Gorman-Rupp Pumps D1-CH23 User Manual

Page 1
ACEG
OM---05171---OE01
January 5, 2001
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
60 SERIES PUMP
MODEL
62 1/2D1---CH23 S/G
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED D ST.THOMAS, ONTARIO, CANADA Printed in U.S.A.
ECopyright by the Gorman-Rupp Company
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The engine exhaust from this product contains chemicals known to the State ofCaliforniato cause cancer, birth defects or other reproductive harm.
Page 3

TABLE OF CONTENTS

INTRODUCTION PAGE I --- 1...................................................
SA F E TY --- S E CTIO N A PA G E A --- 1............................................
IN S TA LLATIO N --- SECTIO N B PA G E B --- 1.....................................
Pump Dimensions PAGE B --- 1.....................................................
PREINSTALLATION INSPECTION PAGE B --- 1............................................
POSITIONING PUMP PA GE B --- 2.......................................................
Mounting PA GE B --- 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B --- 2.........................................
Materials PA GE B --- 2..............................................................
Line Configuration PAGE B --- 2......................................................
Connections to Pump PAGE B --- 2..................................................
Gauges PA GE B --- 2...............................................................
SUCTION LINES PAGE B --- 3...........................................................
Fittings PA GE B --- 3...............................................................
Strainers PA GE B --- 3..............................................................
Sealing PAGE B --- 3...............................................................
Suction Lines In Sumps PAGE B --- 3.................................................
Suction Line Positioning PAGE B --- 3................................................
DISCHARGE LINES PA GE B --- 4........................................................
Siphoning PA GE B --- 4.............................................................
Valves PA GE B --- 4................................................................
OP E R AT ION --- S E CTIO N C PA G E C --- 1.......................................
PRIMING PA GE C --- 1.................................................................
Exhaust Primer PAGE C --- 1........................................................
STARTING PA GE C --- 1................................................................
OPERATION PA GE C --- 2..............................................................
Leakage PAGE C --- 2..............................................................
Liquid Temperature And Overheating PAGE C --- 2.....................................
Strainer Check PAGE C --- 2.........................................................
Pump Vacuum Check PAGE C --- 2..................................................
STOPPING PA GE C --- 2................................................................
Cold Weather Preservation PAGE C --- 3..............................................
TROU BLESH OOT I NG --- S E CTIO N D PA G E D --- 1...............................
PREVENTIVE MAINTENANCE PAGE D --- 2..................................................
PUMP MAINTENANCE AND REPAIR --- SECTION E PAGE E --- 1.................
STANDARD PERFORMANCE CURVE FOR PUMP MODEL 62 1/2D1---CH23 S/G PAGE E --- 1.. PARTS LIST:
Pump Model PA GE E --- 3..........................................................
Pump End Assembly PAGE E --- 5...................................................
Exhaust Primer Assembly PAGE E --- 6...............................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 7.........................
i
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TABLE OF CONTENTS
(continued)
Discharge Check Valve Disassembly PAGE E --- 7.....................................
Exhaust Primer Disassembly PAGE E --- 7............................................
Pump Disassembly PAGE E --- 7.....................................................
Seal Removal and Disassembly PAGE E --- 8..........................................
Seal Reassembly and Installation P AGE E --- 8........................................
Impeller Installation P AGE E --- 10.....................................................
Pump Reassembly PAGE E --- 10.....................................................
Exhaust Primer Reassembly PAGE E --- 10.............................................
Discharge Check Valve Reassembly PAGE E --- 11......................................
LUBRICATION PA GE E --- 11.............................................................
Seal Assembly PAGE E --- 11.........................................................
Engine PA GE E --- 11................................................................
ii
Page 5
60 SERIES
OM--05171

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, single-stage centrifugal model designed for agriculturalor fire fighting ser­vice.Itis close-coupledto aKohler CH23v-twin cyl­inder O.H.V. air cooled gasoline engine and pro­tected by a wrap-around roll cage with rubber mounting feet. The pump features compact, light
The Gorman-Rupp Company or Gorman-Rupp of Canada Limited P.O. Box 1217 70 B urwell Road Mansfield, Ohio 44901-- 1217 St. Thomas, Ontario N5P 3R7
For information or technical assistance on the engine, contact the engine manufacturer’s local dealer or representative.
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:
weight design for portability, as well as rugged construction for easy, low-cost maintenance. The basic material of construction for wetted parts is aluminum w ith bronze wear ring, and a self lubri­cated mechanical seal.
Ifthereare anyquestionsregardingt he pumporits applicationwhichare notcovered inthis manualor in other literature accompanying this unit, please contact your Gorman-Rupp distributor, or write:
Immediate hazards whichWILL 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 COULDresult in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure.
HazardsorunsafepracticeswhichCOULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possi­bledamage which couldresult fromfailure to follow the procedure.
NOTE
Instructions to aid in installation, operation,and maintenance, or which clarify a procedure.
PAGE I -- 1INTRODUCTION
Page 6
60 SERIES OM--05171
SAFETY --- SECTION A
This information applies to 60 Series Engine Drivenpumps. Refer to theman­ual accompanying the engine be fore at­tempting to beg in operation.
This manual will alert personnel to known procedures which require spe­cial attention, to those which c ould damage equipment, and to thosewhich could be dangerous to personnel.How­ever, thismanualcannotpossiblyantici­pate and provide detailed instructions and precautions for every situationthat might occur during maintenance of the unit.Therefore,itisthe responsibility of the owner/maintenance personnel to ensurethatonlysafe, 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.
Beforeattemptingto openorservicethe pump:
This pump is designed to handle clear water for high pressure distribution. Do not attempt to pump volatile,corrosive,
or flammable liquids which may dam­agethepump orendanger personnel as a result of pump failure.
Do not operate the pump against a closed discharge valve for long periods of time. This could bring the liquid to a boil, build pressure, and cause the pump casing to rupture or explode.
Do not remove plates, covers, gauges, pipe plugs, or fittings from an over­heated pump. Vaporpressure withinthe pump can cause parts being disen­gagedtobe ejectedwith great force.Al­low the pump to cool before servicing.
1. Familiarize yourself with thisman­ual.
2. Shutdown the engine and discon­nect the park plug wires to ensure that the pump will remain inopera­tive.
3. Allowthe pump tocompletely 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.
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 tothe 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

PAGE A -- 1SAFETY

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OM--05171
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.Alwaysusethe correcttype offuel.
60 SERIES
Never tamper with the governor to gain more power. The governor establishes safe operating limits that should not be exceeded.
PAGE A -- 2 SAFETY
Page 8
INSTALLATION --- SECTION B
OM--0517160 SERIES
Review all SAFETY information in Section A .
Since pump installations are seldom identical,this section offers only general recommendations and practices required to inspect, position, and ar­range the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is posi­tionedabovethefreelevelofliquidto bepumped.
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 shownon thepump performance curve. (SeeSec­tion E, Page 1.)
Forfurtherassistance, contact yourGorman-Rupp distributor or the Gorman-Rupp Company.
Pump Dimensions
SeeFigure1fortheapproximatephysicaldimen­sions of this pump and engine.
Figure 1. Pump Model 62 1/2D1--CH23 S/G
PREINSTALLATION INSPECTION
Thepump assemblywas inspectedandtested be­fore shipment from the factory. Before installation, inspect the pump for damage which may haveoc ­curred during shipment. Check as follows:
a. Inspect thepumpforcracks, 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.

PAGE B -- 1INSTALLATION

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OM--05171 60 SERIES
c. Carefully read all tags, decals and markings
onthepumpassembly,andfollowtheinstruc­tions indicated.
d. Check all lubricant levels and lubricate as
necessary. Refer to LUBRICATION in the MAINTENANCE AND REP AIRsectionof 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 maximumshelflife.These mustbeinspected or replaced to ensure maximum pump serv­ice.
f. Check to ensure the following standard
equipment items are included with the pump assembly:
S Portable 6.5 gallon fuel tank complete with
quick-connect fitting.
S Suction strainer. S Rubber foot mounting kit (must be
installed). Toinstall feet, positionflatwash­ers on capscrews, slide the capscrews through the rubber feet and holes in the base,and secure withtheflanged hexnut.
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 tak en.
POSITIONING PUMP
This pump is designed to be very light-weightand portable. The total pump weight is approximately 240 pounds (109 kg), not including accessories orengine fuel.Customer installedequipment such as suctionand discharge hoses must be removed before attempting to lift.
Mounting
Locatethepump inanaccessibleplaceascloseas practicalto the liquidbeingpumped. Levelmount­ing is essential for proper operation.
To ensure sufficient lubrication and fuel supply to the engine, do not position the pump and engine morethan 15_ off horizontal for continuous opera­tion. The pump and engine may be positioned up to 30_ off horizontal for intermittent operation only;however,theengine manufacturershould be consulted for continuous operation at angles greater than 15_.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in­creased suction lift, discharge elevation, and fric­tion losses. See the performance curve and oper­ating range shown on Page E-1 to be sure your overall application allows pump to operate within thesafeoperationrange.
Materials
Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatiblewiththe liquidbeingpumped. Ifhoseis used in suction lines, it must be the rigid-wall, rein­forced type to prevent collapse under suction. Us­ing piping couplings in suction lines is not recom­mended.
Line Configuration
Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini­mum use of elbows and fittings, which substan­tiallyincreasefrictionloss. Ifelbows arenecessary, use the long-radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex­actlywith the pump port. Never pulla pipe lineinto 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 linesare used,they shouldhaveadequatesupport to secure them when filled with liquid and under pressure.
The pump may have to be supported orshimmed to provide for level operation or to eliminate vibra­tion.
PAGE B -- 2 INSTALLATION
Gauges
Most pumps are drilled and tapped for installing dischargepressureandvacuumsuctiongauges.If
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OM--0517160 SERIES
these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457,2 mm) from the suction and discharge ports and install the lines. Installationcloserto the pump may result inerratic readings.
SUCTION LINES
Toavoidair pocketswhichcouldaffectpump prim­ing, thes uction line must be as short and direct as possible.Whenoperationinvolvesasuctionlift,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.
The maximum vertical suction lift for this pump is 20 feet (6,1 meters). It is not designed to be oper­ated at a higher lift.
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 in­stalledwith the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor­mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ­ets.
Strainers
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
If a single suction line is installed in a sump, it should be positioned away from the wall of the sumpata distance equal to1 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 suc­tioninlet because theinflowwillcarryair downinto the sump, and air entering the s uction line will re­duce pump efficiency.
Ifitis necessary to positioninflowclose to the suc­tioninlet, installa bafflebetween theinflowandthe 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, theflow pathsmay interact,reducing theefficiency 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.
If a strainer is furnished with the pump, be certain touse it;any sphericalsolidswhichpassthrougha 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 willnot 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.
Suction Line Positioning
The depth of submergence of the suction line is critical to efficient pump operation. Figure 2shows recommended minimum submergence vs. veloc-
ity.
NOTE
The pipe submergence required may be reduced by installing a standard pipe increaserfitting at the endof the suctionline. The largeropening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).
PAGE B -- 3INSTALLATION
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OM--05171 60 SERIES
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
DISCHARGE LINES
Siphoning
Donot terminate the discharge lineat 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
A check valveinthedischargelineis normally rec­ommended, but it is not necessary in low dis­charge head applications.
If a throttlingvalve is desired inthe discharge line, useavalveaslargeasthelargestpipetominimize friction losses. Never install a throttling valve in a suction line.
Withhighdischarge heads,itis recommendedthat 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.
PAGE B -- 4 INSTALLATION
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60 SERIES
OM--05171
OPERATION --- SECTION C
Review all SAFETY information in Section A . Follow the instructions on all tags, labels and
decals attached to the pump.
This pump is designed to handle clear water in high pressure distribution. Do not attempt to pump volatile,corrosive,
or flammable liquids which may dam­agethepump orendanger personnel as a result of pump failure.
Never tamper with the governor to gain more power. The governor establishes safe operating limits that should not be exceeded.
The exhaust primer utilizes engine exhaust gases, directedthrough a venturi,to createa vacuum and draw air out of the suction line and pump casing.
The exhaust primer is capable of priming a pump with a maximum priming lift of 15 feet (4,6 meters) within 90 seconds; less time will be required for priming ata lesser lift.Ifthe pump doesnotprimein a reasonablelengthoftime, check the suctionline for leaks.
Toprime the pump, closethe throttling valve inthe discharge line.
Close the exhaust primer handle (see Figure 1), and open the cock in the priming line. Consult the starting instructions in this manual as well as the engine operating manual, and start the engine. Operate the engine at maximum governed speed and allow the pump to prime untilliquid flows con­tinuously from the exhaust primer nozzle. When the pump is fullyprimed, open the exhaust primer handle, and close the cock in the priming line.
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).
Exhaust Primer
Since this pump is not self-priming, it is equipped with an exhaust primer assembly (Figure 1).
HANDLE
GAS COCK
Once fully primed, reduce the engine speed and partially open the discharge throttling valve. The discharge line should be filled slowly to prevent damage tothe piping, gaskets, and other devices, resulting from the initial shock of liquid filling the lines. When the discharge line is completely filled, adjust the discharge throttling valveto the desired flow rate.
STARTING
Consult the operations manual furnished with the engine.
Attach the fuel line to the quick-connect fitting lo­catedon theengine. Positiontheportable fueltank atthesamelevelasthepump,orslightlyhigher. Squeezetheprimingbulbuntilthefuelcanbeseen in the transparent fuel line at the carburetor inlet. The transparent fuel line need not be completely full. Fuel will be pulled into the carburetor while cranking the engine w ith the choke on.
Figure 1. Exhaust Primer Assembly

OPERATION PAGE C -- 1

Set the ignition toggle switch to the ON position.
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60 SERIESOM--05171
Set the twist-lock throttle control at approximately half open position. Start the engine and follow en­gine manufacturer’s recommendations for carbu­retoradjustmentsto obtainoptimumperformance.
NOTE
Hard starting may be experienced after connecting a new tank of fuel. This can be caused by air trapped in the fuel line. It is recommended that the fuel line be vented and filled by depressing the valve in the female quick connect fitting prior to installing it on the pump.
OPERATION
Pump speed and operating condition points must be within the continuous per­formance range shown on the curve. (See Section E, Page 1.)
heated pump. Vaporpressure withinthe pump can cause parts being disen­gagedtobe ejectedwith great force.Al­lowthe pump to completely coolbefore servicing.
Strainer Check
If a suction strainer has been shipped with t he pump or installed by the user, check the strainer regularly, and clean it as necessary. The strainer shouldalsobe checkedifpumpflowratebeginsto 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 casingor piping to removea blockage.This could result in personal injury or damage t o 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.)
Leakage
No leakage should be visibleat pump mating sur­faces, or at pump connections or fittings. Keepall lineconnectionsand fittingstight tomaintain maxi­mum pump efficiency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is 160_F(71_C). Do not applyit ata higher operating temperature than is recommended.
Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rup­ture or explode. If overheating occurs, stop the pumpand allowit tocompletelycool beforeservic­ing it. Refill the pump casing with cool liquid.
Pump Vacuum Check
Withthe pump inoperative,installa vacuumgauge in the system, using pipe dope on the threads. Block the suction lineandstart thepump. Atoper­ating 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.
Openthe suctionline,andread thevacuum gauge with the pump primed and at operation speed. Shut offthe pump. The vacuumgaugereading will immediately drop proportionate to static suction lift,andshouldthenstabilize. Ifthe 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
Do not remove plates, covers, gauges, pipe plugs, or fittings from an over-
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 connectingvalvesslowly.
OPERATIONPAGE C -- 2
Page 14
60 SERIES
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
Afterstoppingthe pump,switchoffthe engineigni­tion and remove or ground the spark plug to en­sure that the pump will remain inoperative.
Cold Weather Preservation
In below freezing conditions, drain the pump to
OM--05171
preventdamagefrom freezing. Also,clean outany solids by flushing with a hose. Operate the pump for approximatelyone minute; this willremoveany 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. Toprevent 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.
OPERATION PAGE C -- 3
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60 SERIES
OM--05171
TROUBLESHOOTING --- SECTION D
Review all SAFETY information in Section A .
Beforeattemptingto openorservicethe pump:
1. Familiarize yourself with thisman­ual.
2. Shutdown the engine and remove thesparkplug wires toensurethat the pump will remain inoperative.
Table B-1 Troubleshooting Chart TROUBLE ENGINE FAILS TO
START
CAUSE REMEDY
Auxiliary priming device faulty or improperly installed.
Integral discharge check valve clogged or binding.
Spark plug contaminated.
3. Allowthe pump tocompletely cool if overheated.
4. Vent the pump slowly and cau­tiously.
5. Close the suction and discharge valves.
6. Check the temperature before opening any covers, plates, or plugs.
7. Drain the pump.
Forspecificinstructionson enginetroubleshooting or repair, see the engine manual.
Repair priming device or check installation.
Clean valve.
Clean and replace plug; reset gap.
PUMP FAILS T O PRIME
No fuel to engine or fuel con­taminated.
Engine flooded.
Auxiliary priming device faulty or improperly installed.
Integral discharge check valve clogged or binding.
Air leak in suction line. Lining of suction hose col-
lapsed. Leakingorwornsealorpump
gasket. Suction lift or discharge head
to high. Strainer clogged.
Check fuel tank level; vent t ank; purge air from fuel lie; clean fuel filters. Check fuel for proper oil mix; check for contamination.
Dry spark plug; a djust carburetor; see engine manual.
Repair priming device or check installation.
Clean valve.
Correct leak. Replace suction hose.
Check pump vacuum. Replace leaking or worn seal or gasket.
Check piping installation and reduce suction lift and/or discharge head.
Check strainer and clean if necessary.

TROUBLESHOOTING PAGE D -- 1

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OM--05171
TROUBLE PUMP STOPS OR
FAILS TO DELIVER RATED FLOW OR PRESSURE
Table B-1 Troubleshooting Chart (continued)
CAUSE REMEDY
Air leak in suction line. Suction intake not submerged
at proper level or sump too small.
Correct leak. Checkinstallationand correct submergenceas
needed.
60 SERIES
Lining of suction hose col­lapsed.
Dischargelinecloggedorre­stricted; hose kinked.
Impellerorotherwearingparts worn or damaged.
Impeller clogged. Pump speed too slow.
Suction lift or discharge head to high.
Leakingorwornsealorpump gasket.
PUMP REQUIRES TOO MUCH POWER
Exceeding operating limits.
Liquid solution too thick.
PREVENTIVE MAINTENANCE
Sincepump applicationsareseldomidentical,and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature oftheliquidbeingpumped, thissection isintended 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
Replace suction hose.
Check discharge lines; straighten hose.
Replace worn or damaged parts. Check that impelleris properlycentered and rotates freely.
Free impeller of debris. Check engineoutput; consult engineoperation
manual. Check pipinginstallationand reduce suctionlift
and/or discharge head. Check pump vacuum. Replace leaking orworn
seal or gasket. See performance curve in Pump Maintenance
And Repair. Dilute if possible.
equipped) between regularly scheduled inspec­tions can indicate problems that can be corrected before system damage or catastrophic failure oc­curs.The appearanceof wearingpartsshouldalso bedocumented ateach inspectionfor 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 beforefailureoccurs,reducing unscheduleddown time.
For new applications, a first inspection of wearing partsat250 hourswillgiveinsightintothewearrate foryourparticularapplication.Subsequentinspec­tions should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.
TROUBLESHOOTINGPAGE D -- 2
Page 17
60 SERIES
OM--05171
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 18
60 SERIES
OM--05171
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 62 1/2D1--CH23 S/G
Based on 70_ F(21_ C) clear water at sea level with minimumsuction lift.Since pump installations areseldomidentical,yourperformancemaybe dif­ferent due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
formance or part numbers.
Never tamper with the governor to gain
If your pump serial number is followed by an “N”, your pump is NOT astandardproductionmodel. Contact the Gorman-Rupp Company to verifyper-
MAINTENANCE & REPAIR PAGE E -- 1
more power. The governor establishes safe operating limits that should not be exceeded.
Page 19
SECTION DRAWING
60 SERIESOM--05171
Figure 1. Pump Model 62 1/D1---CH23 S/G
MAINTENANCE & REPAIRPAGE E -- 2
Page 20
60 SERIES
OM--05171
PARTS LIST
Pump Model 62 1/2D1---CH23 S/G
(From S/N 1211015 up)
Ifyourpump serialnumber is followedby an “N”,your pumpis 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 1/2D1---(CH23) 1
2 KOHLER CH23PS ENGINE 29127---303 --- --- --- 1
3 ROLLOVER BASE 41583---344 24150 1
4 MUFFLER ASSY 46211---029 24150 1
5 MUFFLER GUARD KIT 29187---111 ------ --- 1
6 PR ESSUR E G AUG E S1 80 --- --- --- 1
7 HAND CARRY DECAL 2613FT --------- 2
8 DISCHARGE STICKER 6588BJ --- --- --- 1
9 SUCTION STICKER 6588AG --- ------ 1
10 COUPLING 2469 14000 2 11 EXHAUST PRIMER ASSY 46112---706 --- --- --- 1 12 WARNING DECAL 2613FE --- --- --- 1 13 BRACKET 34144---036 15080 1 14 FLAT WASHER K06 15991 1 15 HEX HD CAPSCREW B0603 15991 1 16 HEX NUT D06 15991 1 17 DISCONNECT BUSHING 26534---082 --- --- --- 1 18 DUST CAP 26531---301 ------ --- 1 19 JAM NUT AT06S 15991 1 20 FUEL LINE 11308H --- ------ 1 21 HOSE CLAMP S1788 --- --- - -- 2 22 HEX HD CAPSCREW B0606 15991 4 23 FLAT WASHER K06 15991 4 24 FLANGED HEX NUT 21765---314 ------ --- 4 25 STUD C0709 15991 4 26 HEX NUT D07 15991 4 27 LOCKWASHER J07 15991 4
28 RUBBER FOOT MTG KIT 48152---603 ------ -- - 1 29 ---RUBBER BUMPER S1224 --- --- --- 4 30 ---HEX HD CAPSCREW B0504 15991 4 31 ---FLAT WASHER K05 15991 4 32 ---FLANGED HEX NUT 21765---312 --- -- ---- 4 33 NAME PLATE 2613BF 13990 1 34 DRIVE SCREW BM#04---03 17000 4 35 B AT TE R Y B OX A S SY GR P 40 --- 0 5 --- --- --- 1 36 ---HEX HD CAPSCREW B0503 15991 4 37 ---T TYPE LOCKWASHER BL05 15991 1 38 ---FLANGED HEX NUT 21765---312 --- -- ---- 4 39 ---BATTERY BOX 11281 24000 1 40 ---BATTERY S1680 - -- ------ REF 41 ---BATTERY TAG 38818---680 ------ --- 1 42 ---BATTERY BOX COVER 11870 24000 1 43 ---HEX HD CAPSCREW B0504 15991 2 44 ---FLANGED HEX NUT 21765---312 --- -- ---- 2 45 ---GROUND CABLE 47311---542 --- ------ 1 46 ---POS BATTERY CABLE 47311---502 --------- 1 47 FUEL TANK ASSY 46711---086 --- --- -- - 1
NOT SHOWN:
STRAINER 26841---010 - -- ------ 1 ADAPTOR 26115---011 --- --- --- 1 EXHAUST PRIMER TAG 6588X --- - -- --- 1 INSTRUCTION TAG 38817---045 ------ --- 1 ENG START---UP TAG 38816---269 --- --- --- 1
INDICATES PARTSRECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E -- 3
Page 21
SECTION DRAWING
60 SERIESOM--05171
Figure 2. 62 1/2D1---(CH23) Pump End Assembly
MAINTENANCE & REPAIRPAGE E -- 4
Page 22
60 SERIES
OM--05171
PARTS LIST
62 1/2D1---(CH23) Pump End Assembly
ITEM NO.
1 PUMP CASING 11013 13040 1 2 3 4 STUD C0605 1/2 15991 12 5 HEX NUT D06 15991 12 6 INTERMEDIATE 38264---331 13040 1 7 8
9 10 11 CASING DRAIN PLUG P04 15079 1 12 13 CHECK VALVE BODY 6323 13000 1 14 15 CHECK VALVE ARM 6324 14000 1 16 STUD C1009 15991 4 17 HEX NUT D10 15991 4 18 SPRING HOLDER 25273---273 ------ --- 1
PART NAME
IMPELLER 38623---034 13047 1 SEAL ASSEMBLY 25271---903 ------ --- 1
IMPELLER ADJUSTING SHIM 37J 17090 1 SHAFT SLEEVE 3428D 16000 1 BALANCE RING 62ZL6 14000 1 CASING GASKET 11013G 18000 1
WEAR RING 11017 14050 1
CHECK VALVE BODY GASKET 6323G 19060 1
PART NUMBER
MAT’L CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E -- 5
Page 23
60 SERIESOM--05171
Figure 3. Exhaust Primer Detail
ITEM NO.
1 EXHAUST PRIMER VALVE BODY 3643 10010 1
2
3
4 EJECTOR BODY 3552 14000 1
5 VENTURI 2345B 14000 1
6 HEX NIPPLE 26112---053 --- ------ 1
7 SWIVEL FITTING 26571---002 ------ --- 1
8 HOSE ADAPTOR 26523---334 ------ --- 2
9 1 FT HOSE 18513---302 ------ --- 1 10 GAS COCK S2 --- --- --- 1 11 VALVE HAND 1458A 15990 1 12 EXH PRIMER DECAL 6588AS --- ------ 1 13 EXHAUST PRIMER VALVE 1467 10010 1 14 COTTER PIN M0406 15990 2 15 SPRING WASHER S165 --- --- --- 3
PART NAME
PIPE NIPPLE T08 15079 1 EJECTOR JET 3645B 14000 1
PART NUMBER
MAT’L CODE
MAINTENANCE & REPAIRPAGE E -- 6
QTY
Page 24
60 SERIES
OM--05171
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY
Review all SAFETY information in Section A .
Followtheinstructionsonall tags,label andde­cals attached to the pump.
This pump requires little service due to its rugged, minimum-maintenance design. However, if it be­comesnecessarytoinspect orreplacethe wearing parts, followthese instructionswhichare keyed to thesectionalview (seeFigure1)andthe accompa­nying parts list.
Most service functions, such as wear plate, impel­ler, and seal replacement, may be performed by draining the pump and removing the back cover assembly. However, the following instructions as­sume complete disassembly is required.
As described in the SAFETY Section, this manual willalert personnel toknown procedures which re­quire special attention, to those which could dam­age equipment, and to those whichcould be dan­gerousto personnel. However,this manualcannot possibly anticipate and provide detailed precau­tions for every situation that might occur during maintenanceof theunit. Therefore,itis therespon­sibilityof the owner/maintenance personnel toen­sure that only safe, established shop procedures are used, and that any procedures not addressed in this manual are performed only after establish­ing that neither personal safety nor pumpintegrity are compromised by such practices.
2. Shut down the engine and remove the spark plug wires to ensurethat the pump will remain inoperative.
3. Allowthe pump tocompletely 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.
Discharge Check Valve Disassembly (Figure 2)
Removethenuts(17)andseparatethecheckvalve body(13)fromthe pumpcasing(1). Pullthe rubber gasket (14) fromthe flangestuds (16),andpull the check valve arm (15) from the check valve body. Unscrewthepressuregaugeandfirehoseadaptor if required.
Clean the mating surfaces of both flanges and in­spectall partsfor wearor damage. Ifno furtherdis­assembly is required, refer to Discharge Check
Valve Reassembly. Exhaust Primer Disassembly
(Figure 3)
Removethe hoseadaptor (8)fromtheswivelfitting (7). If necessary, remove the gas cock valve (10) andpipenipple(6).
Before attempting to service the pump, switch off the engine ignition and remove the spark plug, or take other precautions to ensure thatit will remain inoperative. Close all valves in the suction and dis­charge lines.
Forengine disassembly and repair, consult the lit­erature supplied with the engine, or contact your local Kohler engine representative.
To remove the exhaust primer body (1) unscrew the body from the muffler (4). To disassemble the exhaust primer, remove the handle (11) and un­screw the various primer components.
If no further disassembly is required, refer to Ex-
haust Primer Reassembly. Pump Disassembly
(Figure 2)
After disconnecting the exhaust primer, remove the casing drain plug (11) and drain the pump cas­ing. Clean and reinstall the plug.
Beforeattemptingto openorservicethe pump:
1. Familiarize yourself with thisman­ual.
MAINTENANCE & REPAIR PAGE E -- 7
For access to the impeller (2) and seal assembly (3), removethe nuts (5) securingthe pumpcasing totheintermediate(6).Removethecasinggasket (10) and clean the contacting surfaces.
Page 25
60 SERIESOM--05171
Inspect the wear ring (12) for excessive wear or damage.Thewearringissecuredinthepumpcas­ing by a press fit. If replacement is required, use a small bit to drill two holes horizontally through the ring, 180_ apart. Use a chisel or other suitable tool to complete the cuts through the ring and remove thering fromthe casing.Be carefulnotto damage the casing bore w hen removing the ring.
Toremovethe impeller,insert a steel baror drift pin between the vanes, and turn the impeller in a counter-clockwise direction (when facing the im­peller)whileholdingthe enginecrankshaft station­ary. Be careful notto damage the impeller vanes. Use caution when unscrewing the impeller; ten­sion on the seal spring will be released as the im­peller is removed.
Inspect t he balance ring (9) for excessive wear or damage. The balance ring is secured in the inter­mediate by a press fit. If replacement is required, use a small bit to drill two holes horizontally through the ring, 180_ apart. Use a chisel or other suitable toolto completethe cuts through the ring and remove t he ring from the intermediate. Be careful notto damagethe intermediatebore when removing the ring.
Seal Removal and Disassembly
(Figure 2 And 4)
Removethe springholder(18) andthe impellerad­justingshims(7). Tieandtag theshims ormeasure and record their thickness for ease ofreassembly.
Removethe seals pring, then slidethe shaft sleeve 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 sealoff the sleeve. Use two stiff wires with hooked ends to pullthe stationary seat from the intermedi­ate bore.
NOTE
Analternatemethodof removing thestationaryseat istoremove thehardware(26 and27,Figure 1)and separate the intermediate from the engine. Use a dowel to press the stationary seat from the inter­mediate.
If no further disassembly is required, refer to Seal Reassembly And Installation.
Seal Reassembly and Installation (Figure 2 And 4)
Cleanthe seal cavityandshaft witha cloth soaked in fresh cleaning solvent.
Most cleaning solvents are toxic and flammable. Usethem only in a well ven ­tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solventcontain­ers.
The sealis not normallyreused because wear pat­terns on the finished faces cannot be realigned during reassembly. This could result in premature failure.Ifnecessary toreuse anoldsealinanemer­gency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.
Handlethe seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shortenseallife.Ifnecessary,cleanthefaceswitha non-oilbased 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 otherdamage that mightcauseleak­age.Clean andpolishtheshaft sleeve,or replaceit if there are cuts or nicks 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 itfrom 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 rotat­ing element O-ring with water or a very small amount of oil, and apply a drop of light lubricating oil on the finishedfaces. Assemble the seal as fol­lows,(seeFigure4).
MAINTENANCE & REPAIRPAGE E -- 8
Page 26
60 SERIES
OM--05171
IMPELLER
IMPELLER SHIM SET
SPRING
RETAINER
BELLOWS
O-RING
INTERMEDIATE
SHAFT SLEEVE
IMPELLER SHAFT
STATIONARY ELEMENT
ROTATING ELEMENT
Figure 4. 25271--903 Seal Assembly
This seal is not designed for operation at temperatures above 160_F(71_C). Donot use at higher operating temperatures.
If the balance ring (9) was removed, the replace­ment ring should be pressed into the intermediate beforeinstallingthe seal. Positionthe ring inthe in­termediatebore withthechamferedendtoward to­ward the bore shoulder and press it into the bore until fully seated.
NOTE
The balance ring must be fully seated in the inter­mediate bore, otherwise binding and/or excessive wear could result.
Lubricate the stationary seat O-ring with light oil andinstallit inthestationary seat.Use thumbpres­sure to press this subassembly into the intermedi­ateboreuntilfullyseated.Be carefulnottodamage thesealface.Afterinstallation,wipethesealfacein a concentric pattern with a clean, lint-free cloth to remove any fingerprints.
Secure the intermediate to the engine with the hardware (26 and 27). Be careful not to damage the stationary seat on the shaft threads.
Slide the rotating portion of the seal (consisting of theretainer,bellowsand rotatingelement)ontothe sleeve(8)untiltherotatingfaceisjust flush with the chamfered end of the sleeve. Slide the sleeve ontotheshaftuntilthesealfaces contact.Continue topushthesleevethroughthesealuntilitseats against the shaft shoulder.
Iftheintermediatewasremoved,layitonaflatsur­face with the impeller side facing up.
MAINTENANCE & REPAIR PAGE E -- 9
Install the seal spring. Make sure that all compo­nents of the seal are seated squarely.
Page 27
60 SERIESOM--05171
Impeller Installation
(Figures 2 and 5)
Inspectthe impeller(2), and replace itif cracked or badly worn.
CD
B 2
AB
B
+
A
2
For maximum pump efficiency, the impeller must becentered withinthe volutescroll. Toverifyimpel­ler positioning, measure the pump casing and im­peller as shown in Figure 5. Use these measure­ments to calculate the required impeller location (dimension E). Add or remove impeller adjusting shims (55) to obtain dimension E.
D 2
E
Step 2Step 1 Step 3
C
+
D 2
=
E
---
Figure 5. Centering Impeller Within Pump Casing
NOTE
After the impeller has been properly positioned, check for free rotation. Correct any scraping or binding before further reassembly.
Pump Reassembly
(Figure 2)
If the wear ring (12) was removed, apply ‘Loctite No. 242 Threadlocker’ or equivalent compound) between thecasing andthewearring. Positionthe replacement ring in the casing bore so that cham­fer on the I.D. faces toward the impeller. Press the ringinto the bore until fullyseatedagainst the cas­ing shoulder.
NOTE
The wear ring must be fully seated in the casing bore, otherwise binding and/or excessive wear could result.
Install the pump casing gasket (10). Carefully guidethewearringintotheeyeoftheimpeller,and securethecasing to the intermediatewith the nuts (5).
NOTE
After the pump casing has been install check the impeller for free rotation. Correct any scraping or binding before further reassembly.
Exhaust Primer Reassembly (Figure 3)
NOTE
Before assembly, apply pipe sealant on all threaded joints.
To install t he exhaust primer body (1) screw the body intothe muffler(4). To assemble theexhaust primer,installthehandle(11)and installthevarious primer components.
Screw the hose adaptor (8) into the swivel fitting (7). Install the gas cock valve (10) and pipenipple (6).
MAINTENANCE & REPAIRPAGE E -- 10
Page 28
60 SERIES
OM--05171
Discharge Check Valve Reassembly
(Figure 2)
Position the pivot of the check valve arm (15) in the slotinthevalvebody (13).Installtherubber gasket (14), and secure the assembly to the casing with the nuts (17). Check for free operation of the valve arm.Inspectthepressuregaugeandhoseadaptor forwearordamagebeforeinstallationandreplace as required.
LUBRICATION
Seal Assembly (Figure 2)
Theseal assemblyis lubricatedbythemediumbe­ing pumped. No addition lubrication is required.
Engine (Figure 1)
Refer to the literature provided with the engine, or contact your local Kohler engine representative.
MAINTENANCE & REPAIR PAGE E -- 11
Page 29
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 D MANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA
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