Page 1
ACE
OM-06413-01
April 6, 2011
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
80 SERIES PUMPS
MODEL
86A2-4024H
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2011 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.
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:
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............................................
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 - 3................................................
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................................................................
Starting PAGE C - 2...............................................................
OPERATION PAGE C - 2..............................................................
Lines With a Bypass PAGE C - 2....................................................
Lines Without a Bypass PAGE C - 2.................................................
Leakage PAGE C - 3..............................................................
Liquid Temperature And Overheating PAGE C - 3.....................................
Strainer Check PAGE C - 3.........................................................
Pump Vacuum Check PAGE C - 3..................................................
STOPPING PAGE C - 3................................................................
Stopping PAGE C - 3..............................................................
Safety Shutdown System PAGE C - 4...............................................
OPERATION IN EXTREME HEAT PAGE C - 4............................................
BEARING TEMPERATURE CHECK PAGE C - 4..........................................
Cold Weather Preservation PAGE C - 5..............................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
i
Page 4
TABLE OF CONTENTS
(continued)
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...................................................
Drive Assembly PAGE E - 6........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 7.........................
Suction Check Valve Removal PAGE E - 7...........................................
Separating Pump And Intermediate From Engine PAGE E - 7..........................
Loosening Impeller PAGE E - 8.....................................................
Pump Casing and Wear Plate Removal PAGE E - 8...................................
Impeller Removal PAGE E - 9......................................................
Seal Removal PAGE E - 9..........................................................
Shaft and Bearing Removal and Disassembly PAGE E - 9.............................
Shaft and Bearing Reassembly and Installation PAGE E - 10............................
Seal Reassembly and Installation PAGE E - 11........................................
Impeller Installation PAGE E - 13.....................................................
Securing Intermediate And Drive Assembly To Engine PAGE E - 13......................
Pump Casing and Wear Plate Installation PAGE E - 14.................................
Suction Check Valve Installation PAGE E - 14.........................................
Final Pump Reassembly PAGE E - 14................................................
LUBRICATION PAGE E - 15.............................................................
Seal Assembly PAGE E - 15.........................................................
Bearings PAGE E - 15..............................................................
Engine PAGE E - 15................................................................
ii
Page 5
80 SERIES
OM-06413
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 with a suction check
valve. The pump is designed to be close‐coupled
to a four cylinder John Deere diesel engine.
The pump is designed for handling most non‐vola
tile, non‐flammable liquids containing specified en
trained solids. The basic material of construction
for all wetted parts is gray iron and steel.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility 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 com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
For information or technical assistance on the en
gine, contact the engine manufacturer's local
dealer or representative.
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.
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.
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 The
Gorman‐Rupp Company:
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
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-06413
SAFETY - SECTION A
This information applies to 80 Series
Engine Driven pumps. Refer to the man
ual accompanying the engine before at
tempting 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. 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 cau
tiously.
7. Drain the pump.
sive, or flammable materials, or any liq
uids which may damage the pump or en
danger 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 dam
age to equipment. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting.
After the pump has been positioned,
make certain that the pump and all pip
ing or hose connections are tight, prop
erly supported and secure before oper
ation.
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 most
non‐volatile, non‐flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corro
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 completely cool before
servicing.
PAGE A - 1SAFETY
Page 7
80 SERIESOM-06413
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make cer
tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color
less, tasteless, and odorless.
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 2100
RPM.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.
Allow an over‐heated pump to com
pletely cool before servicing. Do not re
move plates, covers, gauges, or fittings
from an over‐heated pump. Liquid with
in the pump can reach boiling tempera
tures, and vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump completely cools, drain the
liquid from the pump by removing the
casing drain plug. Use caution when re
moving the plug to prevent injury to per
sonnel from hot liquid.
Fuel used by internal combustion en
gines 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.
PAGE A - 2 SAFETY
Page 8
80 SERIES OM-06413
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
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. 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.
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 86A2-4024H
PAGE B - 1INSTALLATION
Page 9
OM-06413 80 SERIES
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 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 dry
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.
Table 1. Battery Specifications
Cold Reserve Approx.
Crank Capacity Amp/ Overall
Voltage
12 Volts 960‐975 365 175 8.75W
Refer to the information accompanying the battery
and/or electrolyte solution for activation and charg
ing instructions.
Before installing the battery, clean the positive and
negative cable connectors, and the battery termi
nals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corro
sion. Connect and tighten the positive cable first,
then the negative cable.
Amps @80°F Hr. Dims.
@ 0°F (Minutes) Rating (Inches)
20.5L
x
x
9.75H
POSITIONING PUMP
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 end has been stored for more than
12 months, some of the components or lubri
cants may have exceeded their maximum
shelf life. These must be inspected or re
placed 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 deter
mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
Battery Specifications And Installation
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Suction and dis
charge hoses and piping must be re
moved 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.
Unless otherwise specified on the pump order, the
engine battery was not included with the unit. Re
fer to the following specifications when selecting a
battery.
PAGE B - 2 INSTALLATION
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.
Page 10
80 SERIES OM-06413
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.
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 attempt
ing 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 opera
tion. 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.
Clearance
When positioning the pump, allow a minimum
clearance of 18 inches (457 mm) in front of the
back cover to permit removal of the cover and easy
access to the pump interior.
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
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
SUCTION AND DISCHARGE PIPING
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
tially increase friction loss. If elbows are necessary,
use the long‐radius type to minimize friction loss.
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
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 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.
PAGE B - 3INSTALLATION
Page 11
OM-06413 80 SERIES
Strainers
If a strainer is furnished with the pump, be certain
to use it; any spherical solids which pass through a
strainer furnished with the pump will also pass
through the pump itself.
If a strainer is not furnished with the pump, but is
installed by the pump user, make certain that the
total area of the openings in the strainer is at least
three or four times the cross section of the suction
line, and that the openings will not permit passage
of solids larger than the solids handling capability
of the pump.
This pump is designed to handle up to 1‐15/16 inch
(49,21 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 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-06413
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
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.
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
process. This may be accomplished by installing a
bypass line from the top of the pump, back to the
source of liquid. The end of the bypass line must be
submerged. The line must be large enough to pre
vent clogging, but not so large as to affect pump
discharge capacity.
ALIGNMENT
The alignment of the pump and engine are critical
for trouble‐free performance. See Section E, Se
curing Intermediate And Drive Assembly To En
gine in MAINTENANCE AND REPAIR, for details.
PAGE B - 5INSTALLATION
Page 13
80 SERIES
OM-06413
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to the pump.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make cer
tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color
less, tasteless, and odorless.
This pump is designed to handle most
non‐volatile, non‐flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corro
sive, or flammable materials, or any liq
uids which may damage the pump or en
danger personnel as a result of pump
failure.
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.
When installed in a flooded suction application,
simply open the system valves and permit the in
coming liquid to evacuate the air. After the pump
and piping system have completely filled, evacu
ate any remaining air pockets in the pump or suc
tion line by loosening pipe plug or opening bleeder
valves.
Once the pump casing has been filled, the pump
will prime and reprime as necessary.
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 2100
RPM.
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
PRIMING
wise, liquid in the pump forced out un
der pressure could cause injury to per
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
sonnel.
To fill the pump, remove the pump casing fill cover
or fill plug in the top of the casing, and add clean
Page 14
OM-06413 80 SERIES
liquid until the casing is filled. Replace the fill cover
or fill plug before operating the pump.
NOTE
This pump is self‐priming; however, it is not suited
for unattended reprime applications. In the event of
suction check valve failure and loss of prime, the
pump casing must be refilled through the fill cover
or fill plug.
STARTING
Consult the operations manual furnished with the
engine.
Starting
On initial start‐up, set the engine speed at the half‐
throttle position. Turn the keyswitch on the control
panel to “RUN” and press the “ENTER” button on
the engine control panel.
After the engine starts and the unit is fully primed,
adjust the engine RPM until the desired flow rate is
achieved.
If the bypass line is open, air from the suction line
will be discharged through the bypass line back to
the wet well during the priming cycle. 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
power source. Priming is indicated by a positive
reading on the discharge pressure gauge or by a
quieter operation. The pump may not prime imme
diately 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 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.
Pump speed and operating condition
points must be within the continuous per
formance range shown on the curve on
page E‐1.
OPERATION
Pump speed and operating condition
points must be within the continuous per
formance range shown on the curve. (See
Section E, Page 1.)
Lines With a Bypass
If a Gorman‐Rupp Automatic Air Release Valve has
been installed, the valve will automatically open to
allow the pump to prime, and automatically close
after priming is complete (see INSTALLATION for
Air Release Valve operation).
Do not operate the pump against a
closed discharge throttling valve for
long periods of time. If operated against
a closed discharge throttling valve,
pump components will deteriorate, and
the liquid could come to a boil, build
pressure, and cause the pump casing to
rupture or explode.
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
110 F (43C). 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
OPERATIONPAGE C - 2
Page 15
80 SERIES
OM-06413
boil, build pressure, and cause the pump to rup
ture or explode. If overheating occurs, stop the
pump and allow it to cool before servicing it. Refill
the pump casing with cool liquid.
Allow an over‐heated pump to com
pletely cool before servicing. Do not re
move plates, covers, gauges, or fittings
from an over‐heated pump. Liquid with
in the pump can reach boiling tempera
tures, and vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump completey cools, drain the
liquid from the pump by removing the
casing drain plug. Use caution when re
moving the plug to prevent injury to per
sonnel from hot liquid.
Strainer Check
If a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been in
stalled, monitor and record the readings regularly
to detect strainer blockage.
Open the suction line, and read the vacuum gauge
with the pump primed and at operation speed.
Shut off the pump. The vacuum gauge reading will
immediately drop proportionate to static suction
lift, and should then stabilize. If the vacuum reading
falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check
the point of installation of the vacuum gauge.
STOPPING
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
On engine driven pumps, reduce the throttle
speed slowly and allow the engine to idle briefly be
fore stopping.
Stopping
Reduce the throttle speed slowly, and allow the en
gine to idle briefly before turning the keyswitch to
`OFF'.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
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.) If the pump is fitted with a Gorman‐Rupp
double grease lubricated seal, the maximum in
coming pressure must be reduced to 10 p.s.i.
Pump Vacuum Check
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads.
Block the suction line and start the pump. At oper
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.
OPERATION PAGE C - 3
After stopping the pump, close and lock the control
panel cover, or disconnect the positive battery
cable to ensure that the pump will remain inopera
tive.
Safety Shutdown System
The unit is equipped with a safety system to auto
matically shut down the engine under certain con
ditions. The engine will automatically shut down:
1. If the engine exceeds its safe operating tem
perature.
2. If the engine oil pressure drops below design
limits.
3. If the engine fails to start within a pre‐set peri
od of time.
4. If the engine speed exceeds the safe operat
ing range.
Page 16
OM-06413 80 SERIES
Lights on the control panel will indicate which of the
safety features has caused the engine to shut
down.
Should any of the safety features cause the engine
to shut down, the cause must be determined and
corrected before putting the unit back into service.
The engine will not restart until the keyswitch has
been returned to the `OFF' position for at least 10
seconds.
All safety shutdown features are pre‐set at the fac
tory for optimum performance and safety; do not
attempt to adjust these settings.
Never disconnect any of the safety shut
down features; this will void the warran
ty and could result in serious damage to
the unit and/or injury to personnel. Safe
ty 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 ad
ditional information.
low shorter run and longer cooling periods, if pos
sible.
BEARING TEMPERATURE CHECK
Bearings normally run at higher than ambient tem
peratures because of heat generated by friction.
Temperatures up to 160F (71C) are considered
normal for bearings, and they can operate safely to
at least 180F (82C).
Checking bearing temperatures by hand is inaccu
rate. Bearing temperatures can be measured ac
curately 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 cor
rect level (see LUBRICATION in Section E). Bear
ing 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. Con
tinued operation should bring the temperatures
down to normal levels.
OPERATION IN EXTREME HEAT
The safety shutdown system will automatically
stop the unit if engine operating temperature ex
ceeds design limits. If engine over‐temperature
shutdown occurs, allow the unit to completely 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 al
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 con
taining 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 pre
venting 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
Page 17
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Switch off engine ignition and dis
connect the positive battery cable
to ensure that the pump will re
main 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 cau
tiously.
7. Drain the pump.
OM-0641380 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.
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.
Air leak in suction line.
Lining of suction hose collapsed.
Leaking or worn seal or pump gasket.
Strainer clogged.
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 by
pass line if needed. See INSTALLA
TION.
Check strainer and clean if necessary.
Correct leak.
Replace suction hose.
Check pump vacuum. Replace leak
ing or worn seal or gasket.
Check strainer and clean if neces
sary.
TROUBLESHOOTING PAGE D - 1
Page 18
OM-06413 80 SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP STOPS OR FAILS
TO DELIVER RATED
FLOW OR PRESSURE
(cont.)
Suction intake not submerged at
proper level or sump too small.
Impeller or other wearing parts worn
or damaged.
Check installation and correct sub
mergence as needed.
Replace worn or damaged parts.
Check that impeller is properly cen
tered and rotates freely.
PUMP REQUIRES TOO
MUCH POWER
PUMP CLOGS
FREQUENTLY
Impeller clogged.
Discharge head too high.
Suction lift too high.
Pump speed too slow.
Pump speed too high.
Discharge head too low.
Liquid solution too thick.
Bearing(s) frozen.
Discharge flow too slow.
Liquid solution too thick.
Discharge line clogged or re
stricted; hose kinked.
Free impeller of debris.
Install bypass line.
Measure lift w/vacuum gauge. Re
duce lift and/or friction losses in suc
tion 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 in
crease flow rate, and run engine at
maximum governed speed.
Dilute if possible.
Check discharge lines; straighten
hose.
Suction check valve or foot valve
clogged or binding.
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.
Drive misaligned.
Clean valve.
Reduce suction lift and/or friction
losses in suction line. Record vacu
um 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 regular
ly to monitor any increase.
Check for proper type and level of
lubricant.
Check piping installation for proper
support.
Align drive properly.
TROUBLESHOOTINGPAGE D - 2
Page 19
OM-0641380 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 20
80 SERIES OM-06413
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 86A2-4024H
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.
Contact the Gorman‐Rupp Company to verify per
formance 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 per
formance range shown on the curve.
Page 21
PARTS PAGE
80 SERIESOM-06413
SECTION DRAWING
Figure 1. Pump Model 86A2-4024H
MAINTENANCE & REPAIRPAGE E - 2
Page 22
80 SERIES OM-06413
PARTS LIST
Pump Model 86A2-4024H
(From S/N 1535998 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 END ASSY 46124-405 --- 1
2 POWER UNIT KIT 46143-128 --- 1
3 BATTERY SEE OPTIONS --- 1
4 PUMP MOUNTING KIT 48157-030 --- 1
NOT SHOWN:
OPTIONAL:
INDICATES PARTS RECOMMENDED FOR STOCK
PART NAME
G‐R DECAL GR-06 --- 1
CAUTION DECAL 2613FJ --- 1
WARNING DECAL 2613FE --- 1
STRAINER S2278 --- 1
BATTERY 29331-517 --- 1
PART
NUMBER
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 3
Page 23
SECTION DRAWING
80 SERIESOM-06413
NOTE: Generic John Deere Engine Shown
Figure 2. 46143-128 John Deere Power Unit Kit
PARTS LIST
ITEM
NO.
10 NEG. CABLE 47311-134 --- 1
11 OIL DRAIN ASSY 46342-031 --- 1
12 POS. BATTERY CABLE 47311-113 --- 1
PART NAME PART
NUMBER
1 JD 4024H ENGINE 29224-401 --- 1
2 BASE/FUEL TANK 41553-005 24150 1
3 LIFTING BAIL 48274-803 --- 1
4 MUFFLER GUARD NOT USED --5 MALE ELBOW 26351-131 --- 1
6 CONNECTOR S1447 --- 2
7 HOSE ASSEMBLY 46341-789 --- 1
8 CONTROL PANEL 48122-553 --- 1
9 BATTERY BOX KIT 42432-005 --- 1
MAT'L
CODE
QTY ITEM
NOT SHOWN:
PART NAME PART
NO.
13 FUEL PICKUP 29332-145 --- 2
14 FUEL GAUGE 29332-135 --- 1
15 HOSE BARB FITTING 26523-386 --- 2
16 HOSE 11308G --- 1
17 HOSE CLAMP 26518-641 --- 2
18 HEX HD CAPSCREW B1007 15991 4
19 HEX NUT D10 15991 4
20 LOCK WASHER J10 15991 4
21 FLAT WASHER K10 15991 4
ENGINE STARTUP TAG 38816-269 --- 1
FUEL DECAL 38816-196 --- 1
NUMBER
MAINTENANCE & REPAIRPAGE E - 4
MAT'L
CODE
QTY
Page 24
80 SERIES OM-06413
SECTION DRAWING
Figure 3. 46124-405 Pump End Assembly
MAINTENANCE & REPAIR PAGE E - 5
Page 25
PARTS LIST
46124-405 Pump End Assembly
80 SERIESOM-06413
ITEM
NO.
10 DISCHARGE FLANGE 1758 10010 1
11 DISCH FLANGE GSKT 1679G 18000 1
12 FILL PLUG ASSY 48271-069 --- 1
13 IMP ADJ SHIM SET 37J 17090 REF
14 SEAL LINER 2205 14080 REF
15 SEAL WASHER 3349 15990 1
16 HVY PIPE NIPPLE THA0416 15079 1
17 PIPE COUPLING AE04 15079 1
18 GREASE CUP S1509 --- 1
19 GREASE CUP INSTR 6588BD --- 1
20 GREASE CUP S35 --- 1
21 INTERMEDIATE BRKT 36 10010 1
22 HEX HD CAPSCREW B0604 15991 4
23 LOCKWASHER J06 15991 4
24 IMP SHAFT 45 15010 1
25 IMP SHAFT KEY N0607 15990 1
26 BEARING CUP S1086 --- 1
27 BEARING CONE S1087 --- 1
28 BEARING CAP 43X 10010 1
29 INTERMED GUARD 42381-031 24150 2
30 BEARING SHIM SET S114 --- 1
31 BEARING CUP S1086 --- 1
32 BEARING CONE S1087 --- 1
33 BEARING CLOSURE 44 10010 1
PART NAME PART
NUMBER
1 PUMP CASING 7267 10010 1
2 IMPELLER 2521B 10010 1
3 SEAL ASSEMBLY GS1250 --- 1
4 PRIMING STICKER 6588AH --- 1
5 DISCHARGE ELBOW R96 11990 1
6 PIPE NIPPLE T96 15070 1
7 DISCHARGE STICKER 6588BJ --- 1
8 STUD C1211 15991 8
9 HEX NUT D12 15991 8
INDICATES PARTS RECOMMENDED FOR STOCK
MAT'L
CODE
QTY ITEM
NOT SHOWN:
PART NAME PART
NO.
34 STUD C0809 15991 8
35 HEX NUT D08 15991 8
36 SEAL PLATE ASSY 2546 10010 1
37 CASING GSKT SET 34G 18000 1
38 WEAR PLATE 7269A 10010 1
39 STUD C0808 15991 2
40 HEX NUT D08 15991 2
41 LOCKWASHER J08 15991 2
42 CASING DRAIN PLUG P20 10009 1
43 SUCT FLANGE GSKT 1679G 18000 1
44 SUCTION FLANGE 1758 10010 1
45 STUD C1215 15991 8
46 HEX NUT D12 15991 8
47 SUCTION STICKER 6588AG --- 1
48 RD HD MACH SCREW X0404 17090 2
49 CHECK VALVE ASSY 7265 --- 1
50 -HEX HD CAPSCREW B0403 17000 2
51 -LOCKWASHER J04 17090 2
52 -VALVE WEIGHT 7263 15990 1
53 -CHECK VALVE GSKT 7264 19070 1
54 -VALVE WEIGHT 7262 24000 1
55 CHECK VALVE SEAT 7261 10010 1
56 CHCK VLV SEAT GSKT 7261G 18000 1
57 PIPE PLUG P04 15079 1
58 NAME PLATE 38818-024 13990 1
59 DRIVE SCREW BM#04-03 17000 4
STRAINER S2278 --- 1
DRIVE ASSEMBLY 44162-119 --- 1
INSTRUCTION TAG 38817-085 --- 1
LUBE DECAL 38816-075 --- 1
WARNING DECAL 2613FE --- 1
G‐R DECAL GR-06 --- 1
NUMBER
MAT'L
CODE
QTY
MAINTENANCE & REPAIRPAGE E - 6
Page 26
80 SERIES OM-06413
SECTION DRAWING
Figure 4. 84A2-(SAE 4/10) Drive Assembly
ITEM
NO.
1 COUPLING KIT 48112-001 --- 1
2 -BUSHING 24131-345 --- 1
3 -COUPLING ASSEMBLY 44165-011 --- 1
4 SOCKET HD CAPSCREW BD0606-1/2 15991 8
4 SOCKET HD CAPSCREW 22644-220 --- 8
5 LOCKWASHER J06 15991 8
5 LOCKWASHER 21171-536 --- 8
6 HEX HD CAPSCREW B0605 15991 12
6 HEX HD CAPSCREW 22645-164 --- 12
7 LOCKWASHER J06 15991 12
7 LOCKWASHER 21171-511 --- 12
MAINTENANCE & REPAIR PAGE E - 7
PART NAME
USE FOR SAE APPLICATIONS
USE FOR METRIC APPLICATIONS
PART
NUMBER
MAT'L
CODE
QTY
Page 27
80 SERIESOM-06413
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 illustrations (see Figures 1 through 4) and the
accompanying parts lists.
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, shut down
the engine and disconnect the positive battery
cable to ensure that the pump will remain inopera
tive. Close all valves in the suction and discharge
lines.
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.
Suction Check Valve Removal
(Figure 2)
Before attempting to service the pump, remove the
pump casing drain plug (42) and drain the pump.
Clean and reinstall the drain plug.
For access to the check valve, remove the suction
piping. Remove the nuts (46) and separate the
suction flange and gasket (43 and 44) from the
pump casing (1). Replace the suction flange gas
ket as required.
Disengage the machine screws (48) and pull the
check valve seat (55), gasket (56) and check valve
assembly (49) from the suction port.
Inspect the check valve parts for wear or damage.
If replacement is required, remove the hardware
(50 and 51) and separate the check valve gasket
(53) and weights (52 and 54).
Separating Pump and Intermediate from
Engine
For engine disassembly and repair, consult the lit
erature supplied with the engine, or contact your
local engine representative.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Shut down the engine and discon
nect the positive battery cable to
ensure that the pump will remain
inoperative.
(Figure 4)
If the impeller or seal assembly require replace
ment, the pump end and drive assembly must be
separated from the engine.
Support the pump using a suitable hoist and sling.
Remove the hardware securing the pump casing
to the base.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Suction and dis
MAINTENANCE & REPAIRPAGE E - 8
Page 28
OM-0641380 SERIES
charge hoses and piping must be re
moved from the pump before lifting.
Disengage the hardware (6 and 7) securing the
drive assembly to the intermediate. Separate the
pump end and drive assembly from the engine by
pulling the pump end straight away from the en
gine.
As the assemblies separate, the flexible portion of
the coupling assembly (3) will remain on the shaft.
To remove the coupling from the shaft, unscrew the
two allen head setscrews from the bushing (2).
Screw one of the setscrews into the puller hole on
the circumference of the bushing. As the coupling
and bushing separate, remove the bushing, and
slide the coupling off the shaft. Remove the shaft
key (25, Figure 2).
It is not necessary to remove the outer ring of the
coupling from the engine flywheel unless the cou
pling must be replaced. To remove the ring, disen
gage the hardware (4 and 5) securing it to the fly
wheel.
Remove any leveling shims used under the casing
mounting feet. Tie and tag the shims for ease of
reassembly.
shaft (24) with the “V” notch positioned over the
shaft key.
With the impeller rotation still blocked, see Figure 5
and use a long piece of heavy bar stock to pry
against the arm of the lathe dog in a counterclock
wise direction (when facing the drive end of the
shaft). Use caution not to damage the shaft or key
way. When the impeller breaks loose, remove the
lathe dog, key and wood block.
NOTE
Do not remove the impeller until the rotating assem
bly has been removed from the pump casing.
Turn
Counterclockwise
Lathe Dog Arm
“V” Notch
Heavy
Bar Stock
Shaft Key
Impeller
Shaft
Lathe Dog
Move the pump end to a clean, well equipped shop
area for further disassembly.
Figure 5. Loosening Impeller
Loosening Impeller
(Figures 3 and 5)
Before loosening the impeller, turn the cross arm
on the automatic lubricating grease cup (18) clock
wise until it rests against the cover (see Figure 6 in
LUBRICATION). This will prevent the grease in the
cup from escaping when the impeller is removed.
Reach through the suction port and wedge a block
of wood between the vanes of the impeller and the
pump casing to prevent rotation.
If removed, install the shaft key (25) in the shaft
keyway. Install a lathe dog on the drive end of the
MAINTENANCE & REPAIR PAGE E - 9
Pump Casing and Wear Plate Removal
(Figure 3)
To service the impeller (2), seal assembly (3) or the
seal plate (36), the pump casing must be sepa
rated from the base and intermediate (21). See Fig
ure 1 and remove the hardware securing the pump
casing (1) to the base.
To ease reassembly, tie and tag any leveling shims
used under the pump casing mounting feet.
Support the pump casing using a suitable hoist
and sling, and disengage the hardware (35) secur
ing the pump casing to the seal plate (36) and inter
mediate (21). Separate the pump casing and gas
ket set (37) from the seal plate and the intermedi
Setscrew
Page 29
80 SERIESOM-06413
ate. Replace the gasket set as required. For ease of
reassembly, tie and tag the gaskets or measure
and record their thickness.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting.
Inspect the wear plate (38), and replace if scored or
worn. To remove the wear plate, disengage the
hardware (40 and 41) from the wear plate studs,
and pull the wear plate from the pump casing.
Impeller Removal
(Figure 3)
For ease of disassembly, the seal and seal plate
(36) may be removed as a single unit. Before at
tempting to remove the seal plate, remove the au
tomatic grease cup and piping (16, 17 and 18).
Slide the seal washer (15) off the shaft. Remove the
outer rotating element. Slide the seal plate, spacer
sleeve, and remaining seal parts off the shaft as a
unit.
Carefully remove the spacer sleeve, outer station
ary seat, rotating element, packing ring and seal
spring from the seal plate. Remove the inner seal
washer, packing ring, stationary seat and rotating
element.
Inspect the seal liner (14) for wear or grooves that
could cause leakage or damage to the seal pack
ing rings. The seal liner is secured by a press fit into
the seal plate and does not normally require re
placement. If replacement is required, see Seal In
stallation.
If no further disassembly is required, refer to Seal
Installation.
Before removing the impeller, turn the cross arm on
the automatic lubricating grease cup (18) clock
wise until it rests against the cover (see Figure 7 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 (2).
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 counterclock
wise direction (when facing the impeller). Use cau
tion when removing the impeller; tension on the
seal spring will be released as the impeller is un
screwed.
Inspect the impeller and replace it if cracked or
badly worn. Slide the impeller adjusting shims (13)
off the shaft. For ease of reassembly, tie and tag the
shims or measure and record their thickness.
Seal Removal
(Figure 3)
Make certain that the cross arm on the grease cup
has been turned down against the cover before re
moving the seal assembly.
Shaft and Bearing Removal and Disassembly
(Figure 3)
When the pump is properly operated and main
tained, the intermediate should not require disas
sembly. 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.
Disengage the hardware (22 and 23), and remove
the bearing cap (28) and shims (30). Tie and tag
the bearing shims, or measure and record their
thickness for ease of reassembly.
Place a block of wood against the impeller end of
the shaft (24), and tap the shaft and assembled
bearings from the intermediate. Be careful not to
damage the shaft.
NOTE
There are no provisions for draining the grease
MAINTENANCE & REPAIRPAGE E - 10
Page 30
OM-0641380 SERIES
from the intermediate cavity. Place a drip pan under
the intermediate before removing the shaft and
bearings.
Remove the outboard bearing cup (26) from the
bearing cone (27).
Place the intermediate on a level surface with the
drive side down, and press the bearing closure
(33) and inboard bearing cup (31) from the inter
mediate bore.
After removing the shaft and bearings, clean and
inspect the bearings in place as follows.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bear
ings are removed.
Clean the intermediate, shaft and all component
parts (except the bearings) with a soft cloth soaked
in cleaning solvent. Inspect the parts for wear or
damage and replace as necessary.
bearings. This may scratch the rollers or
races, and cause premature bearing fail
ure.
Rotate the bearings by hand to check for rough
ness or binding and inspect the bearing rollers. If
rotation is rough or the rollers are discolored, re
place the bearings.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the bearing
housing. Replace the bearing cups or cones, the
shaft, or intermediate if the proper bearing fit is not
achieved.
If bearing replacement is required, use a bearing
puller to remove the inboard and outboard bearing
cones (27 and 32) from the shaft.
Shaft and Bearing Reassembly and Installation
(Figure 3)
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.
Clean and inspect the bearings as indicated in
Shaft And Bearing Removal And Disassembly.
To prevent damage during removal from
Most cleaning solvents are toxic and
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.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bear
ings are removed.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bear
ings 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
Bearings must be kept free of all dirt and
foreign material. Failure to do so will great
the oil has been previously used, it must be thor
oughly filtered.
ly shorten bearing life. Do not spin dry
MAINTENANCE & REPAIR PAGE E - 11
Page 31
80 SERIESOM-06413
Heat the bearings to a uniform temperature no
higher than 250 F (120 C), and slide the in
board and outboard bearing cones onto the shaft
with the high side of the tapered roller bearings to
ward the lubrication cavity. This should be done
quickly, in one continuous motion, to prevent the
bearings from cooling and sticking on the shaft.
After the bearing cones have been installed and al
lowed to cool, check to ensure that they have not
moved away from the shaft shoulders in shrinking.
If movement has occurred, use a suitably sized
sleeve and a press to reposition the bearings
against the shaft shoulders.
If heating the bearings is not practical, use a suit
ably sized sleeve, and an arbor (or hydraulic) press
to install the bearing cones on the shaft.
When installing the bearings onto the
shaft, never press or hit against the rollers
or roll cage. Press only on the inner race.
Pack the bearing cups and cones with No. 0 lithium
base grease.
Press the bearing closure (33) and inboard bearing
cup (31) into the intermediate until seated squarely
against the intermediate shoulder.
When installing the bearing cups into the
bearing bore, push against the outer race.
Never hit the rollers or roll cage.
Slide the shaft and assembled bearing cones into
the intermediate bore until the inboard bearing
cone (32) fully engages the inboard bearing cup.
Press the outboard bearing cup (26) over the out
board bearing cone (27).
Install the same thickness of bearing adjusting
shims (30) as previously remove, and secure them
with the bearing cap (28) and hardware (22 and
23).
NOTE
Shaft endplay should be between .003 and .005
inch (0,08 to 0,13mm). Add or remove bearing
shims to establish the correct endplay.
Lubricate the bearings as indicated in LUBRICA
TION at the end of this section.
Seal Reassembly and Installation
(Figures 3 and 6)
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 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.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
age. Clean and polish the seal spacer sleeve, or re
place 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 pack
ing rings and seal liner with water or a very small
MAINTENANCE & REPAIRPAGE E - 12
Page 32
OM-0641380 SERIES
amount of oil, and apply a drop of light lubricating
oil on the finished faces. Assemble the seal as fol
PACKING
RINGS
SEAL
WASHER
IMPELLER SHAFT
IMPELLER
SHIMS
SPRING
STATIONARY
WASHERS
GREASE
PIPING
CUP
lows, (see Figure 6).
SEAL
PLATE
SEAL
LINERIMPELLER
STATIONARY
SEAL SEATS
ROTATING
ELEMENTS
SPACER
SLEEVE
Figure 6. GS1250 Seal Assembly
This seal is not designed for operation at
temperatures above 110F (43C). Do not
use at higher operating temperatures.
Inspect the intermediate (21), seal liner (14) and
impeller shaft for burrs or sharp corners, and re
move any that exist. Replace the seal liner if wear or
grooves exist which could cause leakage or dam
age to the seal packing rings.
To replace the seal liner, position the seal plate (14)
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
(6,4 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 drill
ing.
Slide the seal plate onto the shaft until fully seated
against the intermediate. Align the threaded seal
lubricant hole with the intermediate opening, and
temporarily secure the seal plate to the intermedi
ate with two capscrews and nuts (1/2 UNC by 1 1/2
inch long, not supplied).
Position the inboard rotating element on the shaft
with the chamfered side facing the spacer washer,
and slide it on until fully seated.
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 this installation.
The O.D. of the pipe should be approximately the
same diameter as the O.D. of the seal spring.
Install the spacer sleeve and spring.
Subassemble the outboard stationary seat, pack
ing ring and spring washer. Press this subassem
bly into the lubricated seal liner.
Install the outboard rotating element with the
chamfered side facing the impeller.
MAINTENANCE & REPAIR PAGE E - 13
Page 33
80 SERIESOM-06413
Slide the seal spacer washer (15) onto the shaft
with the chamfered side facing the shaft shoulder.
Reinstall the automatic grease cup and piping (16,
17 and 18) in the seal plate. After the impeller has
been installed, lubricate the seal as indicated in
LUBRICATION.
Impeller Installation
(Figure 3)
Inspect the impeller, and replace it if cracked or
badly worn. Inspect the impeller and shaft threads
for dirt or damage, and clean or dress the threads
as required.
The shaft and impeller threads must be
completely clean before reinstalling the im
peller. Even the slightest amount of dirt on
the threads can cause the impeller to seize
to the shaft, making future removal difficult
or impossible without damage to the im
peller or shaft.
Install the same thickness of impeller adjusting
shims (13) as previously removed. Apply `Never‐
Seez' or equivalent to the shaft threads and screw
the impeller onto the shaft until tight. Be sure the
seal spring seats squarely on the back side of the
impeller.
NOTE
At the slightest sign of binding, immediately back
the impeller off, and check the threads for dirt. Do
not try to force the impeller onto the shaft.
A clearance of .020 to .040 inch (0,5 to 1,0 mm) be
tween the impeller and the seal plate is recom
mended for maximum pump efficiency. Measure
this clearance and add or subtract impeller shims
as required.
NOTE
The seal plate must be tight against the intermedi
ate while setting the back impeller clearance.
Securing Intermediate And Drive Assembly To
Engine
(Figure 4)
Install the shaft key (25, Figure 3) in the shaft key
way. Position the flexible portion of the coupling as
sembly (3) on the shaft as shown in Figure 4.
NOTE
The flexible portion of the coupling must be proper
ly positioned on the shaft. The heads of the caps
crews in the center of the coupling must be posi
tioned toward the pump end of the shaft.
Align the keyway in the bushing (2) with the shaft
key, and slide it onto the shaft until it is just flush
with the end of the shaft. Rotate the flexible portion
of the coupling until the tapped holes for the two
setscrews align with those in the bushing, and in
stall the setscrews.
Make certain that the flexible portion of the
coupling is mounted as shown in Figure 4.
This is critical. If the coupling is not prop
erly positioned on the shaft, the coupling
parts may not fully engage, or a pre‐load
condition can cause premature bearing
failure.
The end of the shaft must be just flush with
the face of the bushing. This will allow the
two portions of the coupling to fully engage
when the intermediate is secured to the en
gine bellhousing, without pre‐loading the
bearings.
With the flexible portion of the coupling and the
bushing properly positioned on the shaft, tighten
the two setscrews in an alternating sequence until
the bushing and coupling are fully secured. Torque
the setscrews to 14.5 ft. lbs. (175 in. lbs. or 2,02 m.
kg.).
If the complete coupling assembly is being re
placed, apply `Loctite Retaining Compound No.
242' or equivalent to the threads of the hardware (4
and 5), and secure the outer ring of the coupling to
the engine flywheel by torquing the hardware to 45
ft. lbs. (540 in. lbs. or 6,2 m. kg.).
MAINTENANCE & REPAIRPAGE E - 14
Page 34
OM-0641380 SERIES
Using a suitable lifting device, position the interme
diate (21, Figure 3) so the flexible portion of the
coupling seats inside the outer ring attached to the
engine flywheel.
NOTE
To ease installation, lightly lubricate the rubber por
tion of the coupling with a non‐petroleum based
lubricant such as vegetable oil or glycerin, or a sili
con‐based lubricant such as “WD40” or equivalent.
Do not use petroleum‐based lubricants, or any oth
er substance which may soften or otherwise dam
age the rubber.
Install the intermediate guards (29, Figure 3), and
secure the intermediate to the engine bellhousing
with the previously removed hardware (6 and 7).
Pump Casing and Wear Plate Installation
(Figure 3)
bly (1) to the base with the previously removed
hardware.
Suction Check Valve Installation
(Figure 3)
Inspect the check valve components and replace
them as required. Subassemble the check valve
weights (52 and 54) and gasket (53) using the at
taching hardware (50 and 51).
Install the check valve assembly in the valve seat
(55). Replace the seat gasket (56) and secure the
valve seat to the suction port using the round head
machine screws (48). Replace the suction flange
gasket (43) and secure the suction flange (44) to
the seat with the nuts (46).
Check the operation of the check valve to ensure
proper seating and free movement.
If the wear plate (38) was removed for replace
ment, secure the replacement wear plate to the
pump casing with the hardware (40 and 41).
Remove the two capscrews temporarily securing
the seal plate to the intermediate, and install the
same thickness of pump casing gaskets (13) as
previously removed. Secure the pump casing to
the seal plate and intermediate with the nuts (34).
A clearance of .010 to .020 inch (0,3 to 0,5 mm) be
tween the impeller and the wear plate is also rec
ommended for maximum pump efficiency. This
clearance can be obtained by removing gaskets
from the casing gasket set until the impeller
scrapes against the wear plate when the shaft is
turned. After the impeller scrapes, add approxi
mately .010 inch (0,3 mm) of gaskets.
(Figure 1)
Reinstall any leveling shims used under the pump
casing mounting feet and secure the pump assem
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.
Be sure the pump and engine have been properly
lubricated, see LUBRICATION.
(Figure 3)
Before starting the pump, remove the fill plug as
sembly (12) and fill the pump casing with clean liq
uid. Reinstall the fill plug and tighten (see OPERA
TION, Section C).
MAINTENANCE & REPAIR PAGE E - 15
Page 35
80 SERIESOM-06413
LUBRICATION
Seal Assembly
(Figure 3)
Fill the grease cup (18) through the grease fitting
with No. 2 lithium base grease until grease es
POSITION
WHEN
EMPTY
GREASE
FITTING
capes 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 7).
POSITION
FOR
FILLING
CROSS
ARM
RELIEF
HOLE
POSITION
WHEN
IN USE
Figure 7. Automatic Lubricating Grease Cup
Bearings
(Figure 3)
The intermediate was fully lubricated when
shipped from the factory. Under normal conditions,
turn the cap on the grease cup (18) three complete
turns to add No. 0 lithium base grease to the inter
mediate after each 250 hours of operation or once
each month, whichever comes first. Do not over‐
lubricate. Over‐lubrication can cause the bearings
to over‐heat, resulting in premature bearing failure.
If grease is forced out around the shaft as
new grease is added, the bearing cavity is
full and should be disassembled and
cleaned immediately.
diate must be disassembled to completely clean
and maintain this cavity.
Under normal conditions, change the grease after
each 5000 hours of operation, or at 12 month inter
vals, whichever comes first. Change the grease
more frequently if the pump is operated continu
ously or installed in an environment where variable
hot and cold temperatures are common.
When lubricating a dry (overhauled) intermediate,
fill the cavity through the grease cup with approxi
mately one‐third of a pound (151 gm) of grease
(approximately one‐third full).
For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
lubricant.
Engine
There are no provisions in the bearing cavity to
drain or flush the lubricant. The pump and interme
Consult the literature supplied with the engine, or
contact your local engine representative.
MAINTENANCE & REPAIRPAGE E - 16
Page 36
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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