the engine, support the inter­mediate using a suitable hoist and sling. Remove
the hardware (20 and 21) securing the intermedi­ate (19) and guards (59 and 60) to the engine bell­housing. Separate the assemblies by pulling
straight away from the engine.

(Figure 2)

Make certain that the cross arm on the grease cup
has been turned down against the cover before re­moving the seal assembly.

MAINTENANCE & REPAIR PAGE E − 7

It is not necessary to remove the drive plate assem­bly (26) from the engine flywheel unless replace­ment is necessary. To remove the drive plate as­sembly, remove the hardware (27 and 28) securing
it to the flywheel.

80 SERIESOM−02754

Shaft And Bearing Removal And Disassembly

(Figure 2)

When the pump is properly operated and main­tained, the shaft and bearings 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.

Before attempting to disassemble the intermedi­ate, remove the drain plug (32) and drain the inter­mediate. Clean and reinstall the drain plug.

Remove the hardware (23) and separate the bear­ing cap (24) and bearing gasket (22) from the inter­mediate.

Remove the wavy washer (29). Press the outboard
oil seal (30) from the bearing cap.

Place a block of wood against the impeller end of
the shaft (25) and tap the shaft and assembled
bearings out of the intermediate. Be careful not to
damage the shaft.

Place the intermediate on a level surface with the
drive end down and press the inboard oil seal (34)
from the intermediate bore.

in cleaning solvent. Inspect the parts for wear or
damage and replace as necessary.

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

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 balls. If rotation is
rough or the balls are discolored, replace the bear-

.

ings

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.

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

Shaft and Bearing Reassembly And Installation

(Figure 2)

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

To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and and
bearings are removed.

MAINTENANCE & REPAIRPAGE E − 8

OM−0275480 SERIES

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

The bearings (31 and 33) 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.

BALL LOADING
GROOVE POSITIONED
AWAY FROM IMPELLER

LOADING

GROOVE

DIRECTION OF

THRUST

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.

Use caution when handling hot bear­ings to prevent burns.

NOTE

Position the bearing (33) on the shaft as indicated
by the following illustrations.

BALL LOADING
GROOVE POSITIONED

TOWARD IMPELLER

LOADING
GROOVE

DIRECTION OF

THRUST

INSTALLATION OF NEW DEPARTURE OR

BCA/FEDERAL MOGAL 5300W SERIES BEARINGS

(OPEN OR ENCLOSED IMPELLERS)

Figure 3. Bearing Installation

After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
out of position in shrinking. If movement has oc­curred, use a suitably sized sleeve and a press to
reposition the bearings.

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

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

only on the inner race.

INSTALLATION OF MRC/SKF 5300M OR

FAFNIR 5300W SERIES BEARINGS

(OPEN OR ENCLOSED IMPELLERS)

Press the inboard oil seal (34) into the intermediate
(19) with the lip positioned as shown in Figure 2.

Slide the shaft and assembled bearings into the in­termediate bore from the drive end until the in­board bearing (33) is fully seated against the bore
shoulder. Be careful not to damage the oil seal lip
on the shaft threads.

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

Install the outboard oil seal (30) in the bearing cap
(24) with the lip positioned as shown in Figure 2.

MAINTENANCE & REPAIR PAGE E − 9

80 SERIESOM−02754

Slide the wavy washer (29) onto the shaft. Install
the bearing gasket (22) and secure it with the bear­ing cap and hardware (23).

Lubricate the bearings as indicated in LUBRICA-

TION at the end of this section.

Securing Intermediate And Drive Assembly To
Engine

(Figure 2)

If the drive plate assembly (26) was removed, se­cure it to the engine flywheel with the attaching
hardware (27 and 28).

Slide the splined end of the shaft (25) into the drive
plate. Position the intermediate (19) with the air
vent at the top. Secure the intermediate and
guards (59 and 60) to the engine bellhousing with
the hardware (20 and 21).

NOTE

Mount the intermediate guard (59) on the intermedi­ate so it is over the sight gauge (57).

Seal Reassembly and Installation

(Figures 2 and 4)

Slide the seal plate onto the shaft (25) and against
the intermediate (19). Align the lubrication hole in
the seal plate with the opening in the intermediate.
Temporarily secure the seal plate to the intermedi­ate using two capscrews and nuts (1/2 UNC by
1-1/2 inch long, not supplied).

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 pump casing, seal plate, seal liner and
the impeller shaft for burrs or sharp corners, and
remove any that exist. Replace the seal liner 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 (36)
on the bed of an arbor (or hydraulic) press and use
a new seal liner to press the old liner out. After the
new liner is properly installed, a 1/4-inch diameter
(6,35 mm) hole must be drilled through it to permit
the flow of lubricant to the seal assembly. Be care-
ful to center the drill in the threaded hole so not to
damage the threads in the pump casing. Deburr
the hole from the inside of the seal liner after drill­ing.

Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak­age. Clean and polish the seal spacer sleeve, or re­place it if there are nicks or cuts on either end. If any
components are worn, replace the complete seal;
never mix old and new seal parts.

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

To ease installation of the seal, lubricate the pack­ing rings and seal liner with water or a very small
amount of oil, and apply a drop of light lubricating
oil on the finished faces. Assemble the seal as fol­lows, (see Figure 4).

MAINTENANCE & REPAIRPAGE E − 10

OM−0275480 SERIES

PACKING
RINGS

IMPELLER SHAFT

IMPELLER

GREASE

CUP PIPING

SEAL
PLATE

SEAL

LINER

STATIONARY

SEAL SEATS

ROTATING
ELEMENTS

SPACER
SLEEVE

IMPELLER

SHIMS

SPRING
WASHER

Figure 4. GS1500 Seal Assembly

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

Slide the inboard rotating element onto the shaft
until the chamfered side seats against the shaft
shoulder.

Subassemble the inboard stationary seat, packing
ring and spring washer. Press this subassembly
into the lubricated seal liner. A push tube cut from a
length of plastic pipe would aid in this installation.
The O.D. of the pipe should be approximately the
same diameter as the O.D. of the seal spring.

SPRING

SPRING

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

Reinstall the automatic grease cup and piping (15,
16 and 17) in the seal plate. After the impeller has
been installed, lubricate the seal as indicated in

LUBRICATION.

Impeller Installation

(Figure 2)

Inspect the impeller (2), and replace it if cracked or
badly worn. Install the same thickness of impeller
shims (4) as previously removed and screw the im­peller onto the shaft until tight.

WASHER

Install the spacer sleeve and spring.

The shaft and impeller threads must be
completely clean before reinstalling the im-

Subassemble the outboard stationary seat, pack­ing ring and spring washer. Press this subassem­bly into the lubricated seal liner.

MAINTENANCE & REPAIR PAGE E − 11

peller. Even the slightest amount of dirt on
the threads can cause the impeller to seize
to the shaft, making future removal difficult

80 SERIESOM−02754

or impossible without damage to the im­peller or shaft.

A clearance of .020 to .040 inch (0,51 to 1,02 mm)
between the impeller and the seal plate is recom­mended for maximum pump efficiency. Measure
this clearance and add or subtract impeller shims
until it is reached.

NOTE

The seal plate must be tight against the intermedi­ate while setting the back impeller clearance.

Pump Reassembly

(Figure 2)

If the wear plate (39) was removed for replace­ment, install the O-ring (38) and secure the re­placement wear plate to the pump casing with the
hardware (41 and 42).

Remove the two capscrews temporarily securing
the seal plate, and install the same thickness of
pump casing gaskets (12) as previously removed.
Secure the pump casing to the intermediate with
the nuts (14).

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 can be obtained by removing gaskets
from the casing gasket set until the impeller binds
against the wear plate when the shaft is turned. Af­ter the impeller binds, add .015 inch (0,38 mm) of
gaskets.

Suction Check Valve Installation

(Figure 2)

Inspect the check valve components and replace
them as required. Subassemble the check valve
weights (50 and 53) and gasket (54) using the at­taching hardware (51 and 52).

Secure the check valve assembly (49), valve seat
(44), suction flange gasket (45) and suction flange
(48) to the suction port with the nuts (47).

Check the operation of the check valve to ensure
proper seating and free movement.

Final Pump Reassembly

(Figure 1)

Be sure the pump and intermediate are secure to

the engine and the base.

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

NOTE

If the discharge elbow (8, Figure 2) was removed,
install the hardware (9, Figure 2) on the underside
of the elbow in the pump casing.

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

Before starting the pump, fill the pump casing with
clean liquid. Reinstall the fill plug and tighten. (see

OPERATION, Section C).

NOTE

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

See Figure 1 and reinstall any leveling shims used
under the pump casing mounting feet and secure
the casing to the base (49) with the hardware (50,
51 and 52).

LUBRICATION

Seal Assembly

(Figure 2)

Fill the grease cup (15) through the grease fitting
with No. 2 lithium base grease until grease es­capes from the relief hole. Turn the grease cup arm
counterclockwise until it is at the top of the stem;
this will release the spring to apply grease to the
seal (see Figure 5).

MAINTENANCE & REPAIRPAGE E − 12

OM−0275480 SERIES

POSITION

WHEN

EMPTY

POSITION

FOR

FILLING

GREASE

FITTING

NOTE:

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

CROSS

ARM

RELIEF

HOLE

Figure 5. Automatic Lubricating Grease Cup

POSITION

WHEN

IN USE

Bearings

(Figure 2)

The intermediate was fully lubricated when
shipped from the factory. Check the oil level regu­larly through the sight gauge (57) and maintain it at
the middle of the gauge. When lubrication is re­quired, add SAE No. 30 non-detergent oil through
the hole for the air vent (18). Do not over-lubricate.
Over-lubrication can cause the bearings to over­heat, resulting in premature bearing failure.

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

Monitor the condition of the bearing lubri­cant regularly for evidence of rust or mois­ture condensation. This is especially im­portant in areas where variable hot and
cold temperatures are common.

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

Engine

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

MAINTENANCE & REPAIR PAGE E − 13

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty

or call:

U.S.: 419−755−1280

International: +1−419−755−1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty

or call:

519−631−2870

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

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