Gorman-Rupp Pumps A1-GX390 User Manual

COM−06223−OE01

November 11, 2008

Rev. A. 04/08/10

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

60 SERIES PUMP

MODELS

62 1/2A1−GX390 S/2

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

eCopyright by the Gorman-Rupp Company

Printed in Canada

Register your new

Gorman-Rupp pump online at
www.grpumps.com/register.

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:

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 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Connections to Pump PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gauges PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION LINES PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fittings PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainers PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Suction Lines In Sumps PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

DISCHARGE LINES PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

STARTING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Leakage PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature And Overheating PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainer Check PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

PARTS LISTS PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Model 62 1/2A1−GX390 PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump End Assy PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Hand Primer Disassembly PAGE E − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

TABLE OF CONTENTS

(continued)

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

Seal Removal and Disassembly PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation PAGE E − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Reassembly PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Primer Reassembly PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

60 SERIES

OM−06223

INTRODUCTION

This Installation, Operation, and Maintenance
manual is designed to help you achieve the best
performance and longest life from your Gorman­Rupp pump.

This pump is a 60 Series, centrifugal model with an
enclosed impeller. The pump is designed for high
pressure distribution of clear water in irrigation or

If there are any questions regarding the pump or its application which are not covered in this manual or in
other literature accompanying this unit, please contact your Gorman-Rupp distributor, or write:

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

The following are used to alert maintenance personnel to procedures which require special attention, to
those which could damage equipment, and to those which could be dangerous to personnel:

fire fighting service. It is closed coupled to a single
cylinder, Honda GX390 gasoline engine and
mounted on a common hand-carry base. Stan­dard equipment includes an hand primer system,
discharge check valve and discharge pressure
gauge. The basic material of pump construction is
aluminum with bronze wear ring and a self-lubri­cated mechanical seal.

Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re­quired and the injury which will result
from failure to follow the procedure.

Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.

Hazards or unsafe practices which COULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi­ble damage which could result from failure
to follow the procedure.

NOTE

Instructions to aid in installation, operation,and
maintenance, or which clarify a procedure.

PAGE I − 1INTRODUCTION

60 SERIES

SAFETY - SECTION A

This information applies to 60 Series en­gine driven pumps. Refer to the manual
accompanying the engine before at­tempting to begin operation.

This manual will alert personnel to
known procedures which require spe­cial attention, to those which could
damage equipment, and to those which
could be dangerous to personnel. How­ever, this manual cannot possibly antici­pate and provide detailed instructions
and precautions for every situation that
might occur during maintenance of the
unit. Therefore, it is the responsibility of
the owner/maintenance personnel to
ensure that only safe, established main­tenance procedures are used, and that
any procedures not addressed in this
manual are performed only after estab­lishing that neither personal safety nor
pump integrity are compromised by
such practices.

OM−06223

This pump is designed to handle clear
water for high pressure distribution. Do
not attempt to pump volatile, corrosive,
or flammable liquids which may dam­age the pump or endanger personnel as
a result of pump failure.

Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed dis­charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.

Before attempting to open or service the
pump:

1. Familiarize yourself with this man­ual.

2. Disconnect the spark plug wire to
ensure that the pump will remain
inoperative.

3. Allow the pump to completely cool
if overheated.

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

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cau­tiously.

7. Drain the pump.

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

Overheated pumps can cause severe
burns and injuries. If overheating of the
pump occurs:

1. Stop the pump immediately.

2. Ventilate the area.

3. Allow the pump to completely cool.

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

5. Vent the pump slowly and cau­tiously.

6. Refer to instructions in this manual
before restarting the pump.

PAGE A − 1SAFETY

60 SERIESOM−06223

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

Do not operate an internal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make cer­tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color­less, tasteless, and odorless.

Fuel used by internal combustion en­gines presents an extreme explosion
and fire hazard. Make certain that all
fuel lines are securely connected and
free of leaks. Never refuel a hot or run­ning engine. Avoid overfilling the fuel
tank. Always use the correct type of fuel.

Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. Continuous duty perform­ance is limited to 3600 RPM; however
the engine may be run at 3800 RPM dur­ing intermittent fire fighting service.

PAGE A − 2 SAFETY

60 SERIES OM−06223

INSTALLATION − SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and ar­range the pump and piping.

Most of the information pertains to a standard
static lift application where the pump is positioned
above the free level of liquid to be pumped.

If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
configuration, and priming must be tailored to the

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 Sec­tion 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 dimen­sions of this pump.

Figure 1. Pump Model 62 1/2A1−GX390 S/2

OUTLINE DRAWING

PAGE B − 1INSTALLATION

OM−06223 60 SERIES

PREINSTALLATION INSPECTION

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

a. Inspect the pump and engine for cracks,

dents, damaged threads, and other obvious
damage.

b. Check for and tighten loose attaching hard-

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

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties
indicated.

d. Check levels and lubricate as necessary. Re-

fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per­form duties as instructed.

e. If the pump and engine have been stored for

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

POSITIONING PUMP

Lifting

This pump is designed to be hand carried . The to­tal pump weight for the pull start unit is approxi­mately 134 pounds (61 kg) not including accesso-
ries. Customer installed equipment such as suc­tion and discharge piping must be removed before
attempting to lift.

Mounting

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

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

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

SUCTION AND DISCHARGE PIPING

f. Check to ensure the following standard

equipment items are included with the pump
assembly:

D Hand primer assembly.

D Discharge pressure gauge.

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

PAGE B − 2 INSTALLATION

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

Materials

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

60 SERIES OM−06223

Line Configuration

Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini­mum use of elbows and fittings, which substan­tially increase friction loss. If elbows are necessary,
use the long-radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it ex­actly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or cou­plings.

Lines near the pump must be independently sup­ported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type
lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.

Gauges

Most pumps are drilled and tapped for installing
discharge pressure and vacuum suction gauges.
If these gauges are desired for pumps that are not
tapped, drill and tap the suction and discharge
lines not less than 18 inches (457,20 mm) from the
suction and discharge ports and install the
gauges. Installation closer to the pump may result
in erratic readings.

install it with the stem horizontal to avoid air pock­ets.

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 5/16-inch
(7,9 mm) diameter spherical solids.

Sealing

Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an air­tight seal. Follow the sealant manufacturer’s rec­ommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.

Suction Lines In Sumps

SUCTION LINES

To avoid air pockets which could affect pump prim­ing, the suction line must be as short and direct as
possible. When operation involves a suction lift, the
line must always slope upward to the pump from
the source of the liquid being pumped; if the line
slopes down to the pump at any point along the
suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be in­stalled with the flat part of the reducers uppermost
to avoid creating air pockets. Valves are not nor­mally used in suction lines, but if a valve is used,

If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to 1-1/2 times the diame­ter of the suction line.

If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc­tion inlet because the inflow will carry air down into
the sump, and air entering the suction line will re­duce pump efficiency.

If it is necessary to position inflow close to the suc­tion inlet, install a baffle between the inflow and the
suction inlet at a distance 1-1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.

If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency

PAGE B − 3INSTALLATION

OM−06223 60 SERIES

of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a dis­tance equal to at least 3 times the diameter of the
suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is
critical to efficient pump operation.

Figure 3 shows

recommended minimum submergence vs. veloc­ity.

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 3. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

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

Valves

friction losses. Never install a throttling valve in a
suction line.

With high discharge heads, it is recommended that
a throttling valve and a system check valve be in­stalled in the discharge line to protect the pump
from excessive shock pressure and reverse rota­tion when it is stopped.

If the application involves a high discharge

If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize

PAGE B − 4 INSTALLATION

head, gradually close the discharge
throttling valve before stopping the pump.

60 SERIES

OPERATION − SECTION C

Review all SAFETY information in Section A.

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

OM−06223

This pump is designed to handle clear
water for high pressure distribution. Do
not attempt to pump volatile, corrosive,
or flammable liquids which may dam­age the pump or endanger personnel as
a result of pump failure.

Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. Continuous duty perform­ance is limited to 3600 RPM; however
the engine may be run at 3800 RPM dur­ing intermittent fire fighting service.

PRIMING

Install the pump and piping as described in IN­STALLATION. Make sure that the piping connec-

tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri­cated (see LUBRICATION in MAINTENANCE

AND REPAIR).

Figure 1. Hand Primer Assembly

The hand−operated priming pump, connected di­rectly to the pump, is designed to draw air out of
the suction line and the volute. The hand−oper­ated priming pump can be used while the pump is
either stopped or operating. To prime the pump,
close the drain cock in the hand primer. Operate
the handle of the pump until liquid flows into the
pump and the pump is fully primed. After use,
open the drain cock in the hand primer and drain
any liquid from the hand primer.

STARTING

Consult the operations manual furnished with the
engine.

OPERATION

Leakage

No leakage should be visible at pump mating sur­faces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maxi­mum pump efficiency.

Liquid Temperature And Overheating

The maximum liquid temperature for this pump is
160_ F (71,1_C). Do not apply it at a higher operat­ing temperature.

Overheating can occur if operated with the valves

Hand Primer

Since this pump is not self-priming, it is equipped
with an hand−operated vacuum priming pump.
(see Figure 1).

OPERATION PAGE C − 1

in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup­ture or explode. If overheating occurs, stop the
pump and allow it to cool before servicing it. Refill

the pump casing with cool liquid.

OM−06223 60 SERIES

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.

Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over­heated pump. Vapor pressure within the

STOPPING

pump can cause parts being disen­gaged to be ejected with great force. Al­low the pump to cool before servicing.

Strainer Check

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 a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been in­stalled, monitor and record the readings regularly
to detect strainer blockage.

Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
could result in personal injury or damage to the
equipment. If backflushing is absolutely neces­sary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve. (See Section E,
Page 1.)

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 (508,0 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

On engine driven pumps, reduce the throttle
speed slowly and allow the engine to idle briefly be­fore stopping.

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

After stopping the pump, disconnect the spark
plug wire 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 rotat­ing parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids con­taining a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and pre­venting the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.

OPERATIONPAGE C − 2

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. Shut down the engine and discon­nect the spark plug wire to ensure
that the pump will remain inopera­tive.

3. Allow the pump to completely cool if
overheated.

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

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

OM−0622360 SERIES

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.

Air leak in suction line. Correct leak.

Lining of suction hose collapsed. Replace suction hose.

Leaking or worn seal or pump gasket.

Suction lift or discharge head too high.

Strainer clogged (if installed)

Auxiliary priming device faulty or im­properly installed.

Integral discharge check valve clogged
or binding.

Air leak in suction line. Correct leak.

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

Lining of suction hose collapsed. Replace suction hose.

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

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

Check strainer and clean if neces­sary

Repair priming device or check in­stallation.

Clean valve.

Check installation and correct sub­mergence as needed.

TROUBLESHOOTING PAGE D − 1

OM−06223 60 SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

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

PUMP REQUIRES
TOO MUCH
POWER

EXCESSIVE NOISE Cavitation in pump. Reduce suction lift and/or friction

Impeller or other wearing parts worn
or damaged.

Suction lift too high.

Pump speed too slow. Check engine output; consult en-

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

Exceeding operating limits. See performance curves in PUMP

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

Free impeller of debris.Impeller clogged.

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

gine operation manual.

leaking or worn seal or gasket.

Check engine output.Pump speed too high.

Dilute if possible.Liquid solution too thick.

MAINTENANCE AND REPAIR.

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

Pumping entrained air.

Impeller clogged or damaged.

Locate and eliminate source of air
bubble.

Secure mounting hardware.Pump or drive not securely mounted.

Clean out debris; replace damaged
parts.

TROUBLESHOOTINGPAGE D − 2

OM−0622360 SERIES

PREVENTIVE MAINTENANCE

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

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

equipped) between regularly scheduled inspec­tions can indicate problems that can be corrected
before system damage or catastrophic failure oc­curs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same
duty cycle, the part can be checked and replaced
before failure occurs, reducing unscheduled down
time.

For new applications, a first inspection of wearing
parts at 250 hours will give insight into the wear rate
for your particular application. Subsequent inspec­tions should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

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

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

Daily Weekly Monthly Semi-

Annually

Annually

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

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

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

TROUBLESHOOTING PAGE D − 3

60 SERIES

OM−06223

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 MODELS 62 1/2A1−GX390 S/2

Based on 70_ F (21 _ C) clear water at sea level

with minimum suction lift. Since pump installations
are seldom identical, your performance may be dif­ferent due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.

Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be

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 per­formance or part numbers.

MAINTENANCE & REPAIR PAGE E − 1

exceeded. Continuous duty perform­ance is limited to 3600 RPM; however
the engine may be run at 3800 RPM dur­ing intermittent fire fighting service.

SECTION DRAWING

60 SERIESOM−06223

Figure 1. Pump Model 62 1/2A1−GX390 S/2

MAINTENANCE & REPAIRPAGE E − 2

60 SERIES

OM−06223

PARTS LIST

Pump Model 62 1/2A1−GX390 S/2

(Canadian S/N 106873 and up)

If your pump serial number is followed by an N", your pump is NOT a standard production model. Contact
the Gorman-Rupp Company to verify part numbers.

ITEM

PART NAME PART

NO.

NUMBER

MAT’L
CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

MAT’L
CODE

QTY

1 PUMP END ASSY 62 1/2A1−(GX390) 1
2 HONDA GX390 ENG 29122-036 −−− 1
3 HANDPRIMER S1252 −−− 1
4 HAND CARRY DECAL 2613FT −−− 2
5 PRESSURE GAUGE S180 −−− 2
6 RUBBER FOOT MTG KIT 48152-603 −−− 1
7 DISCHARGE STICKER 6588BJ −−− 1
8 SWIVEL FITTING 26571-002 −−− 1

9 .38 I.D. X 12" HOSE 18513-302 −−− 1
10 HOSE ADAPTOR 26523−334 2
11 PIPE BUSHING AP0806 15079 1
12 STREET ELBOW RS08 11999 1
13 HANDPRIMER BRKT 50784 −−− 1

. 14 WARNING DECAL 2613FE −−− 1

15 HEX HD CAPSCREW B0606 15991 4
16 FLAT WASHER K06 15991 4
17 FLANGED HEX NUT 21765-314 −−− 4

INDICATES PARTS RECOMMENDED FOR STOCK

18 STUD C0606−1/2 15991 4
19 HEX NUT D06 15991 4
20 LOCKWASHER J06 15991 4
21 SUCTION STICKER 6588AG −−− 1
22 ROLLOVER BASE 41583-317A 24150 1
23 HEX HEAD CAPSCREW B0604 15991 4
24 LOCKWASHER J06 15991 4
25 HEX HEAD CAPSCREW B0604 15991 2
26 HEX NUT D06 15991 2
27 LOCKWASHER J06 15991 2
28 COUPLING 2469 14000 1
29 COUPLING 2469 14000 1

NOT SHOWN:

NAMEPLATE 38812−045 −−− 1
ENG. START UP TAG 38816-269 −−− 1
INSTRUCTION TAG 38817-085 −−− 1

MAINTENANCE & REPAIR PAGE E − 3

SECTION DRAWING

60 SERIESOM−06223

Figure 2. Pump End 62 1/2A1−(GX390)

MAINTENANCE & REPAIRPAGE E − 4

60 SERIES

OM−06223

PARTS LIST

Pump End 62 1/2A1−(GX390)

ITEM
NO.

1 ' PUMP CASING ASSEMBLY 1492 13040 1
2 IMPELLER 1493Y 1301C 1
3 SEAL ASSEMBLY 25271−192 −−− 1
4 IMPELLER SHIM SET 2X 17090 1
5 SHAFT SLEEVE 2146 14000 1
6 INTERMEDIATE 38264−305 13040 1
7 SEAL RING 2A 15020 1
8 STUD C0606 15991 8

9 HEX NUT D06 15991 8
10 CASING GASKET SET 3G 18000 1
11 PIPE PLUG P04 15079 1
12 WEAR RING 1494 14000 1
13 CHECK VALVE BODY 6323 13000 1
14 CHECK VALVE GASKET 6323G 19060 1
15 CHECK VALVE ARM 6324 14000 1
16 STUD C1008 15991 4
17 HEX NUT D10 15991 4

PART NAME

PART
NUMBER

MAT’L
CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

' PUMP CASING ASSEMBLY INCLUDES WEAR RING, ITEM 12

MAINTENANCE & REPAIR PAGE E − 5

60 SERIESOM−06223

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.

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

This pump requires little service due to its rugged,
minimum-maintenance design. However, if it be­comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional views (see Figures 1 and 2) and the
accompanying parts lists.

As described on the following pages, this manual
will alert personnel to known procedures which re­quire special attention, to those which could dam­age equipment, and to those which could be dan­gerous to personnel. However, this manual cannot
possibly anticipate and provide detailed precau­tions for every situation that might occur during
maintenance of the unit. Therefore, it is the respon­sibility of the owner/maintenance personnel to en­sure that only safe, established maintenance pro-
cedures are used, and that any procedures not ad­dressed in this manual are performed only after es-
tablishing that neither personal safety nor pump in­tegrity are compromised by such practices.

Before attempting to service the pump, remove the
suction and discharge hoses and disconnect the
spark plug wire to ensure that it will remain inopera­tive. Close all valves in the suction and discharge
lines.

For engine disassembly and repair, consult the lit­erature supplied with the engine, or contact your
local Honda engine representative.

3. Allow the pump to completely cool
if overheated.

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

5. Close the suction and discharge
valves.

6. Vent the pump slowly and cau­tiously.

7. Drain the pump.

Hand Primer Disassembly

(Figure 1 or 2)

Disconnect the hose connection (11) from the
hand primer (3) to the pump sub−assembly.(see
Figure 1) Remove hex head capscrews (25), nuts
(26), and lockwashers (27) securing the hand
primer bracket to the rollover base, and remove the
hand primer (see Figure 2)

If no further pump disassembly is required, refer to

Hand Primer Reassembly.

Pump Disassembly

(Figure 2)

After disconnecting the rubber priming line, re­move the drain plug (11) to drain the pump. Clean
and reinstall the plug.

Remove the hardware (9) and separate the pump
casing (1) from the intermediate (6). Carefully re­move the casing gasket set (10) and clean the con­tacting surfaces.

Inspect the wear ring (12) for severe erosion or
damage. The wear ring is a press fit in the pump
casing. To remove the ring, apply heat to the out­side of the casing or split the ring. Be careful not to
damage the pump casing.

Before attempting to open or service the
pump:

1. Familiarize yourself with this man­ual.

2. Disconnect the spark plug wire to
ensure that the pump will remain
inoperative.

To remove the impeller (2), insert a steel bar or drift
pin between the vanes and turn it in a counter­clockwise direction (when facing the impeller)
while holding the engine crankshaft stationary. Be
careful not to damage the impeller vanes. Use
caution when unscrewing the impeller; tension on
the seal spring will be released as the impeller is re­moved.

MAINTENANCE & REPAIRPAGE E − 6

Seal Removal and Disassembly

(Figure 2)

OM−0622360 SERIES

Remove the impeller adjusting shims (4). Tie and
tag the shims or measure and record their thick­ness for ease of reassembly.

Remove the seal spring and slide the shaft sleeve
(5) and rotating portion of the seal off the engine
shaft as a unit. Apply oil to the sleeve and work it up
under the bellows. Slide the rotating portion of the
seal off the sleeve.

Slide two stiff wires with hooked ends along the
shaft and pull stationary seat and O-ring from the
intermediate bore.

NOTE

An alternate method of removing the stationary seat
is to remove the hardware (19 and 20, Figure 1 or
Figure 2) and separate the intermediate (6) from the
engine. Use a dowel to press the stationary seat
and O-ring from the intermediate.

If the seal ring (7) requires replacement, remove
the intermediate as described above, and slide the
seal ring off the shaft.

If no further disassembly is required, refer to Seal

Reassembly And Installation.

Seal Reassembly and Installation

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

The seal is not normally reused because wear pat­terns on the finished faces cannot be realigned
during reassembly. This could result in premature
failure. If necessary to reuse an old seal in an emer­gency, carefully wash all metallic parts in fresh
cleaning solvent and allow to dry thoroughly.

Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non-oil based solvent and a clean, lint-free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.

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

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

(Figures 2 and 3)

Clean the seal cavity and shaft with a cloth soaked
in fresh cleaning solvent.

MAINTENANCE & REPAIR PAGE E − 7

To ease installation of the seal, lubricate the O­rings and shaft sleeve 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 3).

60 SERIESOM−06223

SPRING

DRIVE BAND

IMPELLER ADJ SHIMS

IMPELLER

RETAINER

INTERMEDIATE

O-RING

STATIONARY

SEAT

SHAFT SLEEVE

SHAFT

BELLOWS

Figure 3. 25271−192 Seal Assembly

This seal is not designed for operation at
temperatures above 160_ F (71_C). Do not
use at higher operating temperatures.

If the intermediate was removed, lay it on a flat sur­face with the impeller side facing up. Subassemble
the O-ring in the stationary seat and press it into the
intermediate bore until it seats squarely against the
shoulder. Install the seal ring (7) on the shaft and
secure the intermediate to the engine with the
hardware (19 and 20, Figure 1). Be careful not to
damage the stationary seat on the shaft threads.

NOTE

If the intermediate was not removed, subassemble
the O-ring in the stationary seat and use thumb
pressure to press it into the intermediate bore until it
seats squarely against the shoulder.

Subassemble the rotating element in the retainer
and bellows, then slide this subassembly onto the

ROTATING ELEMENT

shaft sleeve (5) until the face of the rotating element
is just flush with the chamfered end of the sleeve.
Slide the sleeve onto the shaft until the seal faces
contact. Continue to push the sleeve through the
seal until it seats against the seal ring (7).

Position the seal spring on the retainer and pro­ceed with Pump Reassembly.

Pump Reassembly

(Figure 2)

If the wear ring (12) was removed, press the re­placement ring into the casing bore until fully
seated against the casing shoulder.

NOTE

The wear ring must seat squarely in the casing bore
or binding and/or excessive wear will result.

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

MAINTENANCE & REPAIRPAGE E − 8

OM−0622360 SERIES

For maximum pump efficiency, the impeller should
be centered within the volute scroll. Use the casing
gaskets (10) and the impeller shims (4) to center
the impeller as described below.

To verify the impeller positioning, measure the

CD

B
2

AB

B

+

A

2

pump casing and impeller as shown in Figure 4.
Use these measurements to calculate the required
impeller location (dimension E). Add or remove im­peller adjusting shims until dimension E is ob­tained.

D
2

E

Step 2Step 1 Step 3

C

+

D
2

=

E

−

Figure 4. Centering Impeller Within Volute Scroll

NOTE

After the impeller has been properly positioned,
check for free rotation. Correct any scraping bind­ing before further reassembly.

Install the casing gasket set (10). Carefully guide
the wear ring into the eye of the impeller and se­cure the casing to the intermediate with the hard­ware (9).

Hand Primer Reassembly

(Figure 1 or 2)

Install the hex head capscrews (25), nuts (26), and

lockwashers (27) securing the hand primer brack­et to the rollover base. (Figure 2) Connect the hose
connection from the hand primer to the pump
sub−assembly. (Figure 1)

LUBRICATION

Seal Assembly

The shaft seal is lubricated by the liquid being
pumped and no additional lubrication is required.

Engine

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

MAINTENANCE & REPAIR PAGE E − 9

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty

or call:

U.S.: 419−755−1280

International: +1−419−755−1011

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty

or call:

519−631−2870

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

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