Page 1
OM-02164-01
April 9, 1984
Rev. D 08‐30‐13
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
80 SERIES PUMP
MODEL
81 1/2P47A-E2 1P
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
1984 The Gorman‐Rupp Company
Page 2
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the
spaces provided below. Your Gorman‐Rupp distributor
needs this information when you require parts or service.
Pump Model:
Serial Number:
Page 3
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................
Materials PAGE B - 2..............................................................
Line Configuration PAGE B - 2......................................................
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 - 3.................................................
Suction Line Positioning PAGE B - 4................................................
DISCHARGE LINES PAGE B - 5........................................................
Siphoning PAGE B - 5.............................................................
Valves PAGE B - 5................................................................
Bypass Lines PAGE B - 5..........................................................
ELECTRICAL CONNECTIONS PAGE B - 5...............................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
OPERATION PAGE C - 2..............................................................
Lines With a Bypass PAGE C - 2....................................................
Lines Without a Bypass PAGE C - 2.................................................
Leakage PAGE C - 2..............................................................
Liquid Temperature And Overheating PAGE C - 2.....................................
Strainer Check PAGE C - 2.........................................................
Pump Vacuum Check PAGE C - 2..................................................
STOPPING PAGE C - 3................................................................
Cold Weather Preservation PAGE C - 3..............................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
STANDARD PERFORMANCE CURVE PAGE E - 1........................................
PARTS LIST:
Pump Model PAGE E - 3..........................................................
i
Page 4
TABLE OF CONTENTS
(continued)
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 4.........................
Pump Casing and Vane Plate Removal PAGE E - 4...................................
Impeller Removal PAGE E - 4......................................................
Seal Removal PAGE E - 5..........................................................
Seal Reassembly and Installation PAGE E - 5........................................
Impeller Installation PAGE E - 6.....................................................
Vane Plate and Pump Casing Installation PAGE E - 7..................................
Final Pump Assembly PAGE E - 7..................................................
LUBRICATION PAGE E - 7.............................................................
Seal Assembly PAGE E - 7.........................................................
ii
Page 5
80 SERIES
OM-02164
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, self‐
priming centrifugal model without a suction check
valve. It is close‐coupled to a 2 H.P., single phase,
totally enclosed, fan‐cooled electric motor. The ba
sic material of construction for wetted parts is fiber
glass reinforced polyester (Valox grade 420).
The pump is designed for handling water and most
water‐soluable herbicides and pesticides, as well
as certain chemicals and waste solutions within
specified temperatures and concentrations. Con
sult the factory for information about your specific
application or for a copy of our chemical compati
bility guide. This pump is not recommended for
handling volatile or flammable liquids.
For information or technical assistance on the mo
tor, contact the motor manufacturer's local dealer
or representative.
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
The following are used to alert maintenance per
sonnel to procedures which require special atten
tion, to those which could damage equipment, and
to those which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re
quired and the injury which will result
from failure to follow the procedure.
This manual will alert personnel to known proce
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel. However,
this manual cannot possibly anticipate and provide
detailed precautions for every situation that might
occur during maintenance of the unit. Therefore, it
is the responsibility of the owner/maintenance per
sonnel to ensure that only safe, established main
tenance procedures are used, and that any proce
dures not addressed in this manual are performed
only after establishing that neither personal safety
nor pump integrity are compromised by such prac
tices.
If there are any questions regarding the pump or
its application which are not covered in this man
ual or in other literature accompanying this unit,
please contact your Gorman‐Rupp distributor, or:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
or:
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
Hazards or unsafe practices which COULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi
ble damage which could result from failure
to follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
Page 6
80 SERIES
OM-02164
SAFETY ‐ SECTION A
This information applies to 80 Series
electric motor driven pumps. Refer to
the manual accompanying the motor
before attempting to begin operation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre
cautions for each specific application.
Therefore, it is the owner/installer's re
sponsibility to ensure that applications
not addressed in this manual are per
formed only after establishing that nei
ther operator safety nor pump integrity
are compromised by the installation.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Disconnect the incoming power to
the motor and lock it out to ensure
that the pump will remain inopera
tive.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
fied temperatures and concentrations.
Do not attempt to pump volatile or flam
mable materials which may damage the
pump or endanger personnel as a result
of pump failure.
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.
Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed dis
charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.
This pump is designed to handle materi
als which could cause illness or injury
through direct exposure or emitted
fumes. Wear protective clothing, such
as rubber gloves, face mask and rubber
apron, as necessary, before discon
necting or servicing the pump or piping.
This pump is designed to handle water
and most water‐soluable herbicides
and pesticides, as well as certain chem
icals and waste solutions within speci
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to cool before servicing.
PAGE A - 1SAFETY
Page 7
80 SERIESOM-02164
Do not install and operate a non‐explo
sion proof motor in an explosive atmo
sphere. Install, connect, and operate
the motor in accordance with the Na
tional Electric Code and all local codes.
If there is a conflict between the instruc
tions in the manual accompanying the
unit and the National Electric Code or
the applicable local code, the National
or local code shall take precedence.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a qu
alified electrician to troubleshoot, test
and/or service the electrical compo
nents of this pump.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.
PAGE A - 2 SAFETY
Page 8
80 SERIES OM-02164
INSTALLATION - SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and ar
range the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is positioned
above the free level of liquid to be pumped.
If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
configuration, and priming must be tailored to the
OUTLINE DRAWING
specific application. Since the pressure supplied
to the pump is critical to performance and safety,
be sure to limit the incoming pressure to 50% of the
maximum permissible operating pressure as
shown on the pump performance curve (see Sec
tion E, Page 1).
For further assistance, contact your Gorman‐Rupp
distributor or the Gorman‐Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimen
sions of this pump.
Figure 1. Pump Model 81 1/2P47A-E2 1P
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation,
inspect the pump for damage which may have oc
curred during shipment. Check as follows:
a. Inspect the pump and motor 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
Page 9
OM-02164 80 SERIES
ing, check for loose hardware at mating sur
faces.
c. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties
indicated.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per
form duties as instructed.
e. If the pump and
more than 12 months, some of the compo
nents or lubricants may have exceeded their
maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv
ice.
motor have been stored for
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a qu
alified electrician to troubleshoot, test
and/or service the electrical compo
nents of this pump.
The pump assembly can be seriously
damaged if the chains or cables used to lift
and move the unit are improperly wrapped
around the pump.
The pump casing, flanges and seal plate
are made of fiberglass‐reinforced polyes
ter, which can crack under impact or
shock. Take every precaution against
dropping the pump or striking pump com
ponents.
Mounting
Locate the pump in an accessible place as close as
practical to the liquid being pumped. Level mount
ing is essential for proper operation.
The pump may have to be supported or shimmed
to provide for level operation or to eliminate vibra
tion.
SUCTION AND DISCHARGE PIPING
If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman‐Rupp distributor or the factory to deter
mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
POSITIONING PUMP
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.
PAGE B - 2 INSTALLATION
Pump performance is adversely effected by in
creased suction lift, discharge elevation, and fric
tion losses. See the performance curve on Page
E‐1 to be sure your overall application allows pump
to operate within the safe operation range.
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is
used in suction lines, it must be the rigid‐wall, rein
forced type to prevent collapse under suction. Us
ing piping couplings in suction lines is not recom
mended.
Line Configuration
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini
mum use of elbows and fittings, which substan
Page 10
80 SERIES OM-02164
tially increase friction loss. If elbows are necessary,
use the long‐radius type to minimize friction loss.
Flexible connectors are required on suction and
discharge connections in order to prevent piping
loads.
The suction and discharge lines must be
supported and connected to the pump
with flexible connectors in order to prevent
piping loads. The pump warranty will be
voided if flexible connectors are not
used.
Connections to Pump
Before tightening a connecting flange, align it ex
actly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or cou
plings.
Lines near the pump must be independently sup
ported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose‐type
lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.
Gauges
slopes down to the pump at any point along the
suction run, air pockets will be created.
The suction line should not exceed 20 feet (6 me
ters) in length.
Fittings
The use of plastic fittings to connect suction and
discharge lines to the pump is recommended. Use
a good grade of pipe sealant on the threads of the
fittings. Draw the fittings up hand tight, then give
them one full turn with a wrench.
Suction lines should be the same size as the pump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be in
stalled with the flat part of the reducers uppermost
to avoid creating air pockets. Valves are not nor
mally used in suction lines, but if a valve is used,
install it with the stem horizontal to avoid air pock
ets.
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.
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 prim
ing, the suction line must be as short and direct as
possible. When operation involves a suction lift, the
line must always slope upward to the pump from
the source of the liquid being pumped; if the line
This pump is designed to handle up to 9/16 inch
(14,3 mm) diameter spherical solids.
Sealing
Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an air
tight seal. Follow the sealant manufacturer's rec
ommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.
Suction Lines In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
PAGE B - 3INSTALLATION
Page 11
OM-02164 80 SERIES
sump at a distance equal to 1‐1/2 times the diame
ter of the suction line
If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc
tion inlet because the inflow will carry air down into
the sump, and air entering the suction line will re
duce pump efficiency.
If it is necessary to position inflow close to the suc
tion inlet, install a baffle between the inflow and the
suction inlet at a distance 1‐1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a dis
tance equal to at least 3 times the diameter of the
suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation.
recommended minimum submergence vs. veloc
ity.
Figure 2 shows
NOTE
The pipe submergence required may be reduced
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
PAGE B - 4 INSTALLATION
Page 12
80 SERIES OM-02164
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a si
phon breaker is used in the line. Otherwise, a si
phoning action causing damage to the pump
could result.
Valves
A check valve in the discharge line is normally rec
ommended, but it is not necessary in low dis
charge head applications.
If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize
friction losses. Never install a throttling valve in a
suction line.
With high discharge heads, it is recommended that
a throttling valve and a system check valve be in
stalled in the discharge line to protect the pump
from excessive shock pressure and reverse rota
tion when it is stopped.
process. This may be accomplished by installing a
bypass line from the top of the pump, back to the
source of liquid. The end of the bypass line must be
submerged. The line must be large enough to pre
vent clogging, but not so large as to affect pump
discharge capacity.
ELECTRICAL CONNECTIONS
Before connecting the motor to the incoming
power, check that the electrical service available
matches the pump motor requirements stamped
on the motor nameplate.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a qu
alified electrician to make all electrical
connections.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
Bypass Lines
If a system check valve is used due to high dis
charge head, it may be necessary to vent trapped
air from the top of the pump during the priming
MODEL
81 1/2P47A-E2 1P 2
VOLTAGE PHASE HP Hz RPM F.L. AMPS
115/230 1 60 3450 20.0/10.0
Do not install and operate a non‐explo
sion proof motor in an explosive atmo
sphere. Install, connect, and operate
the motor in accordance with The Na
tional Electric Code and all local codes.
If there is a conflict between the instruc
tions in the manual accompanying the
unit and The National Electric Code or
the applicable local code, The National
or local code shall take precedence.
Refer to the following motor data before making
electrical connections.
PAGE B - 5INSTALLATION
Page 13
80 SERIES
OM-02164
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to the pump.
This pump is designed to handle water
and most water‐soluable herbicides
and pesticides, as well as certain chem
icals and waste solutions within speci
fied temperatures and concentrations.
Do not attempt to pump volatile or flam
mable materials which may damage the
pump or endanger personnel as a result
of pump failure.
Do not install and operate a non‐explo
sion proof motor in an explosive atmo
sphere. Install, connect, and operate
the motor in accordance with the Na
tional Electric Code and all local codes.
If there is a conflict between the instruc
tions in the manual accompanying the
unit and the National Electric Code or
the applicable local code, the National
or local code shall take precedence.
Pump speed and operating condition
points must be within the continuous per
formance range shown on the curve (see
Section E, Page 1).
PRIMING
cated (see LUBRICATION in MAINTENANCE
AND REPAIR).
This pump is self‐priming, but the pump should
never be operated unless there is liquid in the
pump casing.
Never operate this pump unless there is
liquid in the pump casing. The pump will
not prime when dry. Extended operation of
a dry pump will destroy the seal assembly.
Add liquid to the pump casing when:
1. The pump is being put into service for the
first time.
2. The pump has not been used for a consider
able length of time.
3. The liquid in the pump casing has evapo
rated.
Once the pump casing has been filled, the pump
will prime and reprime as necessary.
After filling the pump casing, reinstall
and tighten the fill plug. Do not attempt
to operate the pump unless all connect
ing piping is securely installed. Other
wise, liquid in the pump forced out un
der pressure could cause injury to per
sonnel.
This pump is not equipped with a plug for filling the
pump casing. To fill the pump, remove the dis
charge line and add approximately 1 gallon (3,8 li
ters) of clean liquid. Reconnect the discharge line
and proceed with pump operation.
Install the pump and piping as described in IN
STALLATION. Make sure that the piping connec
tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri
OPERATION PAGE C - 1
STARTING
Consult the operations manual furnished with the
motor.
Page 14
OM-02164 80 SERIES
OPERATION
Lines With a Bypass
Close the discharge throttling valve (if so
equipped) so that the pump will not have to prime
against the weight of the liquid in the discharge
line. Air from the suction line will be discharged
through the bypass line back to the wet well during
the priming cycle. When the pump is fully primed
and liquid is flowing steadily from the bypass line,
open the discharge throttling valve. Liquid will then
continue to circulate through the bypass line while
the pump is in operation.
Lines Without a Bypass
Open all valves in the discharge line and start the
motor. Priming is indicated by a positive reading on
the discharge pressure gauge or by a quieter op
eration. The pump may not prime immediately be
cause the suction line must first fill with liquid. If the
pump fails to prime within five minutes, stop it and
check the suction line for leaks.
After the pump has been primed, partially close the
discharge line throttling valve in order to fill the line
slowly and guard against excessive shock pres
sure which could damage pipe ends, gaskets,
sprinkler heads, and any other fixtures connected
to the line. When the discharge line is completely
filled, adjust the throttling valve to the required flow
rate.
ture 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 over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to cool before servicing.
Strainer Check
If a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been in
stalled, monitor and record the readings regularly
to detect strainer blockage.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
could result in personal injury or damage to the
equipment. If backflushing is absolutely neces
sary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve (see Section E,
Page 1).
Pump Vacuum Check
Leakage
No leakage should be visible at pump mating sur
faces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maxi
mum pump efficiency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160 F (71C). Do not apply it at a higher operating
temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup
Since this pump does not have a suction check
valve, the discharge line must be fitted with a check
valve if a pump vacuum reading is to be taken.
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads.
Block the suction line and start the pump. At oper
ating speed the pump should pull a vacuum of 20
inches (508 mm) or more of mercury. If it does not,
check for air leaks in the seal, gasket, or discharge
valve.
Open the suction line, and read the vacuum gauge
with the pump primed and at operation speed.
Shut off the pump. The vacuum gauge reading will
immediately drop proportionate to static suction
lift, and should then stabilize. If the vacuum reading
OPERATIONPAGE C - 2
Page 15
80 SERIES
OM-02164
falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check
the point of installation of the vacuum gauge.
STOPPING
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
After stopping the pump, disconnect the incoming
power to the motor and lock it out to ensure that the
pump will remain inoperative.
Cold Weather Preservation
In below freezing conditions, drain the pump to
prevent damage from freezing. Also, clean out any
solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotat
ing parts.
If the pump will be idle for more than a few hours, or
if it has been pumping liquids containing a large
amount of solids, drain the pump, and flush it thor
oughly 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 sol
ids by flushing with a hose.
OPERATION PAGE C - 3
Page 16
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
2. Disconnect the incoming power to
the motor and lock it out to ensure
that the pump will remain inoperative.
3. Allow the pump to completely cool if
overheated.
4. Check the temperature before open
ing any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
OM-0216480 SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO
PRIME
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
Not enough liquid in casing. Add liquid to casing. See PRIMING.
Suction check valve contaminated or
damaged.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
Suction lift or discharge head too high. Check piping installation and install
Strainer clogged. Check strainer and clean if neces
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Suction intake not submerged at
proper level or sump too small.
Impeller or other wearing parts worn
or damaged.
Clean or replace check valve.
leaking or worn seal or gasket.
bypass line if needed. See INSTAL
LATION.
sary.
Check installation and correct
submergence as needed.
Replace worn or damaged parts.
Check that impeller is properly
centered and rotates freely.
TROUBLESHOOTING PAGE D - 1
Page 17
OM-02164 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
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leaking or worn seal or gasket.
Free impeller of debris.Impeller clogged.
Low or incorrect voltage. Measure control box voltage, both
when pump is running and when
shut off.
No voltage at line side of circuit
breaker.
Suction lift or discharge head too high. Check piping installation and install
Motor shaft or bearings defective. Disassemble pump and check mo
Discharge head too low.
Discharge flow too slow.
Suction check valve or foot valve
clogged or binding.
Check power source for blown fuse,
open circuit breaker or control box,
broken lead, or loose connection.
bypass line if needed. See INSTAL
LATION.
tor and bearings.
Adjust discharge valve.
Dilute if possible.Liquid solution too thick.
Open discharge valve fully to in
crease flow rate, and run motor at
maximum governed speed.
Clean valve.
EXCESSIVE NOISE Cavitation in pump. Reduce suction lift and/or friction
losses in suction line. Record vac
uum and pressure gauge readings
and consult local representative or
factory.
Pumping entrained air.
Impeller clogged or damaged. Clean out debris; replace damaged
Locate and eliminate source of air
bubble.
Secure mounting hardware.Pump or drive not securely mounted.
parts.
TROUBLESHOOTINGPAGE D - 2
Page 18
OM-0216480 SERIES
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
of the liquid being pumped, this section is intended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine pre
ventive maintenance schedule will help assure
trouble‐free performance and long life from your
Gorman‐Rupp pump. For specific questions con
cerning your application, contact your Gorman‐
Rupp distributor or the Gorman‐Rupp Company.
Record keeping is an essential component of a
good preventive maintenance program. Changes
in suction and discharge gauge readings (if so
equipped) between regularly scheduled inspec
tions can indicate problems that can be corrected
before system damage or catastrophic failure oc
curs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same
duty cycle, the part can be checked and replaced
before failure occurs, reducing unscheduled down
time.
For new applications, a first inspection of wearing
parts at 250 hours will give insight into the wear rate
for your particular application. Subsequent inspec
tions should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.
Preventive Maintenance Schedule
Service Interval*
Item
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearing Lubrication I R
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V‐Belts (If So Equipped) I
Air Release Valve Plunger Rod (If So Equipped) I C
Front Impeller Clearance (Wear Plate) I
Rear Impeller Clearance (Seal Plate) I
Check Valve I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Bearings I
Bearing Housing I
Piping I
Driver Lubrication - See Mfgr's Literature
Daily Weekly Monthly Semi‐
Annually
Annually
Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
TROUBLESHOOTING PAGE D - 3
Page 19
80 SERIES OM-02164
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 81 1/2P47A-E2 1P
Based on 70F (21C) clear water at sea level
with minimum suction lift. Since pump installations
are seldom identical, your performance may be dif
ferent due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.
Pump speed and operating condition
points must be within the continuous per
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 per
formance or part numbers.
MAINTENANCE & REPAIR PAGE E - 1
formance range shown on the curve. Use
caution not ot overload the motor when
handling liquids with a specific gravity
greater than 1.0.
Page 20
PARTS PAGE
80 SERIESOM-02164
SECTION DRAWING
Figure 1. Pump Model 81 1/2P47A-E2 1P
MAINTENANCE & REPAIRPAGE E - 2
Page 21
80 SERIES OM-02164
PARTS LIST
Pump Model 81 1/2P47A-E2 1P
(From S/N 801799 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.
1 PUMP CASING 38231-401 23200 1
2 IMPELLER 38617-703 23200 1
3 SEAL ASSEMBLY 25271-412 --- 1
4 IMPELLER KEY N0302-1/2 17000 1
5 O‐RING 25152-363 --- 1
6 TAP SCREW 21287-596 --- 2
7 HEX HD CAPSCREW B0503S 17000 4
8 FLAT WASHER KB05 17000 4
9 MOTOR, 2 H.P., 1P 28156-560 --- 1
10 SPACER 31133-114 15030 1
11 INTERMEDIATE 38264-213 23200 1
12 IMP ADJ SHIM SET 48261-032 --- 1
13 O‐RING 25152-010 --- 1
14 HEX HD CAPSCREW B0405 17000 10
15 HEAVY NYLOCK NUT 21765-146 --- 10
16 RD HD MACH SCREW X0403S 17000 1
17 VANE PLATE 38632-507 23200 1
18 VANE PLATE O‐RING 25152-134 --- 1
19 PIPE PLUG 26471-003 --- 1
20 FLOW GUIDE O‐RING 25152-155 --- 1
21 FLOW GUIDE 38354-018 23200 1
22 TAP SCREW 21287-584 --- 2
23 NAME PLATE 38812-052 --- 1
24 WARNING DECAL 38816-091 --- 1
NOT SHOWN:
OPTIONAL:
PART NAME
STRAINER 26841-007 --- 1
WARNING DECAL 2613FE --- 1
WARNING DECAL 2613FF --- 1
G‐R DECAL GR-02 --- 1
ROTATION DECAL 2613M --- 1
INSTRUCTION TAG 38817-029 --- 1
SUCTION STICKER 6588AG --- 1
DISCHARGE STICKER 6588BJ --- 1
SUCTION NIPPLE 26523-303 --- 1
DISCHARGE ELBOW 26525-202 --- 1
REPAIR KIT (INCLUDES ALL ITEMS ABOVE) 48221-019 --- 1
PART
NUMBER
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 3
Page 22
80 SERIESOM-02165
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de
cals attached to the pump.
This pump requires little service due to its rugged,
minimum‐maintenance design. However, if it be
comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional view (see Figure 1) and the accompa
nying parts list.
This manual will alert personnel to known proce
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel. However,
this manual cannot possibly anticipate and provide
detailed precautions for every situation that might
occur during maintenance of the unit. Therefore, it
is the responsibility of the owner/maintenance per
sonnel to ensure that only safe, established main
tenance procedures are used, and that any proce
dures not addressed in this manual are performed
only after establishing that neither personal safety
nor pump integrity are compromised by such prac
tices.
Before attempting to service the pump, disconnect
incoming power to the motor and lock it out to en
sure that it will remain inoperative. Close all valves
in the suction and discharge lines.
For motor disassembly and repair, consult the lit
erature supplied with the motor, or contact your lo
cal motor 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 cau
tiously.
7. Drain the pump.
This pump is designed to handle materi
als which could cause illness or injury
through direct exposure or emitted
fumes. Wear protective clothing, such
as rubber gloves, face mask and rubber
apron, as necessary, before discon
necting or servicing the pump or piping.
Pump Casing and Vane Plate Removal
Before attempting to service the pump, remove the
pump casing drain plug (25) and drain the pump.
Clean the drain plug and wrap the threads with
PTFE thread tape before reinstallation.
To service the impeller (2), vane plate (17) or seal
assembly (3), disconnect the suction and dis
charge piping.
Remove the capscrews and nuts (14 and 15) and
self‐tapping screws (6) securing the pump casing
(1) to the intermediate (11). Remove the pump cas
ing by pulling straight away.
The flow guide (21) rarely requires removal or re
placement, but if replacement is necessary, disen
gage the self‐tapping screws. Pull the flow guide
out of the pump casing and remove the O‐ring (20).
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Disconnect the incoming power to
the motor and lock it out to ensure
that the pump will remain inopera
tive.
3. Allow the pump to completely cool
if overheated.
Pull the vane plate off of the alignment pins on the
intermediate. Remove the vane plate and casing
O‐rings (5 and 18).
Impeller Removal
Insert a large screwdriver in the slot in the end of
the motor shaft to prevent shaft rotation. Remove
the impeller screw and O‐ring (13 and 16) and pull
the impeller off the shaft; retain the impeller key (4).
MAINTENANCE & REPAIRPAGE E - 4
Page 23
OM-0216580 SERIES
Inspect the impeller and replace it if cracked or
badly worn. Slide the impeller adjusting shims (12)
off the impeller shaft. Tie and tag the shims, or
measure and record their thickness for ease of
reassembly.
Seal Removal
(Figures 1 and 2)
To remove the seal assembly (3), remove the rotat
ing seat and element from the impeller cavity. Use a
pair of stiff wires with hooked ends if necessary.
NOTE
The stationary portion of the seal assembly is se
cured in the intermediate bore with “Loctite 30516
Aviation Gasket Sealant”. The seal cage can be
damaged during removal; only remove the station
ary seal components if replacement is required.
flammable. Use them only in a well‐ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
The seal is not normally reused because wear pat
terns on the finished faces cannot be realigned
during reassembly. This could result in premature
failure. If necessary to reuse an old seal in an emer
gency, carefully wash all metallic parts in fresh
cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non‐oil based solvent and a clean, lint‐free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
Pry the remainder of the seal components from the
intermediate as a unit. If the intermeidate is re
moved, the seal components can be pressed our
from the back of the intermediate.
To remove the intermediate, disengage the hard
ware (7 and 8) securing it to the motor (9).
Seal Reassembly and Installation
(Figures 1 and 2)
Clean the seal cavity and shaft with a cloth soaked
in fresh cleaning solvent.
Most cleaning solvents are toxic and
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
age. Clean and polish the seal area of the shaft.
Small nicks and burrs can be removed using a fine
file or emery cloth. If any components are worn, re
place 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 seal
area of the shaft 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 2).
MAINTENANCE & REPAIR PAGE E - 5
Page 24
80 SERIESOM-02165
IMPELLER
IMPELLER
KEY
ROTATING
ELEMENT
ROTATING
SEAT
BELLOWS
SPRING
STATIONARY
ELEMENT
INTERMEDIATE
IMPELLER
SHAFT
RETAINER
Figure 3. Seal Assembly
This seal is not designed for operation at
temperatures above 160F (71C). Do not
use at higher operating temperatures.
When pressing the stationary seal components
into the intermediate, use hand pressure only. A
push tube cut from a length of plastic pipe will aid in
this installation. The I.D. of the push tube should be
just large enough to slide over the stationary ele
ment and seat against the shoulder on the seal re
tainer.
Clean all of the old aviation gasket sealant from the
intermediate bore before attempting to install the
stationary seal components.
If removed at disassembly, slide the intermediate
(11) over the shaft and spacer (10).
mounting flange pointed down. Secure the inter
mediate to the motor (9) with the hardware 97 and
8). Torque the capscrews (7) alternately to 55 in.
lbs. (6,3 m. kg.).
Apply a small amount of “Loctite 30516 Aviation
Gasket Sealant” or equivalent compound to the
O.D. of the seal retainer and carefully press this as
sembly into the bore of the intermediate until fully
seated. Clean any residual aviation cement off of
the seal retainer and intermediate.
Apply a drop of water or light oil on the seal face of
the stationary elment; never use grease.
Subassemble the rotating element into the rotating
seat. Apply a small amount of light oil to the O.D. of
the rotating seat and press this assembly into the
impeller until fully seated.
Impeller Installation
The intermediate is offset and not concentric to the
shaft; be sure to position the intermediate against
the motor with the drain holes in the neck of the
Inspect the impeller, and replace it if cracked or
badly worn. Install the same thickness of impeller
shims (14) as previously removed. Install the im
MAINTENANCE & REPAIRPAGE E - 6
Page 25
OM-0216580 SERIES
peller key (4) and slide the impeller onto the shaft,
taking care not to damage the sealing elements.
Install a new impeller O‐ring (13). Insert a large
screwdriver in the slot in the end of the motor shaft
to prevent shaft rotation. Install the impeller screw
(16) to 15 to 20 in. lbs. (1,7 to 2,3 m. kg.).
The vane plate (17) will seat properly in
only one position; do not try to force the
vane plate onto the intermediate alignment
pins.
A clearance of .008 to .015 inch ( 0,30 to 0,38 mm)
between the impeller and the vane plate (17) is
necessary for maximum pump efficiency. Position
the vane plate over the impeller and the alignment
pins on the intermediate. The vane plate will seat
properly in only one position; do not try to force the
vane plate onto the intermediate alignment pins.
flow guide to the pump casing (1) by torquing the
self‐tapping screws (22) in an alternating pattern to
8 to 10 ft. lbs. (0,9 to 1,1 m. kg.).
Install the vane plate O‐ring (18) and the pump cas
ing O‐ring (5). Position the vane plate over the im
peller and the alignment pins on the intermediate.
Check impeller‐to‐vane plate clearance as de
scribed in Impeller Installation.
Carefully slide the pump casing over the vane plate
and secure it to the intermediate by torquing the
self‐tapping screws (6) in an alternating pattern to
15 to 20 in. lbs. (1,7 to 2,3 m. kg.).
Install the capscrews and nuts (14 and 15) and
torque them in an alternating pattern to 20 to 25 in.
lbs. (2,3 to 2,9 m. kg.).
Final Pump Assembly
Be sure the pump and motor are securely
mounted to the base.
Use a feeler gauge to measure this clearance. Add
or remove impeller shims until the proper clear
ance is achieved.
Vane Plate and Pump Casing Installation
Follow all torque recommendations when
securing the pump hardware. Over‐tight
ening can cause pump components to
crack or threads to strip.
If the flow guide (21) was removed at disassembly,
install a new flow guide O‐ring (20) and secure the
Install the suction and discharge lines and open all
valves. Make certain that all piping connections are
tight, properly supported and secure.
Fill the pump casing with clean liquid.
Refer to OPERATION, Section C, before putting
the pump back into service.
LUBRICATION
Seal Assembly
The seal assembly is lubricated by the medium be
ing pumped. No additional lubrication is required.
MAINTENANCE & REPAIR PAGE E - 7
Page 26
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
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